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Mitsubishi FB13PNT, Quick Start Manual

The Mitsubishi FB13PNT is a versatile and efficient forklift perfect for warehouse and industrial use. To ensure optimal performance, don't forget to download the free Quick Start Manual from manualshive.com for easy setup and operation. Get your manual today and make the most of your Mitsubishi FB13PNT.

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2-20

2-20

502814

502814

  

CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS

CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS

3

3

4

4

14

14

15

15

16

16

17

17

18

18

20

20

8

8

9

9

11

11

1

1

2

2

1

1

2

2

5

5

6

6

3

3

4

4

CAN

CAN

5

5

3

3

4

4

6

6

11

11

9

9

10

10

11

11

12

12

Power

Power

Power card

Power card

E-05

E-05

E-16

E-16

E-16

E-16

DSP

DSP

card

card

Inside

Inside

 

 

of 

of 

cover

cover

Inside

Inside

 

 

of 

of 

 case

 case

IMS

IMS

card

card

P

P

N

N

U

U

V

V

W

W

U

U

V

V

W

W

M

M

37

37

36

36

Flat

Flat

cable

cable

Pump inverter

Pump inverter

PW

PW

PU

PU

PV

PV

IU

IU

IV

IV

IW

IW

Pump motor

Pump motor

 Therma

 Therma

l

l

sensor

sensor

Fuse

Fuse

Battery (-)

Battery (-)

GND

GND

12V

12V

14V

14V

8V

8V

GND

GND

GND

GND

W

W

L

L

Br/B

Br/B

B

B

341Ω 150°C [302°F]

341Ω 150°C [302°F]

125kΩ -30°C [-22°F]

125kΩ -30°C [-22°F]

Logics

Logics

E-02

E-02

E-02

E-02

E-01

E-01

E-01

E-01

E-05

E-05

R/L

R/L

R/L

R/L

R/Y

R/Y

B

B

-

-

23

23

2

2

1 1

1 1

9

9

1

1

7 1

7 1

5

5

-

-

-

-

9

9

7

7

5

5

3

3

1

1

-

-

24

24

-

-

2

2

0

0

1

1

8

-

8

-

-

-

-

-

-

-

8

8

6

6

4

4

2

2

1

1

5 1

5 1

3 1

3 1

1

1

9

9

-

-

5

5

3

3

-

-

1

1

6

6

1

1

4

4

1

1

2 1

2 1

0

0

-

-

6

6

4

4

-

-

1

1

2

2

1

1

5

-

5

-

1

1

1

9

1

9

-

-

-

-

3

3

1

1

1

1

6

6

1

1

4

-

4

-

-

-

-

-

-

-

4

4

2

2

-

-

17

17

2

2

0

0

1

1

8

8

Summary of Contents for FB13PNT

Page 1: ...1 up FB16PNT FB16PNT EFB23 00011 up EFB23 00011 up FB18PNT FB18PNT EFB23 50011 up EFB23 50011 up FB20PNT FB20PNT EFB24 00011 up EFB24 00011 up FB16CPN FB16CPN EFB27 00011 up EFB27 00011 up FB18CPN FB1...

Page 2: ......

Page 3: ...he time of printing Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring Mitsubishi Forklift Trucks reserves the right to change speci...

Page 4: ...n and are of the correct capacity Be sure hooks are and are of the correct capacity Be sure hooks are positioned correctly Lifting eyes are not to be side positioned correctly Lifting eyes are not to...

Page 5: ...sidual pressure when raised position Release the residual pressure when removing apressurizeddevice removing apressurizeddevice 21 21 Do not operate a tru Do not operate a truck if any rotating part i...

Page 6: ...nd unit unit Force Force 1 1 N N 0 102 0 102 kgf kgf 0 225 0 225 lbf lbf P Pr re es ss su ur re e 1 1 M MP Pa a 1 10 0 1 19 97 72 2 k kg gf f c cm m2 2 145 038 psi 145 038 psi Torque Torque 1 N 1 N m...

Page 7: ...r Fea eatu ture re 1 1 1 17 7 4 1 4 1 PDS PDS Pr Prese esence nce Det Detect ection ion Sys System tem fe featu ature re 1 1 17 17 4 2 4 2 Dis Displa play fun y functi ction on 1 1 19 19 4 3 4 3 Par P...

