Mitsubishi FB13PNT User manual


99759-5M300
99759-5M300
FC/MCFC/MC
FB13PNTFB13PNT EFB21-00011-up EFB21-00011-up
FB15PNTFB15PNT EFB21-50011-up EFB21-50011-up
FB16CPNTFB16CPNT EFB22-00011-up EFB22-00011-up
FB18CPNTFB18CPNT EFB22-50011-up EFB22-50011-up
FB16PNTFB16PNT EFB23-00011-up EFB23-00011-up
FB18PNTFB18PNT EFB23-50011-upEFB23-50011-up
FB20PNTFB20PNT EFB24-00011-up EFB24-00011-up
FB16CPNFB16CPN
 EFB27-00011-up EFB27-00011-up
FB18CPNFB18CPN EFB27-50011-up EFB27-50011-up
FB16PNFB16PN EFB28-00011-up EFB28-00011-up
FB18PNFB18PN EFB28-50011-up EFB28-50011-up
FB20PNFB20PN EFB29-00011-up EFB29-00011-up
Service ManualService Manual
ControllerController

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ii
FOREWORDFOREWORD
This service mThis service manual is a guide for anual is a guide for servicing Mitsubishi servicing Mitsubishi Forklift Trucks.Forklift Trucks.
The long productive life of The long productive life of your forklift truck(s) depends on regular and your forklift truck(s) depends on regular and proper servicing, servicing consistent with what youproper servicing, servicing consistent with what you
will learn by reading this will learn by reading this service manual.service manual.
Read the respective sections of this manual Read the respective sections of this manual carefully and familiarize yourself with all of carefully and familiarize yourself with all of the components before attempting tothe components before attempting to
start a test, repair or rebuild start a test, repair or rebuild the forklift truck.the forklift truck.
The descriptions, illustratioThe descriptions, illustrations and specifications contained in this manual arns and specifications contained in this manual are for forklift trucks with sere for forklift trucks with serial numbers in effect atial numbers in effect at
the time of printing.the time of printing.
Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurringMitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring
obligations. For your convenience the instructions are grouped by systems as an obligations. For your convenience the instructions are grouped by systems as an easy reference.easy reference.
SSaaffeetty y rreellaatteed d ssiiggnnss MMeeaanniinnggss
RRWARNINGWARNING Indicates a potentially hazardous situation which, if Indicates a potentially hazardous situation which, if not avoided, could result in death or not avoided, could result in death or seriousserious
injury.injury.
RRCAUTIONCAUTION Indicates Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderatea potentially hazardous situation which, if not avoided, may result in minor or moderate
injury, or damage to your machine.injury, or damage to your machine.
NONOTETE InIndidicacatetes a s a cocondndititioion tn thahat ct can an cacaususe de damamagage te to oo or sr shohortrten en seservrvicice le lifife oe of tf the he mamachchinine.e.
Unauthorized copying and lending are prohibited.Unauthorized copying and lending are prohibited.