Page 8: ...H r R H O Over verhea heatin ting E g E0 0 2 4 2 4 3 2 3 2 Tra Tracti ction M on Moto otor L H r L H O Over verhea heatin ting E g E1 1 2 7 2 7 3 3 3 3 Pum Pump Mo p Motor tor Ov Overh erheat eating...

Page 9: ...41 Tract Traction In ion Inverter L verter L H Fa H Fault 6 ult 64 4 2 2 93 93 3 42 3 42 Pump Pump Inver Inverter F ter Fault 6 ault 65 5 2 96 2 96 3 43 3 43 Input Input Unit F Unit Fault ault 67 67...

Page 10: ...estio tions f ns for Re or Remov moval al 3 12 3 12 9 9 Di Disa sass ssem embi bing ng Pu Pump mp Mo Moto tor r 3 3 14 14 9 1 9 1 Dis Disass assemb embly Se ly Seque quenc nce e 3 1 3 14 4 10 10 Ins I...

Page 11: ...2 2 2 She Sheet S et Symb ymbol ol 4 4 6 6 2 3 2 3 Con Connec necti ting L ng Line ines s 4 4 7 7 2 4 2 4 Equ Equipm ipment ent 4 8 4 8 2 5 2 5 Rel Relay Co ay Conta ntacto ctor an r and Co d Coil il...

Page 12: ......

Page 13: ...d to connected tothe other d the other devices evices 500918 500918 U U V V W W M M M M Right traction motor Right traction motor Left traction motor Left traction motor Pumpmotor Pumpmotor Right Righ...

Page 14: ...data LogicUnit LogicUnit Logiccard Logiccard Trave Traveling control ling control Liftingcontrol Liftingcontrol Safety function Safety function etc etc Lift lock solenoid unload solenoid control sign...

Page 15: ...0920 500920 Right Right traction traction inverter inverter Left Left traction traction inverter inverter Logic Logic unit unit D Di is sp pl la ay y E EP PS S controller controller Input Input unit u...

Page 16: ...if the power supply for the logic unit is secured even if the power supply for the logic unit is turned turned off This information is set at the factory off This information is set at the factory Th...

Page 17: ...of f l lo og gi ic c c ca ar rd d 2 2 P Pi in n l lo oc ca at ti io on n o of f p po ow we er r c ca ar rd d 500922 500922 1 1 2 2 1 1 L Log ogic icc car ard s d sid ide e 2 2 Ha Harn rnes ess s si s...

Page 18: ...ONTROLLER CHAPTER 1 CONTROLLER 1 6 1 6 Power supply card Power supply card 1 1 P Po ow we er r s su up pp pl ly y c ca ar rd d s si id de e 2 2 H Ha ar rn ne es ss s s si id de e E E 0 01 1 500924 500...

Page 19: ...ction 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 cardhas the DSP chip has the DSP chipthat enables...

Page 20: ...s 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 mo It also monitors malfunctions of m...

Page 21: ...onitors for the It is the dedicated input unit for connecting equipment such as the FC control levers and switches It monitors for the malfunction of connected equipment and its condition When a malfu...

Page 22: ...itors for the malfunction of the solenoid valves and its condition When a malfunction of the solenoid valves and its condition When a malfunction occurs it informs to the logic unit malfunction occurs...

Page 23: ...i dire rect ctio ion l n lev ever ers a s are re in in th the o e opp ppos osit ite e directions directions The lever re The lever regeneration st generation starts when the t arts when the travel dir...

Page 24: ...d traveling applied during prolonged slow speed traveling The speed limi The speed limitation is classified into tation is classified intotwo major two majortypes and available to types and available...

Page 25: ...o 23 Note The turning speed depends on the regen power setting of SUO 21 to 23 I It te em m D De es sc cr ri ip pt ti io on n S SU UO O N No o H Ha ar rn ne es ss s P Pi in n N No o A Au ux xi il li i...

Page 26: ...uation and acceleration are detected by acceleration are detected by the hydraulic sensor the hydraulic sensor of the of the load Then load Then the torque for the torque for reducing the reducing the...

Page 27: ...d setting ing 4 4 A Au ux xi il li ia ar ry y 1 1 s sp pe ee ed d A At tt ta ac ch hm me en nt t 1 1 5 5 A Au ux xi il li ia ar ry y 2 2 s sp pe ee ed d A At tt ta ac ch hm me en nt t 2 2 6 6 Refer to...

Page 28: ...t ent menu on the display unit menu on the display unit 502801 502801 Note The Note The load meter indication is affe load meter indication is affected by the setting of SUO 44 M cted by the setting o...

Page 29: ...sensoradjustment adjustment 51 51 This This controller controller is is part part of of the the Presence Presence Detection Detection System System PDS PDS of of the the truck truck This This system...

Page 30: ...Travel speed el speed 0 5km h 0 5km h Seat SW ag ON Seat SW ag ON Seat SW ag OFF Seat SW ag OFF Direction lever N Direction lever N Accelerator pedal OFF Accelerator pedal OFF Hydraulic Control PDS Hy...

Page 31: ...5 6 1 2 3 4 5 6 0 H R 0 H R 8 56 8 56 5 5 6 6 1 1 1 1 1 1 00KG 00KG 0 0 K K G G 10 9 10 9 0 0 9 9 1 1 1 1 1 1 3 3 5 5 2 2 6 6 8 8 7 7 9 9 1 10 0 1 11 1 1 12 2 1 13 1 3 14 4 1 15 5 1 16 6 1 17 7 1 18 8...

Page 32: ...it 501951 501951 This feature show This feature shows with 11 levels s with 11 levels BDI 0 to BDI 10 o BDI 0 to BDI 10 of remaining batte f remaining battery capacity of the ry capacity of thecurren...

Page 33: ...reading between the logistics and EPS controller exceeds 1 hour HR NG will be logistics and EPS controller exceeds 1 hour HR NG will be indicated on the display indicated on the display Upon receivin...

Page 34: ...el l i in nf fo or rm ma at ti io on n 4 40 0 t to o 5 55 5 The Group 1 The Group 1 and 2 and 2 are available are available to set to set the default value the default value in a in a one step operat...

Page 35: ...l R Re eg ge en ne er ra at ti io on n M Me ed di iu um m M Me ed di iu um m H Hi ig gh h H Hi ig gh h H Hi ig gh h Default value Default value S St ta ar rt t L Li if ft t S Sp pe ee ed d 1 1 1 1 1...

Page 36: ...r operation Lever operation 100 100 0 0 SW1 SW1 Close Close SUO 3 SUO 3 SUO 2 SUO 2 10 10 9 9 8 8 SW2 SW2 Close Close Pump motor output characteristics lift up operation Pump motor output characterist...

Page 37: ...tics attachment 1 and 2 chment 1 and 2 operation operation F FC C M MC C Pump motor Pump motor output output Lever angle Lever angle 0 0 100 100 10 10 6 6 1 1 2 2 100 100 Pump motor Pump motor output...

Page 38: ...n of limited torque under a condition of overheating or battery voltage low or overheating or battery voltage low or maintenance time over maintenance time over 10 Service Indicator 10 Service Indicat...

Page 39: ...it t s sw wi it tc ch h o op pe en ne ed d 6 6 P Po ow we er r r re ed du uc ct ti io on n s sw wi it tc ch h c cl lo os se ed d 1 1 Place the lever in neutral Lift moves by operating the lever again...

Page 40: ...he setting range is 0 to 100 ange is 0 to 100 Effective Effectivewhen the data o when the data of 14 is 3 or 6 f 14 is 3 or 6 17 Aux Input for Lift Drive Speed 3 17 Aux Input for Lift Drive Speed 3 Ha...

Page 41: ...ange is 1 to setting range is 1 to 10 10 500940 500940 100 100 100 100 10 10 1 1 Amount of lever Amount of lever regeneration regeneration Level of throttle pedal Level of throttle pedal Value of 22 V...

Page 42: ...be decreasedaccording to t according to the regenera he regenerative rate of 21 tive rate of 21to 23 to 23 500932 500932 0 0 4 45 5 4 45 5 9 90 0 90 90 5 km h 5 km h 10 km h 10 km h 15 km h 15 km h 20...

Page 43: ...to the solenoid will be reduced but this does not mean it affects the lowering speed immediately due to tolerance in oil flow and immediately due to tolerance in oil flow and oil characteristics Furth...

Page 44: ...V B BD DI I 3 36 6V V 4 48 8V V 0 0 3 34 4 4 4 4 45 5 9 9 0 0 3 35 5 2 2 4 46 6 9 9 1 1 3 34 4 5 5 3 34 4 8 8 4 46 6 0 0 4 46 6 4 4 1 1 3 35 5 3 3 3 35 5 5 5 4 47 7 0 0 4 47 7 3 3 2 2 3 34 4 9 9 3 35...