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11.. SSaaffeettyy
WARNING
WARNING
-- The proThe proper and sper and safe lubrafe lubricatiication and maion and maintenntenance foance for these fr these forkliorklift trucft trucks, recoks, recommenmmended by Mided by Mitsubitsubishi Forshi Forklift Trklift Trucks, arucks, aree
outlined in the SERVICE MANUAL. Read and understand the SERVICE MANUAL before performing any lubrication oroutlined in the SERVICE MANUAL. Read and understand the SERVICE MANUAL before performing any lubrication or
maintenance on these trucks. Improper performance of lubrication or maintenance procedures is dangerous and couldmaintenance on these trucks. Improper performance of lubrication or maintenance procedures is dangerous and could
result in injury or death. The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makesresult in injury or death. 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.it important to use caution when performing service work.
-- Do not opDo not operaterate these te these trucks urucks unless you hnless you have reaave read and unded and understorstood the insod the instructructions in ttions in the SERVhe SERVICE MANUICE MANUAL. ImprAL. Improperoper
truck operation is dangerous and could result in truck operation is dangerous and could result in injury or death.injury or death.
A knowledge of the system and/or components is importantA knowledge of the system and/or components is important
before the removal or disassembly of any component.before the removal or disassembly of any component.
Because of the size of some of the truck components, theBecause of the size of some of the truck components, the
serviceman or mechanic should check the weights serviceman or mechanic should check the weights noted innoted in
this Manual.this Manual.
Use proper lifting procedures when removing anyUse proper lifting procedures when removing any
components.components.
Following is a list of basic Following is a list of basic precautions that should always beprecautions that should always be
observed.observed.
(1)(1) Read aRead and undnd understerstand all wand all warniarning platng plates and des and decals oecals onn
the truck before operating, lubricating or repairing thethe truck before operating, lubricating or repairing the
product.product.
(2)(2) AlwaAlways wear prys wear protecotective gltive glasses anasses and proted protective sctive shoeshoes
when working around trucks. In particular, wearwhen working around trucks. In particular, wear
protective glasses when using a hammer or sledge onprotective glasses when using a hammer or sledge on
any part of the truck or its attachments with a hammerany part of the truck or its attachments with a hammer
or sledge.or sledge.
Use welders gloves, hood/goggles, apron and otherUse welders gloves, hood/goggles, apron and other
protective clothing appropriate to the welding jobprotective clothing appropriate to the welding job
being performed. Do not wear loose fitting or tornbeing performed. Do not wear loose fitting or torn
clothing. Remove all rings from fingers when workingclothing. Remove all rings from fingers when working
on machinery.on machinery.
(3)(3) Do not Do not work owork on any trn any truck thauck that is suppt is supporteorted only by ld only by liftift
jacks jacks or or a a hoist. hoist. Always Always use use blocks blocks or or jack jack stands stands toto
support the truck before performing any support the truck before performing any disassembly.disassembly.
(4)(4) LoweLower the for the forks or orks or other ither implemplementments to the gs to the grounroundd
before performbefore performing any work on the truck. If ing any work on the truck. If this cannotthis cannot
be done, make sure the forks or other implements arebe done, make sure the forks or other implements are
blocked correctly to prevent them from droppingblocked correctly to prevent them from dropping
unexpectedly.unexpectedly.
(5)(5) Use sUse steps ateps and grnd grab handab handles (iles (if applif applicablecable) whe) whenn
mounting or dismounting a truck. Clean any mud ormounting or dismounting a truck. Clean any mud or
debris from steps, walkways or work platforms beforedebris from steps, walkways or work platforms before
using. Always face truck when using steps, ladders andusing. Always face truck when using steps, ladders and
walkways. When it is not possible to use the designedwalkways. When it is not possible to use the designed
access system, provide ladders, scaffolds, or workaccess system, provide ladders, scaffolds, or work
platforms to perform safe repair platforms to perform safe repair operations.operations.
(6)(6) To avoTo avoid bacid back injuk injury, usry, use a hoe a hoist wist when lihen liftingfting
components which weigh 23 kg (51 lb) or more. Makecomponents which weigh 23 kg (51 lb) or more. Make
sure all chains, hooks, slsure all chains, hooks, slings, etc., are in good conditionings, etc., are in good condition
and are of the correct capacity. Be sure hooks areand are of the correct capacity. Be sure hooks are
positioned correctly. Lifting eyes are not to be sidepositioned correctly. Lifting eyes are not to be side
loaded during a lifting loaded during a lifting operation.operation.
(7)(7) To avoTo avoid burid burns, be ans, be alert olert of the hof the hot sectt sections anions and hotd hot
fluids in lines, tubes and compartments, even when idlefluids in lines, tubes and compartments, even when idle
or off.or off.
(8)(8) Be carBe careful wheful when remen removing coving cover pover plateslates. Gradu. Graduallyally
remove the last two bolts or nuts located at oppositeremove the last two bolts or nuts located at opposite
ends of the cover or device and pry cover loose toends of the cover or device and pry cover loose to
relieve any springs or other pressures, before removingrelieve any springs or other pressures, before removing
the last two bolts or the last two bolts or nuts completely.nuts completely.
(9)(9) Be carBe careful wheful when remen removing foving filler ciller caps, breaps, breatherathers ands and
plugs on the truck. Wrap a plugs on the truck. Wrap a cloth around the cap or plugcloth around the cap or plug
to prevent being sprayed or splashed by liquids underto prevent being sprayed or splashed by liquids under
pressure. Be aware that the danger of pressure. Be aware that the danger of being sprayed orbeing sprayed or
splashed is ever greater if it is immediately aftersplashed is ever greater if it is immediately after
stopping the truck, as fluids is very hot.stopping the truck, as fluids is very hot.
(10)(10) Use tools well maUse tools well maintained. And use the toointained. And use the tools in properls in proper
way.way.
(11)(11) Reinstall all fasteners with samReinstall all fasteners with same part number. Do ne part number. Do notot
use a lesser quality fastener if replacements areuse a lesser quality fastener if replacements are
necessary.necessary.
(12)(12) If possible, make all repairs wIf possible, make all repairs with the truck parked on aith the truck parked on a
level, hard surface. Block truck so it does not roll whilelevel, hard surface. Block truck so it does not roll while
working on or under truck.working on or under truck.
(13)(13) Before starting Before starting to work on truck, hang "Do nto work on truck, hang "Do not Operate"ot Operate"
tag in the tag in the Operator CompartmeOperator Compartment.nt.
(14)(14) Repairs, which reRepairs, which require welding, quire welding, should be performshould be performeded
only with the appropriate reference information and byonly with the appropriate reference information and by
personnel adequately trained and knowledgeable inpersonnel adequately trained and knowledgeable in
welding procedures. Determine the type of metal andwelding procedures. Determine the type of metal and
select the correct welding procedure and electrodes,select the correct welding procedure and electrodes,
rods or wire to provide a weld metal strengthrods or wire to provide a weld metal strength
equivalent at least to that of equivalent at least to that of parent metal.parent metal.
(15)(15) Do not damage wirDo not damage wiring during the ring during the removal process. Doemoval process. Do
not reuse the damaged wiring. Reinstall the wiringnot reuse the damaged wiring. Reinstall the wiring
paying attention not to contact sharp corners or hotpaying attention not to contact sharp corners or hot
parts. Place wiring away from oil parts. Place wiring away from oil pipe.pipe.
(16)(16) Be sure all proteBe sure all protective devices inctive devices including guards andcluding guards and
shields are properly installed and functioning correctlyshields are properly installed and functioning correctly
before starting a repair.before starting a repair.
If a guard or shield must be removed to perform theIf a guard or shield must be removed to perform the
repair work, use extra repair work, use extra caution.caution.
(17)(17) Always support the mast and carAlways support the mast and carriage to keep carrriage to keep carriageiage
or attachments raised when maintenance or repairor attachments raised when maintenance or repair
work is performed, which requires the mast in thework is performed, which requires the mast in the
raised position.raised position.
(18)(18) Loose or Loose or damaged fuel, damaged fuel, lubricant and hydraulic lubricant and hydraulic lines,lines,
tubes and hoses could cause fires. Do tubes and hoses could cause fires. Do not bend or strikenot bend or strike
high pressure lines or install ones which have beenhigh pressure lines or install ones which have been
bent or damaged. Inspect lines, tubes and hosesbent or damaged. Inspect lines, tubes and hoses
carefully. Do not check for leaks with your hands. Pincarefully. Do not check for leaks with your hands. Pin
hole (very small) leaks could result in a hole (very small) leaks could result in a high velocity oilhigh velocity oil
stream that will be invisible close to the hose. This oilstream that will be invisible close to the hose. This oil
could penetrate the skin and cause could penetrate the skin and cause personal injury. Usepersonal injury. Use
cardboard or paper to locate pin hole leaks.cardboard or paper to locate pin hole leaks.