Page 45: ...oltage Adjust 46 Battery Voltage Adjust This This setting setting corrects corrects the the difference difference between between the the actual actual battery voltage and controller recognized batter...

Page 46: ...output unit and tilt lock valve for this job this job To stop the mast in a horizont To stop the mast in a horizontal position during emp al position during empty load ty load or when the mast is til...

Page 47: ...se et tt ti in ng g f fo or r a at tt ta ac ch hm me en nt t 2 2 1 to 10 1 to 10 1 SLOW to 10 FAST 1 SLOW to 10 FAST 3 3 7 7 T To op p T Tr ra av ve el l S Sp pe ee ed d L Li im mi it t M Ma ax xi im...

Page 48: ...dislimitedtoset value value The The maximum maximumspeed speed is defined at 15 is defined at 15 The amo The amount of unt ofpower power reduction is defined reduction is defined at 16 at 16 S Sa am m...

Page 49: ...30 30 Turtle SW Input Turtle SW Input Setting Setting This setting define This setting defines s the function of the function of Speed Limit W Speed Limit W switch switch According to the According to...

Page 50: ...on the service tool actual battery voltage voltage 5 5 0 0 t to o 1 12 20 0 0 0 V V 4 47 7 F Fo oo ot t D Di ir re ec ct ti io on n This option is used t This option is used to enable the o enable the...

Page 51: ...ith the stics with the Step 0 in t Step 0 in the table Withou he table Without sitting in t sitting in the seat tur the seat turn ON the n ON the key switch acco key switch according to t rding to the...

Page 52: ...fuse Tur Turn O n OFF t FF the k he key s ey swit witch t ch to ex o exit f it fro rom th m the di e diagn agnost ostics ics mode mode Rep Repair airall f all faul aults f ts foun ound im d imme medi...

Page 53: ...h h R R b bu ut tt to on n o on n m me et te er r p pa an ne el l 0 06 6 6 6 Handle Tire Handle Tire angle sensor angle sensor See display See display P Pa as ss s N No ot te e 2 2 F Fa ai il l P Pu u...

Page 54: ...procedure Diagnostics procedure Perform the procedure using the Self Diagnostics Power steering system table in Perform the procedure using the Self Diagnostics Power steering system table in accordan...

Page 55: ...t te ee er ri in ng g f fu us se e Close line contactor and Close line contactor and check power line voltage check power line voltage P Pa as ss s 1 16 6 Contactorcloses Contactorcloses and opens and...

Page 56: ...Drivingpower reduction reduction Cool Cool E6 E6 Traction Inverte Traction Inverter r L H Overheating L H Overheating MOSFET 100 C or higher MOSFET 100 C or higher 25 C 13 F or lower 25 C 13 F or low...

Page 57: ...f 41 41 Steering Steering ContactorFault ContactorFault The differenc The difference in voltage e in voltage between battery and power between battery and power steering cont steering controller roll...

Page 58: ...or rm ma al l s st to op p T Tu ur rn n k ke ey y o of ff f 60 60 Display Display Communication Communication Fault Fault Display failure or Display failure or communicationline communicationline dis...

Page 59: ...y recovery Recover Recover communica communica tion tion Both CAN and life signal are Both CAN and life signal are abnormal abnormal 9 9 z z Steering Steering emergency emergency stop stop Turn key of...

Page 60: ...ess or 4 9 V 0 1 V or less or 4 9 V or more or more of load sensor input voltage of load sensor input voltage continues 400 ms or more continues 400 ms or more z z z z Pitch control Pitch control OFF...

Page 61: ...ySettingfor Pump Pump Leaving Leaving the the seat seat z z z z P PDS DS fu func ncti tion on FN FNR N R Neu eutr tral al Accel open Accel open Seat SW Seat SW close close H1 H1 Lift Lever Faulty Lift...

Page 62: ...n 0 16A whenshort circuit whenshort circuit protection protection is activated is activated z z z z Drivingpower Drivingpower reduction reduction Turn key off Turn key off A8 A8 Battery Side Way Batte...

Page 63: ...FF F O ON N 9 9 9 9 9 9 Steering Steering emergency emergency stop stop Line and steering contactors are Line and steering contactors are turned off upon detection of a turned off upon detection of a...

Page 64: ...ved The fail safe is considered to be a normal for partial failure and function will be recovered when the condition is removed The fail safe is considered to be a normal for partial failure and degen...

Page 65: ...resistor t stor to the P an o the P and N term d N terminals fo inals for r approx five seconds measure the voltage between the approx five seconds measure the voltage between the terminals with a mu...

Page 66: ...plate of the inverter inverter 2 2 Apply thermal past Apply thermal paste approx 1 mm e approx 1 mm 0 04 in thick to 0 04 in thick to the area whe the area where the alum re the aluminum base plate i...

Page 67: ...he case may cause damage to the inside card while holding the cable may nside card while holding the cable may cause wire breakage cause wire breakage 3 3 Push an Push and lift up at the fou d lift up...

Page 68: ...rface in the direction shown in the illustration Verify that the cable is Verify that the cable is inserted squarely into the connector inserted squarely into the connector 4 4 Install the Install the...

Page 69: ...e logi e logic card a c card and nd power supply card power supply card 500956 500956 CAUTION CAUTION When disconnecting the connector hold the connector housing and plug and unlock When disconnecting...

Page 70: ...e sure to discharge all inverters Be sure to discharge all inverters 2 2 Disco Disconnect al nnect all four pow l four power cabl er cables from P es from P N U and W termi N U and W terminals nals In...

Page 71: ...the logic unit case to remove the logic card remove the logic card 4 4 Remo Remove the ve thegrom grommet f met from t rom the log he logic car ic card d 1 1 C Co ov ve er r 2 2 L Lo og gi ic c u un...

Page 72: ...unit case to remove the power supply card supply card 4 4 Remo Remove the g ve the gromm rommet fro et from the po m the power su wer supply car pply card d 1 1 C Co ov ve er r 2 2 L Lo og gi ic c u...

Page 73: ...the connector hold the connector housing and plug and unlock the connector the connector Holding the case may cause damage to the i Holding the case may cause damage to the inside card while holding t...

Page 74: ...ck the When disconnecting the connector hold the connector housing and plug and unlock the connector connector Holding the case may cause damage to the Holding the case may cause damage to the inside...

Page 75: ...500961 1 1 2 2 3 3 WARNING WARNING Disconnect the battery plug before in Disconnect the battery plug before inspecting or adjusting the controller specting or adjusting the controller WARNING WARNING...

Page 76: ...S SW W 3 33 3 S SE EA AT T S SW W 3 34 4 P PA AR RK K B BR RA AK KE E S SW W 3 37 7 F FO OR RW WA AR RD D S SW W 3 38 8 B BR RA AK KE E F FL LU UI ID D S SW W 39 39 4 40 0 A AU UX X S SW W 1 1 4 41 1...

Page 77: ...6 0 0V V D DS SP P 4 4 8 8V V 8 8V V D DS SP P 5 5 V VG G 1 12 2V V D DS SP P 6 6 G GN ND D 0 0V V D DS SP P 7 7 V VE E L L V Vb ba at tt t 8 8 V VE E L L V Vb ba at tt t 9 9 V VL L 1 13 3 0 0 t to o...

Page 78: ...c GND terminal GND terminal 4 4 C CA AN NL L 0 0 t to o 5 5V V 0 0 t to o 5 5V V 5 5 R RO OT TA AR RY Y S SE EN NS SO OR R 1 12 2V V 1 12 2V V 1 12 2V V 6 6 R RO OT TA AR RY Y S SE EN NS SO OR R A A 0...

Page 79: ...HN ND DL LE E B BR RA AK KE E C CO OI IL L D Di is sc ch ha ar rg ge e D DO O 0 0 t to o V V b ba at tt te er ry y 1 18 8 V VL L P PO OW WE ER R I IN N P PO OW WE ER R I IN N 1 13 3 t to o 1 16 6V V...

Page 80: ...R RA AL L A AR RM MR RE ES ST T 2 20 0 P PI I 6 6 0 0 t to o 1 15 5V V 0 0V V R RE EV VE ER RS SE E A AR RM MR RE ES ST T 2 21 P 1 PI I 7 7 0 0 t to o 1 15 5V V 0 0V V A AL LS S S SW W F FC C 22 22 2...

Page 81: ...LV VE E A A 2 22 2 S SO OL L P PW WM M 2 2 0 0V V 0 0 t to o V Vb ba at tt t L LI IF FT T V VA AL LV VE E B B 2 23 3 S SO OL L P PW WM M 1 1 2 2 0 0V V 0 0 t to o 0 0 5 5V V L LI IF FT T V VA AL LV V...