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2.2. How How to Uto Use Tse This his ManManualual
2.2.11 TrTrucuck Mok Modedell
(19)(19) Tighten connections to thTighten connections to the correct torquee correct torque. Make sure. Make sure
that all heat shields, clamps and guards are installedthat all heat shields, clamps and guards are installed
correctly to avoid excessive heat, vibration or rubbingcorrectly to avoid excessive heat, vibration or rubbing
against other parts during operation. Shields thatagainst other parts during operation. Shields that
protect against oil spray onto hot protect against oil spray onto hot exhaust componentsexhaust components
in event of a line, tube or seal failure, must be installedin event of a line, tube or seal failure, must be installed
correctly.correctly.
(20)(20) Relieve all pressure Relieve all pressure in air, oil or water systein air, oil or water systems beforems before
any lines, fittings or related items are disconnected orany lines, fittings or related items are disconnected or
removed.removed.
Place blocks to prevent a device from falling if it is in Place blocks to prevent a device from falling if it is in thethe
raised position. Release the residual pressure whenraised position. Release the residual pressure when
removing a pressurized device.removing a pressurized device.
(21)(21) Do not operate a truDo not operate a truck if any rotating part is damageck if any rotating part is damagedd
or contacts any other part during operation.or contacts any other part during operation.
Any high speed rotating component that has beenAny high speed rotating component that has been
damaged or altered should be checked for balancedamaged or altered should be checked for balance
before reusing.before reusing.
MC Truck (Manual Control System)MC Truck (Manual Control System)
Mechanically controlled hydraulic system (conventionalMechanically controlled hydraulic system (conventional
lever system)lever system)
501489
501489
FC (Fingertip Control System) TruckFC (Fingertip Control System) Truck
This model allows a fingertip operation of lifting This model allows a fingertip operation of lifting and tiltingand tilting
jobs, and majobs, and may improve y improve the job ethe job efficiency with fficiency with less operatioless operationn
fatigue.fatigue.
501490
501490
Connector numberConnector number
A connector number is allocated to each connector.A connector number is allocated to each connector.
Refer to the CHAPTER 5 CIRCUIT DIAGRAM or Refer to the CHAPTER 5 CIRCUIT DIAGRAM or the connectorthe connector
number.number.

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iviv
33.. UUnniittss
-- SI SI UnUnitits as are re usused ed in in ththis is mamanunualal..
-- The The follofollowing wing table table shows shows the the conveconversiorsion of n of SI uSI unit nit and and custocustomary mary unit.unit.
Item Item SI SI unit unit Metric Metric unit unit Yard-pound Yard-pound unitunit
Force Force 1 1 N N 0.102 0.102 kgf kgf 0.225 0.225 lbflbf
PPrreessssuurre e 1 1 MMPPaa 1100..1199772 2 kkggff//ccmm22 145.038 psi145.038 psi
Torque Torque 1 N1 N··m m 0.102 0.102 kgfkgf
··mm 00..7733776 6 llbbf f  ··ftft
LengthLength 1 1 mmm m -- 00..00339 9 iinn..
1 1 m m -- 33..22881 1 ffeeeett
WWeeiigghht t 1 1 kkg g -- 22..22005 5 llbb
Temperature Temperature 1 °C1 °C -- °F=1.8°F=1.8 xx °C+32°C+32
VVoolluumme e 1 1 L L -- 00..22664 4 UUSS..ggaall..

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TABLE OF CONTENTSTABLE OF CONTENTS
TOC-1TOC-1
CChhaaptpteer 1r 1 CCOONTNTRROOLLLLEERR
1.1. CoContntrorollller er SySyststem em . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-.1-11
1.11.1 SysSystem tem LayLayout out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .1-11-1
1.21.2 ConControtrolleller Arer Area Nea Netwotwork (rk (CANCAN) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . .1-3-3
1.31.3 OutOutlinline of Le of Logiogic Unc Unit it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .1-41-4
1.41.4 OutOutlinline of Ie of Invenverterter r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-77
1.51.5 OutOutlinline of Ee of EPS CPS Contontrolroller ler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-88
1.61.6 OutOutlinline of Ie of Inpnput uut unit nit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .1-91-9
1.71.7 OutOutlinline of Oe of Outputput uut unit nit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-10-10
2.2. TrTracactiotion Cn Conontrtrololleler Fr Feaeatuture re . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .1-1-111
2.12.1 ModifiModificatication of ton of tractiraction chon charactaracteristeristics . . . . ics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. . . . .1-1111
2.22.2 UntUnti-ri-rollollbacback k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-1111
2.32.3 BooBoost st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-12-12
2.42.4 LimLimitaitatition oon of maxf maximuimum trm traveavel spl speed . . . . . . eed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .1-11-122
2.52.5 TurTurnining sng speepeed lid limit mit funfunctiction on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. . .1-1313
2.62.6 MisMiscelcellanlaneoueous fes featuatures res for tfor tracractiotion n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1.1-133
2.72.7 PitcPitching hing ContControl (Orol (Optioption) . . . . . . n) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . .1-14-14
3.3. LiLiftftining Cg Conontrtrololleler Fer Feataturure e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . .1-1-155
3.13.1 SetSettinting ang and lid limitmitatiation oon of liff lift wot work sprk speed eed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-1515
3.23.2 LifLift stt stop . . . . op . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-15-15
3.33.3 LoaLoad med meter (ter (optoptionion) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .1-11-166
3.43.4 TilTilt hot horizrizon (on (optoptionion) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-1717
4.4. OtOtheher Fr Feaeatuture re . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .1-1-177
4.14.1 PDS PDS (Pr(Preseesence nce DetDetectection ion SysSystemtem) fe) featuature re . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. . .1-1717
4.24.2 DisDisplaplay funy functiction on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-19-19
4.34.3 ParParkinking Brg Brake Iake Intenterlorlock ck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-2020
4.44.4 BDI BDI (Ba(Battettery dry discischarharge ige indindicatcator) or) disdisplaplay feay featurtures es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-20-20
4.54.5 MisMiscelcellanlaneoueous fes featuatures res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-20-20
4.64.6 HouHour Metr Meter er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-21-21
5.5. SeSetutup Op Optptioion n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .1-2-222
5.15.1 OutOutlinline e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-2222
5.25.2 DetDetailails of Ss of Setuetup Opp Optiotions (ns (GroGroup-up-1) 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-2323
5.35.3 DetDetailails of Ss of Setuetup Opp Optiotions (ns (GroGroup-up-2) 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-2727
5.45.4 DetDetailails of Ss of Setuetup Opp Optiotions (ns (GroGroup-up-3) 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-3232
5.55.5 SetSetup Oup Optiptions ons (Gr(Group oup 1) 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-3535
5.65.6 SetSetup Oup Optiptions ons (Gr(Group oup 2) 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-3636
5.75.7 SetSetup Oup Optiptions ons (Gr(Group oup 3) 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-3838
6.6. DiDiagagnonoststicics s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .1-3-399
6.16.1 OutOutlinline e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-3939
6.26.2 OpeOperatration ion ProProcedcedure . . . . . . . . . . ure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-.1-3939
6.3 6.3 SelSelf-Df-Diagiagnosnostictics s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-41-41
6.46.4 PowPower Ster Steereering ing DiaDiagnognostistics cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-42-42
6.56.5 Run Run TimTime Die Diagnagnostosticics s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .1-44-44
6.66.6 Fail-Fail-Safe RSafe Restricestriction tion List List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-51.1-51
7.7. ReRemomovaval al and nd InInststalallalatition on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .1-5-533
7.17.1 InvInverterter Der Discischarharginging Prg Proceocedure . . . dure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. . .1-5353
7.27.2 RepReplaclacing ing InvInverterter er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-.1-5454
7.37.3 RepReplaclacing ing DSP DSP (Di(Digitgital Sal Signignal Pal Procrocessessor) Cor) Card ard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-. .1-5555


TABLE OF CONTENTSTABLE OF CONTENTS
TOC-2TOC-2
7.47.4 RepReplaclacing ing LogLogic Uic Unit nit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57. . . . . 1-57
7.57.5 RepReplaclacing ing EPS EPS ConControtrolleller r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58. . . . . 1-58
7.67.6 RepReplaclacing ing LogLogic Cic Card ard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59. . . . . 1-59
7.77.7 RepReplaclacing ing PowPower Ser Suppupply Cly Card ard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60. . . 1-60
7.87.8 RepReplaclacing ing InpInput Unut Unit (it (FC MFC MODEODEL ONL ONLY) LY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61. . . 1-61
7.97.9 RepReplaclacing ing OutOutput put UniUnit (Ft (FC MOC MODEL DEL ONLONLY) Y) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62. . . . . 1-62
8.8. BasBasic ic ChChececk k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-1-6363
8.18.1 TesTestinting Tog Tools ols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-633
8.28.2 MeaMeasursuremeement ont of Caf Card Vord Voltaltage ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-633
8.38.3 CheCheckicking Cng Contontactactor Cor Coil oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70. . 1-70
8.48.4 CheCheckicking Cng Contontactactor Tor Tips ips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70. . 1-70
8.58.5 CheCheckicking Ing Invenverterter r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-711
8.68.6 RegRegeneeneratration ion CheCheck ck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71. . . 1-71
9.9. AC AC MoMototor Sr Sysystetem Bm Basasicics s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-1-7272
9.19.1 FeaFeaturture of e of AC mAC motootor r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72. . . 1-72
9.29.2 SpeSpeed ced contontrol rol of iof indunductiction mon motootors rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-722
9.39.3 InvInverterter er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-733
ChChaptapter 2er 2 TROTROUBUBLELESHOSHOOTOTING FING FOR COOR CONTRNTROL CIOL CIRCRCUITUITSS
1.1. GeGeneneraral Il Infnforormamatiotion n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .2-2-11
1.11.1 BefBefore rore repleplaciacing dng devievices . . . . . . ces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-1
1.21.2 ConConnecnectiotion of tn of the she servervice ice tootool l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-1
1.31.3 How How to cto clealean han harnerness css connonnectectors ors and and syssystem tem comcomponponentents s . . . . . . . . . . . . . . . . 2-2. . . . . . 2-2
2.2. LiList st of of ErErroror Cr Cododes es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-2-33
3.3. TrTrououblbleseshohoototining g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-2-44
3.13.1 TraTractiction Mon Motootor R.Hr R.H.,O.,Oververheaheatinting (Eg (E0) . . . . . . 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. . . . . 2-4
3.23.2 TraTractiction Mon Motootor L.Hr L.H.,O.,Oververheaheatinting (Eg (E1) 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. . . . . 2-7
3.33.3 PumPump Mop Motortor,Ov,Overherheateatinging(E2(E2) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-100
3.43.4 TraTractiction Ion Invenverterter R.r R.H., OH., Oververheaheatinting (Eg (E5) 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13. . . 2-13
3.53.5 TraTractiction Ion Invenverterter L.Hr L.H., Ov., Overherheateatining (E6g (E6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-166
3.63.6 PumPump Inp Inververterter, Ov, Overherheateating ing (E7(E7) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19. . . . . 2-19
3.73.7 PS CPS Contontrolrollerler,Ov,Overherheateatining (Eg (E9) 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22-222
3.83.8 TraTractiction Mon Motootor Curr Currenrent Set Sensonsor R.Hr R.H., F., Faulault (1t (14) 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22-255
3.93.9 TraTractiction Mon Motootor R.Hr R.H., O., Overver-cu-currerrent (nt (15) . . . . . . . . . 15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22-277
3.103.10 TractTraction ion Motor Motor R.H., SR.H., Stall Ttall Timer (imer (16) 16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-302-30
3.113.11 TractTraction ion Motor Motor CurrenCurrent Sent Sensor L.Hsor L.H., Faul., Fault (24) t (24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32. . . 2-32
3.123.12 TractTraction ion Motor Motor L.H., L.H., Over-Over-currencurrent (25t (25) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34. . . . . 2-34
3.133.13 TractTraction ion Motor Motor L.H., L.H., Stall Stall TimeTimer (26) r (26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-372-37
3.143.14 Pump Pump Motor Motor CurreCurrent Sent Sensor Fnsor Fault (ault (34) 34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39. . . . . 2-39
3.153.15 Pump Pump Motor Motor Over-Over-currecurrent (3nt (35) 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41. . . . . 2-41
3.163.16 Line CLine Contacontactor Fautor Fault (40lt (40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
3.173.17 SteeriSteering Cong Contacntactor Fator Fault (4ult (41) 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-462-46
3.183.18 TractTraction ion Motor Motor R.H., OR.H., Open (pen (45) 45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48. . . . . 2-48
3.193.19 TractTraction ion Motor Motor L.H., L.H., Open Open (46) (46) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50. . . . . 2-50
3.203.20 Pump Pump Motor Motor Open Open (47) (47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52. . . 2-52
3.213.21 PS MotoPS Motor Open r Open (49) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (49) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-542-54
3.223.22 Tire Tire Angle Angle SensoSensor Faulr Fault (50) . . . . . . . . . . t (50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56. . . . . 2-56
3.233.23 AcceAcceleratolerator Sensor Sensor Fault (r Fault (51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-582-58
3.243.24 TractTraction ion Motor RMotor R.H., P.H., Pulse Iulse Input nput Fault Fault (52) (52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-602-60