Page 82: ...sitive terminal of positive terminal of the multimeter to the positive side coil the multimeter to the positive side coil terminal large terminal terminal large terminal 6 6 Connect Connect the batter...

Page 83: ...h ill check the e regenerat regeneration ion operation operation 1 1 Plac Place the cla e the clamp amm mp ammeter o eter onto th nto the cable c e cable connec onnected to ted to theinverter s theinv...

Page 84: ...er supply The speed of an AC motor motor is determined by the frequency of the power supply AC is determined by the frequency of the power supply AC current and the load on the current and the load on...

Page 85: ...ng DC voltage shown in Fig 3 Fig 3 Fig 3 500967 500967 Switch Switch V VB B V VL L T1 T1 T2 T2 T1 T1 T2 T2 ON ON ON ON S Sm ma al ll l d du ut ty y r ra at ti io o L La ar rg ge e d du ut ty y r ra at...

Page 86: ...1 73 1 73 Fig 5 Fig 5 500969 500969...

Page 87: ...and system components on page 2 2 Ensur Ensure that t e that the main ha he main harness i rness is not sho s not short ci rt circui rcuited to t ted to the tru he truck body b ck body by using t y u...

Page 88: ...ts cleaner ner 502884 502884 1 1 Electronic parts cleaner Electronic parts cleaner Three Bond 29B Three Bond 29B Note The cleaner liquid is volatile evaporates by itself Note The cleaner liquid is vol...

Page 89: ...rr re en nt t S Se en ns so or r F Fa au ul lt t 7 71 1 E EP PS S C Co on nt tr ro ol ll le er r F Fa au ul lt t 3 35 5 P Pu um mp p M Mo ot to or r O Ov ve er r c cu ur rr re en nt t 7 72 2 C Co on n...

Page 90: ...of 25 C to 145 C 13 F to 293 F C 13 F to 293 F Recovers when moto Recovers when motor temperature is in range of 20 to 70 C 4 to r temperature is in range of 20 to 70 C 4 to 158 F 158 F Checks Checks...

Page 91: ...nd E 07 4 4 Check continuity between E 02 6 and E 07 4 4 Continuity Continuity No continuity No continuity 19 Connect connector E 01 then turn on power again 19 Connect connector E 01 then turn on pow...

Page 92: ...r card Power card E 01 E 01 E 01 E 01 E 07 E 07 E 07 E 07 E 17 E 17 E 14 E 14 E 14 E 14 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P P N N U U V...

Page 93: ...or r O ON N O Ov ve er rh he ea at t i in nd di ic ca at to or r O OF FF F 2 on motor becomes normal 2 on motor becomes normal 3 Disconnect battery plug 3 Disconnect battery plug Disengage brake and p...

Page 94: ...alue is 8V 2V Normal Abnormal Normal Abnormal 22 Disconnect battery plug 22 Disconnect battery plug 16 Replace left traction motor 16 Replace left traction motor 20 Repair or replace harness 20 Repair...

Page 95: ...ower card Power card E 01 E 01 E 01 E 01 E 06 E 06 E 06 E 06 E 18 E 18 E 18 E 18 E 15 E 15 E 15 E 15 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P...

Page 96: ...es Overheat Overheat indicator indicator ON ON Overheat Overheat indicator indicator OFF OFF 2 Pump motor becomes normal 2 Pump motor becomes normal 3 Check if truck is operated to lift large cargo lo...

Page 97: ...E 05 3 3 Check continuity between E 02 6 and E 05 4 4 Check continuity between E 02 6 and E 05 4 4 Check continuity between E 05 14 and E 05 15 Check continuity between E 05 14 and E 05 15 Continuity...

Page 98: ...V V W W M M 37 37 36 36 Flat Flat cable cable Pump inverter Pump inverter PW PW PU PU PV PV IU IU IV IV IW IW Pump motor Pump motor Therma Thermal l sensor sensor Fuse Fuse Battery Battery GND GND 12V...

Page 99: ...o rature is in range of 20 to 70 C 4 to 158 F 158 F Checks Checks 1 Let truck cool for 15 minutes 1 Let truck cool for 15 minutes O Ov ve er rh he ea at t i in nd di ic ca at to or r O ON N O Ov ve er...

Page 100: ...7 4 4 Continuity Continuity No No continuity continuity 17 Measure voltage between E 07 18 11 and 17 Measure voltage between E 07 18 11 and E 07 20 12 E 07 20 12 Confirm v Confirm value is alue is 8 8...