TABLE OF CONTENTSTABLE OF CONTENTS
TOC-3TOC-3
3.253.25 TractTraction Moion Motor L.tor L.H., PulH., Pulse Inpse Input Faulut Fault (53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62t (53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62
3.263.26 FC LeFC Lever Fauver Fault (54lt (54) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64. .2-64
3.273.27 OutpOutput Uniut Unit Solent Solenoid Fauoid Fault (55lt (55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
3.283.28 OutpOutput Unut Unit it SolenSolenoid Coid Currenurrent Leak t Leak (56) (56) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68. . .2-68
3.293.29 FNR LFNR Lever oever or Accer Acceleratolerator, Faulr, Faulty Setty Setting ting (E) (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . .2-70-70
3.303.30 Seat SwSeat Switchitch, Fault, Faulty Settiy Setting for Tng for Tractiraction ((Eon ((E)) )) . . . . . . . . . . . . . . . . . . . . . . . . . . .2-. . . . . . . . . . . . . . . . . . . . . . . . . . .2-7272
3.313.31 Lift Lift LeverLever, Fault, Faulty Setty Setting (ing (H1) H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7. . . .2-744
3.323.32 Tilt Tilt LeverLever, Faul, Faulty Setty Setting ting (H2) (H2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76. .2-76
3.333.33 AttacAttachmenhment 1 Levet 1 Lever, Faulr, Faulty Settty Setting (ing (H3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78H3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78
3.343.34 AttacAttachmenhment 2 Levet 2 Lever, Faulr, Faulty Settty Setting (ing (H4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80H4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80
3.353.35 Seat SwSeat Switchitch, Fault, Faulty Settiy Setting for Hng for Hydraulydraulic ((Lic ((L)) )) . . . . . . . . . . . . . . . . . . . . . . . . . .2-8. . . . . . . . . . . . . . . . . . . . . . . . . .2-822
3.363.36 FNR LFNR Lever Fever Fault (ault (EE) EE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84. .2-84
3.373.37 DispDisplay Colay Communmmunicatiication Faon Fault (6ult (60) 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86. .2-86
3.383.38 LogiLogic Card Ic Card Initinitialize Falize Failure ailure (61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-88(61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-88
3.393.39 LogiLogics Faucs Fault (62) . . . lt (62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89. . . .2-89
3.403.40 TractTraction Inion Inverter Rverter R.H., F.H., Fault (6ault (63) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-93) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-900
3.413.41 TractTraction Inion Inverter Lverter L.H., Fa.H., Fault (6ult (64) 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9393
3.423.42 Pump Pump InverInverter Fter Fault(6ault(65) 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-96. .2-96
3.433.43 Input Input Unit FUnit Fault (ault (67) 67) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-99-99
3.443.44 OutpOutput Uniut Unit Fault (t Fault (68) 68) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-101-101
3.453.45 EPS CoEPS Controlntroller Fauler Fault (71) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1lt (71) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10303
3.463.46 ContContactor actor Coil FCoil Fault (7ault (72) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-102) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1066
3.473.47 HydrauHydraulic Llic Lock Solock Solenoienoid Fault d Fault (74) (74) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-108108
3.483.48 ParkiParking Brng Brake ake Fault Fault (75) . . . . . . . . . (75) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-. . . .2-110110
3.493.49 PDS BuzPDS Buzzer Fauzer Fault (76lt (76) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112. . . .2-112
3.503.50 BatteBattery Volry Voltage Ttage Too Looo Low (78) w (78) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. . . .2-11414
3.513.51 BatteBattery Volry Voltage Ttage Too Hioo High (7gh (79) 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11. .2-1166
3.523.52 BatteBattery Consry Consumptumption Toion Too Much (o Much (Lo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11Lo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1188
3.533.53 Tilt Tilt AnglAngle Sense Sensor Fauor Fault (80lt (80) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. . . .2-12020
3.543.54 Load SeLoad Sensor Fnsor Fault (8ault (81) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1222
3.553.55 HandlHandle Sense Sensor Fauor Fault (82lt (82) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12. .2-1244
3.563.56 PS MotPS Motor Cuor Current rrent SensoSensor Faulr Fault (A4) t (A4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12. .2-1266
3.573.57 PS MotoPS Motor Over-r Over-currencurrent (A5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-128t (A5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-128
3.583.58 PS HanPS Handle Bradle Brake Fauke Fault (A7lt (A7) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-. . . . .2-130130
3.593.59 BatteBattery Side ry Side Way ExcWay Exchanghange Inte Interlocerlock (A8) k (A8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13. .2-1322
3.603.60 BatteBattery Conry Consumpsumption tion Much Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. . . .2-13434
3.613.61 Brake OBrake Oil, Loil, Low Levew Level l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-136-136
3.623.62 RTC BRTC Battery attery Low Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. . . .2-13838


TABLE OF CONTENTSTABLE OF CONTENTS
TOC-4TOC-4
CChhaapptteer r 33 MMOOTTOORR
1.1. MoMototor Ir Insnstatallllatatioion Pn Pososititioions ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 3-3-11
2.2. SpSpececifificicatatioions . ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .3-3-33
3.3. StStruructcturures es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .3-3-44
3.13.1 TraTractiction mon motootor r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. . . . . 3-4
3.23.2 PumPump mop motor tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53-5
3.33.3 EPS EPS motmotor . . . . . . . or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. . . 3-6
4.4. ReRemomoviving ng TrTranansfsfer er AsAssesembmblilieses, T, Traractctioion mn motootors rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .3-3-77
5.5. DiDisasassssememblblining Tg Traractctioion mn mototor or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .3-3-88
5.15.1 DisDisassassembembly Sely Sequequencnce e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83-8
6.6. InInspspecectiting ng TrTracactition on MoMototor . . r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-3-99
6.16.1 InsInspecpectinting Rog Rotor . tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. . . 3-9
6.26.2 InsInspecpectinting Mog Motor tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. . . 3-9
6.36.3 InsInspecpectiotion of n of insinsulaulatiotion . . . . . . . . n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10. . . . . 3-10
7.7. ReResasassssememblblining Tg Traractction ion momototor r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-3-1111
7.17.1 ResResassassembembly Sely Sequequence nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-111
8.8. ReRemomoviving ng PuPump mp MoMototor r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3-3-1212
8.18.1 SugSuggesgestiotions fns for Reor Removmoval al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12. . . . . 3-12
9.9. DiDisasassssemembibing ng PuPump mp MoMototor r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3-3-1414
9.19.1 DisDisassassembembly Sely Sequequencnce e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-144
10.10. InsInspecpectinting Pg Pump ump MotMotor or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-13-155
10.110.1 InspeInspectincting Rotog Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
10.210.2 InspeInspectincting Motog Motor r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15. . . 3-15
10.310.3 InspeInspection ction of insof insulatiulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163-16
11.11. ResResassassembemblinling Pug Pump mmp motootor r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3-13-177
11.111.1 ResassResassemblembly Sequey Sequence nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-173-17
12.12. TigTightehteninning of g of HigHigh-ph-poweower Cr Cablable Te Termerminainals ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-13-188
13.13. RemRemovioving Eng EPS PS MotMotor or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-13-199
13.113.1 SuggeSuggestionstions for Res for Removal moval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19. . . . . 3-19
14.14. DisDisassassembemblinling Eg EPS MPS Motootor r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3-13-199
15.15. InsInspecpectinting EPg EPS MoS Motor tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-23-211
15.115.1 InspeInspectincting Armatg Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-213-21
15.215.2 InspeInspectincting Motog Motor r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23. . . 3-23
15.315.3 InspeInspectincting Oil Sg Oil Seal and Peal and Permanermanent Maent Magnet . . . . . . . . . . . . . . . . . . . . gnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-243-24
16.16. InsInspecpectinting EPg EPS MoS Motor tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-23-255
16.116.1 Brush Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25. . . 3-25
17.17. TroTroublublesheshootooting ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3-23-266


TABLE OF CONTENTSTABLE OF CONTENTS
TOC-5TOC-5
ChChaptapter er 44 HOHOW TW TO O REREAD AD CIRCIRCUICUIT DT DIAGIAGRARAMSMS
1.1. DeDescscririptption ion of of CiCircrcuiuit Dt Diaiagrgramams s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-.4-11
1.11.1 SchSchemaematic tic diadiagragram . . . . m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-. .4-11
1.21.2 ConConnecnector tor DiaDiagragrams ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .4-14-1
2.2. HoHow tw to Ro Reaead Cd Cirircucuit it DiDiagagrarams ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-.4-22
2.12.1 SymSymbolbols s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-. .4-33
2.22.2 SheSheet Set Symbymbol ol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-. .4-66
2.32.3 ConConnecnectiting Lng Lineines s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . .4-7-7
2.42.4 EquEquipmipment . . . ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8.4-8
2.52.5 RelRelay Coay Contantactoctor anr and Cod Coil il . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-. .4-99
2.62.6 ConConnecnectortors s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . .4-9-9
2.7 2.7 IndIndicaicatiotion of Cn of Connonnectectining Lig Line ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-.4-1010
2.82.8 IndIndicaicatiotion of n of GND GND (Ea(Earthrth) ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-. .4-1010
2.92.9 IndicIndication ation of Anof Anotheother Sper Specificificatiocation n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. .4-111
3.3. HoHow tw to Ro Reaead Cd Cononnenectctor or DiDiagagrarams ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .4-1-122
ChChapapteter 5r 5 CICIRCRCUIUIT DT DIAIAGRGRAMAM


CHAPTER 1 CONTROLLERCHAPTER 1 CONTROLLER
1-11-1
CChhaapptteer 1r 1 CCOONNTRTROOLLLLEERR
11.. CCoontntrorolllleer r SSyysstteemm
11..11 SSyysstteem Lm Laayyoouutt
System layout for FC typeSystem layout for FC type
Five or seven independent controllers are linked togetherFive or seven independent controllers are linked together
by the Controller Area Network (CAN) to communicate withby the Controller Area Network (CAN) to communicate with
each other to control the truck.each other to control the truck.
The logic The logic unit is unit is the heart the heart of the of the control system control system for the for the liftlift
trucks.trucks.
The configuration of The configuration of the controller system the controller system is classified is classified intointo
two types according to the lifting system.two types according to the lifting system.
The input unit The input unit is connected to is connected to the FC contrthe FC control lever.ol lever.
The The output output unit unit is is connected connected to to the the FC FC hydraulic hydraulic controlcontrol
valve assembly.valve assembly.
The inverters and EPS The inverters and EPS controller are connected to the controller are connected to the eacheach
motor.motor.
The logic unit is The logic unit is connected to connected to the other dthe other devices.evices.
500918500918
UU
VV
WW
MM
MM
Right traction motorRight traction motor Left traction motorLeft traction motor Pump motorPump motor
 Right Right
traction invertertraction inverter
 Left Left
traction invertertraction inverter Pump inverterPump inverter
SwitchesSwitches
ContactorsContactors
AcceleratorAccelerator
Direction leverDirection lever
KeyKey
switchswitch
DisplayDisplay
InputInput
unitunit
OutputOutput
unitunit
EPSEPS
controllercontroller
Lift cLift cylinderylinder,,
Tilt cylinderTilt cylinder
FC hydraulicFC hydraulic
control valvecontrol valve
assemblyassembly
HydraulicHydraulic
pumppump
Power stearingPower stearing
MotorMotor
FC control leverFC control lever
CAN busCAN bus
Lift lockLift lock
solenoid valvesolenoid valve
UU
WW
UU
VV
WW
MM
SensorsSensors
UU
VV
WW
MM
SensorsSensors
Motor controlMotor control
commandcommand
SensingSensing
datadata
FC lever inputFC lever input
FC solenoidFC solenoid
commandcommand
FC solenoidFC solenoid
control signalcontrol signal
Logic UnitLogic Unit
Logic cardLogic card
TraTraveling controveling control,l,
Lifting control,Lifting control,
Safety function,Safety function,
etc.etc.
Lift lock solenoid control signalLift lock solenoid control signal
Contactor control signalContactor control signal
LineLine
contactorcontactor BatteryBattery
Electric powerElectric power
SteeringSteering
contactorcontactor
DSP cardDSP card DSP cardDSP card DSP cardDSP card
__