Page 101: ...er card Power card E 01 E 01 E 01 E 01 E 07 E 07 E 07 E 07 E 17 E 17 E 14 E 14 E 14 E 14 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P P N N U U V...

Page 102: ...s in range of 20 to 70 C 4 rature is in range of 20 to 70 C 4 to 158 F to 158 F Checks Checks 1 Let truck cool for 15 minutes 1 Let truck cool for 15 minutes Overheat Overheat indi indicator cator ON...

Page 103: ...25 Replace left lace left traction inver traction inverter ter DS DSP card is normal P card is normal 24 Disconnect battery plug then perform inverter 24 Disconnect battery plug then perform inverter...

Page 104: ...ower card Power card E 01 E 01 E 01 E 01 E 06 E 06 E 06 E 06 E 18 E 18 E 18 E 18 E 15 E 15 E 15 E 15 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P...

Page 105: ...ange of 20 to 70 e is in range of 20 to 70 C 4 to 158 F C 4 to 158 F Checks Checks 1 Let truck cool for 15 minutes 1 Let truck cool for 15 minutes Overheat Overheat indi indicator cator ON ON Overheat...

Page 106: ...n on power again Then turn on power again E7 E7 Not Not E7 E7 25 Replace pump inverter DSP card is normal 25 Replace pump inverter DSP card is normal 24 Disconnect battery plug then perform inverter 2...

Page 107: ...V V W W M M 37 37 36 36 Flat Flat cable cable Pump inverter Pump inverter PW PW PU PU PV PV IU IU IV IV IW IW Pump motor Pump motor Therma Thermal l sensor sensor Fuse Fuse Battery Battery GND GND 12V...

Page 108: ...nutes 15 minutes and turn the key off and turn the key off and on and on O Ov ve er rh he ea at t i in nd di ic ca at to or r O ON N O Ov ve er rh he ea at t i in nd di ic ca at to or r O OF FF F 2 Le...

Page 109: ...f logic unit 20 Replace power supply card of logic unit CAN CAN 22 Replace EPS Controller 22 Replace EPS Controller 19 Ensure all connectors are connected 19 Ensure all connectors are connected Then t...

Page 110: ...f of case case IMS IMS card card P P N N U U W W U U W W M M Flat Flat cable cable EPScontroller EPScontroller TWR TWR TUR TUR IUR IUR IWR IWR PS motor PS motor Fuse Fuse Battery Battery 12V 12V 14V 1...

Page 111: ...t of 120 A to 120 A When turning on power current sensor value is out of 120 A to 120 A Checks Checks 2 Follow the inverter testing procedure 2 Follow the inverter testing procedure Normal Abnormal No...

Page 112: ...er card Power card E 01 E 01 E 01 E 01 E 07 E 07 E 07 E 07 E 17 E 17 E 14 E 14 E 14 E 14 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P P N N U U V...

Page 113: ...terminal for burning and small 2 Check traction motor body and terminal for burning and small Normal Abnormal Normal Abnormal 4 Replac 4 Replace t e traction motor raction motor 7 Replace traction 7 R...

Page 114: ...connect and turning on powe ct and turning on power r If fault 15 remains If fault 15 remains 23 Perform inverter discharging work 23 Perform inverter discharging work 25 Perform inverter discharging...

Page 115: ...er card Power card E 01 E 01 E 01 E 01 E 07 E 07 E 07 E 07 E 17 E 17 E 14 E 14 E 14 E 14 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P P N N U U V...

Page 116: ...ic unit of logic unit Check continuity between E 02 5 and E 07 3 3 Check continuity between E 02 5 and E 07 3 3 Check continuity between E 02 6 and E 07 4 4 Check continuity between E 02 6 and E 07 4...

Page 117: ...er card Power card E 01 E 01 E 01 E 01 E 07 E 07 E 07 E 07 E 17 E 17 E 14 E 14 E 14 E 14 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P P N N U U V...

Page 118: ...lue is out of 120 A to 120 A When turning on power current sensor value is out of 120 A to 120 A Checks Checks 2 Follow the inverter testing procedure 2 Follow the inverter testing procedure Normal Ab...

Page 119: ...Power card Power card E 01 E 01 E 01 E 01 E 06 E 06 E 06 E 06 E 18 E 18 E 18 E 18 E 15 E 15 E 15 E 15 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card...