CHAPTER 1 CONTROLLERCHAPTER 1 CONTROLLER
1-21-2
System layout for MC typeSystem layout for MC type
500919
500919
UU
VV
WW
MM
Right traction motorRight traction motor Left traction motorLeft traction motor Pump motorPump motor
 Right Right
traction invertertraction inverter  Left Left
traction invertertraction inverter Pump inverterPump inverter
SwitchesSwitches
ContactorsContactors
AcceleratorAccelerator
Direction leverDirection lever
KeyKey
switchswitch
DisplayDisplay
CAN busCAN bus
UU
VV
WW
MM
SensorsSensors
UU
VV
WW
MM
SensorsSensors
Motor controlMotor control
commandcommand
SensingSensing
datadata
Logic UnitLogic Unit
Logic cardLogic card
TraveTraveling control,ling control,
Lifting control,Lifting control,
Safety function,Safety function,
etc.etc.
Lift lock solenoid/unload solenoid control signalLift lock solenoid/unload solenoid control signal
Contactor control signalContactor control signal
LineLine
contactorcontactor BatteryBattery
Electric powerElectric power
DSP cardDSP card DSP cardDSP card DSP cardDSP card
Lift cylinder,Lift cylinder,
Tilt cylinderTilt cylinder
MC hydraulicMC hydraulic
control valvecontrol valve
assemblyassembly
HydraulicHydraulic
pumppump
Micro switchesMicro switches
Hydraulic lever inputHydraulic lever input
MM
EPSEPS
contollercontoller
Power stearingPower stearing
MotorMotor
UU
WW__
SteeringSteering
contactorcontactor
Lift lockLift lock
solenoid valvesolenoid valve


CHAPTER 1 CONTROLLERCHAPTER 1 CONTROLLER
1-31-3
1.1.22 CoContntrorollller er ArArea ea NeNetwtworork (k (CACAN)N)
Main specificationsMain specifications
Each controller is linked with the truck harness to form aEach controller is linked with the truck harness to form a
network as follows.network as follows.
The The terminal terminal resistors resistors are are built built into into the the display display and and thethe
pump inverter.pump inverter.
If the terminal resistors are not properly connected, theIf the terminal resistors are not properly connected, the
communication failure may occur between the logic unitcommunication failure may occur between the logic unit
and other controllers.and other controllers.
The input unit and The input unit and output unit are output unit are used for FC mused for FC models only.odels only.
For details, see the "Traction Inverter R.H. Fault (63)",For details, see the "Traction Inverter R.H. Fault (63)",
"Traction Inverter L.H. Fault (64)" and "Pump Inverter Fault"Traction Inverter L.H. Fault (64)" and "Pump Inverter Fault
(65)", "EPS Controller fault (71)" in "Troubleshooting for(65)", "EPS Controller fault (71)" in "Troubleshooting for
Control Circuits."Control Circuits."
1)1) Input Input unit aunit and ound output utput unit anit are usre used foed for FC r FC modemodel onlyl only..
500920
500920
RightRight
tractiontraction
inverterinverter
LeftLeft
tractiontraction
inverterinverter
LogicLogic
unitunit
DDiissppllaayyEEPPSS
controllercontroller InputInput
unitunit OutputOutput unitunit PumpPump inverterinverter
CAN HCAN H
CAN LCAN L
11))11))
The data are eThe data are expressed as elexpressed as electric potential dctric potential difference beifference between high- and tween high- and low-level signals as folow-level signals as follows.llows.
The signals are tThe signals are transferred transferred to each controlleo each controller through tr through the serial commhe serial communication protocunication protocol.ol.
500921
500921
VCAN-LVCAN-L
VCAN-HVCAN-H
timetime
recessiverecessive
VdiffVdiff
dominantdominant
VdiffVdiff
recessiverecessive
pp
oo
tt
ee
nn
tt
ii
aa
ll
Kind ofKind of
bitbit LogicLogic
dominantdominant
recessiverecessive
00
11
IItteemm SSppeecciiffiiccaattiioonnss
CCoommmmuunniiccaattiioon n pprroottooccooll CCAANNbbuus s 22..00B B ppaassssiivvee Non-Return to Zero methodNon-Return to Zero method
Broadcast communication protocolBroadcast communication protocol
CCoommmmuunniiccaattiioon n lliinnee DDuuaal l 22--wwiirre e ttyyppe e sseerriiaal l ccoommmmuunniiccaattiioonn
CCoommmmuunniiccaattiioon n ssppeeeedd 55000 0 kkbbppss
DDaatta a lleennggtthh 0 0 tto o 8 8 bbyytteess


CHAPTER 1 CONTROLLERCHAPTER 1 CONTROLLER
1-41-4
11..33 OOuuttlliinne e oof f LLooggiic c UUnniitt
Model informationModel information
This This controller controller includes includes the the power power supply supply card card and and logiclogic
card.card.
It controls all the jobs for the truck based on the operator'sIt controls all the jobs for the truck based on the operator's
input.input.
The controller sends a motor control command to the rightThe controller sends a motor control command to the right
and left traction inverters from the input of the directionand left traction inverters from the input of the direction
lever or the accelerator pedal. It lever or the accelerator pedal. It also monitors malfunctionsalso monitors malfunctions
of the traction system.of the traction system.
The The lever lever input input triggers triggers to to send send the the motor motor controlcontrol
commands to the pump inverter. It also monitorscommands to the pump inverter. It also monitors
malfunctions in the hydraulic control system. In the FCmalfunctions in the hydraulic control system. In the FC
specifications, this controller sends a control command tospecifications, this controller sends a control command to
the solenoid valves from the output unit by the lever input.the solenoid valves from the output unit by the lever input.
A malfunction in the valve control system is A malfunction in the valve control system is also monitoredalso monitored
by this controller.by this controller.
The truck The truck speed and speed and residual battery power residual battery power are monitoredare monitored
and shown on the display unit.and shown on the display unit.
The The logic logic unit unit sets sets its its model model information information and and optionaloptional
default data into internal memory. The information isdefault data into internal memory. The information is
secured even if the power supply for the logic unit is secured even if the power supply for the logic unit is turnedturned
off. This information is set at the factory.off. This information is set at the factory.
The The following following table table shows shows the the model model information. information. TheThe
system will not work properly if the actual controller systemsystem will not work properly if the actual controller system
is different from the is different from the model information.model information.
IItteemm DDeessccrriippttiioonn SSUUO O NNoo..
Truck typeTruck type Model setModel set #40#40
BBaatttteerry y vvoollttaaggee 336 6 VV, , 448 8 VV ##4411
BBaatttteerry y ttyyppee BBaatttteerry y ttyyppee ##4422
HHyyddrraauulliic c ccoonnttrrool l sseelleeccttiioonn FFC C ttyyppee, , MMC C ttyyppee ##4433
MMaasst t ttyyppee MMaasst t ttyyppee ##4444
VVaallvve e sseeccttiioonn NNuummbbeer r oof f vvaallvveess ##4455
BBaatttteerry vy voollttaagge e aaddjjuussttmmeenntt BBaatttteerry vy voollttaagge ae addjjuussttmmeenntt ##4466
FFoooot t ddiirreeccttiioonn OOppttiioonnaal l eeqquuiippmmeenntt ##4477
LLooaad d mmeetteer r ffuunnccttiioonn OOppttiioonnaal l eeqquuiippmmeenntt ##4488
Tilt horizon funcTilt horizon functiontion Optional equipmOptional equipmentent #50#50
The current The current information is available information is available to confirm to confirm and modify.and modify.
Refer to Setup Option on pageRefer to Setup Option on page 1-221-22for details and for details and setting proceduresetting procedure..
The model infoThe model information and variormation and various features arus features are set by the See set by the Setup Option (tup Option (SUO).SUO).
The power suThe power supply card changepply card changes the battery vos the battery voltage and supplies poltage and supplies power to the wer to the logic card and logic card and the DSP cardthe DSP card..


CHAPTER 1 CONTROLLERCHAPTER 1 CONTROLLER
1-51-5
Logic unitLogic unit
Logic cardLogic card
11)) PPiin n llooccaattiioon n oof f llooggiic c ccaarrdd 22)) PPiin n llooccaattiioon n oof f ppoowweer r ccaarrdd
500922
500922
  

1)1)
2)2)
1)1) LLogogic ic ccarard sd sididee
2)2) HaHarnrnesess s siside de E-E-0202
3)3) HaHarnrnesess s siside de E-E-0303
4)4) HaHarnrnesess s siside de E-E-0404
500923
500923
1)1)
22))33))44))


CHAPTER 1 CONTROLLERCHAPTER 1 CONTROLLER
1-61-6
Power supply cardPower supply card
11)) PPoowweer r ssuupppplly y ccaarrd d ssiiddee 22)) HHaarrnneesss s ssiidde e EE--0011
   
   




500924500924
11))22))


CHAPTER 1 CONTROLLERCHAPTER 1 CONTROLLER
1-71-7
11..44 OOuuttlliinne e oof f IInnvveerrtteerr
Traction inverters (right and left) and Pump inverterTraction inverters (right and left) and Pump inverter
The The inverter is inverter is a a motor drive motor drive controller that controller that consists consists of of Digital Signal Digital Signal Processor (DSP) Processor (DSP) card, Insulated card, Insulated Metal Substrate Metal Substrate (IMS)(IMS)
module and their drive boards.module and their drive boards.
It drives the AC It drives the AC induction motor according to the motor control command from the logic unit. induction motor according to the motor control command from the logic unit. It also monitors malfunctions ofIt also monitors malfunctions of
the motor and its condition. When a the motor and its condition. When a malfunction occurs, it stops the motor and informs to malfunction occurs, it stops the motor and informs to the logic unit.the logic unit.
The DSP card The DSP card has the DSP chip has the DSP chip that enables high-spethat enables high-speed calculation and ed calculation and controls the AC controls the AC induction motoinduction motor.r.
The IMS module has multiple MOS-FET modules which convert battery DC current into AC current for the traction and pumpThe IMS module has multiple MOS-FET modules which convert battery DC current into AC current for the traction and pump
motors.motors.
11.. DDSSP P ccaarrdd
500925
500925
11
Traction inverter DSP cards (right and left) and Pump inverter DSP cardTraction inverter DSP cards (right and left) and Pump inverter DSP card
11)) IInnvveerrtteer r ccaarrd d ssiiddee 22)) HHaarrnneesss s ssiiddee, , TTrraaccttiioon n RRiigghht t EE--0077
Harness side, Traction Left E-06Harness side, Traction Left E-06
Harness sideHarness side, Pump , Pump E-05E-05


500926500926
1)1)2)2)


CHAPTER 1 CONTROLLERCHAPTER 1 CONTROLLER
1-81-8
1.1.55 OOututliline ne of of EEPPS CS Coontntrrolollelerr
EPS controller is a motor drive controller. It drives the EPS controller is a motor drive controller. It drives the DC motor according to the steering input and tire angle input.DC motor according to the steering input and tire angle input.
It also monitors malfunctions of moIt also monitors malfunctions of motor and its condition. tor and its condition. When a malfunction occurs, it stops the moWhen a malfunction occurs, it stops the motor and informs to thetor and informs to the
logic unit.logic unit.
11)) CCNN11
500927
500927
        
             
           
                            
1)1)