Page 120: ...les 3 Check motor terminal U V W phases for shorting to 3 Check motor terminal U V W phases for shorting to the motor body and truck frame the motor body and truck frame N No ot t s sh ho or rt ti in...

Page 121: ...place the traction inverter ASSY with the original 26 Replace the traction inverter ASSY with the original inverter ASSY again then replace the traction motor inverter ASSY again then replace the trac...

Page 122: ...ower card Power card E 01 E 01 E 01 E 01 E 06 E 06 E 06 E 06 E 18 E 18 E 18 E 18 E 15 E 15 E 15 E 15 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P...

Page 123: ...heck continuity between E 02 5 and E 06 3 3 Check continuity between E 02 5 and E 06 3 3 Check continuity between E 02 6 and E 06 4 4 Check continuity between E 02 6 and E 06 4 4 Continuity Continuity...

Page 124: ...ower card Power card E 01 E 01 E 01 E 01 E 06 E 06 E 06 E 06 E 18 E 18 E 18 E 18 E 15 E 15 E 15 E 15 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P...

Page 125: ...out of 120 A to 120 A When turning on power current sensor value is out of 120 A to 120 A Checks Checks 2 Follow the inverter testing procedure 2 Follow the inverter testing procedure Normal Abnormal...

Page 126: ...V V W W M M 37 37 36 36 Flat Flat cable cable Pump inverter Pump inverter PW PW PU PU PV PV IU IU IV IV IW IW Pump motor Pump motor Therma Thermal l sensor sensor Fuse Fuse Battery Battery GND GND 12V...

Page 127: ...erminals P N U V W Check motor terminals for shorting to the motor body Check motor terminals for shorting to the motor body Check the cables for shorting to the frame Check the cables for shorting to...

Page 128: ...CAN 5 5 3 3 4 4 6 6 11 11 9 9 10 10 11 11 12 12 Power Power Power card Power card E 05 E 05 E 16 E 16 E 16 E 16 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS...

Page 129: ...tactor coil Check continuity of the control line fuse for contactor coil C Co on nt ti in nu ui it ty y N No o c co on nt ti in nu ui it ty y 12 12 Perform inverter discharging work then replace logic...

Page 130: ...Because the card is normal 15 Remove DSP cover of all inverters and check DSP flat cable for looseness or wire breakage 15 Remove DSP cover of all inverters and check DSP flat cable for looseness or w...

Page 131: ...06 Traction Tractioninverter inverter right right Traction in Traction inverter verter left left P P P P W W 3 3 4 4 3 3 4 4 E 05 E 05 P P KEY KEY EMG EMG CAN CAN L L Pump inverter Pump inverter E 07...

Page 132: ...ter discharging work 8 Measure resistance of contactor coil 8 Measure resistance of contactor coil 61 at 30 C 22 F to 91 at 80 C 176 F 61 at 30 C 22 F to 91 at 80 C 176 F Within Within range range Out...

Page 133: ...2 1 15 5 1 11 9 1 9 3 3 1 1 1 16 6 1 14 4 4 4 2 2 17 17 2 20 0 1 18 8 E 04 E 04 6 63 3 6 61 1 5 59 9 5 55 5 5 53 3 5 51 1 4 49 9 43 43 6 64 4 6 62 2 6 60 0 5 56 6 5 52 2 5 50 0 4 48 8 44 44 Logics Lo...

Page 134: ...terminals of both cable ends between U and U V and V and W and W ends between U and U V and V and W and W Less than Less than 1 1 1 1 or or mo more re 15 Repair or replace harness 15 Repair or replac...

Page 135: ...1 17 1 7 15 5 9 9 7 7 5 5 3 3 1 1 24 24 2 20 0 1 18 8 8 8 6 6 4 4 2 2 7 5 7 5 3 3 1 1 1 16 6 6 4 6 4 2 2 1 19 9 1 17 7 2 20 0 1 18 8 3 3 4 4 16 16 17 17 18 18 20 20 3 3 4 4 2 2 1 1 2 2 1 1 5 5 6 6 3...

Page 136: ...harness 15 Repair or replace harness 8 Connect connector securely 8 Connect connector securely 10 Replace motor cables 10 Replace motor cables 9 Repla 9 Replace left ce left traction motor traction m...

Page 137: ...6 6 4 4 23 23 2 21 1 1 19 9 1 17 1 7 15 5 9 9 7 7 5 5 3 3 1 1 24 24 2 20 0 1 18 8 8 8 6 6 4 4 2 2 1 1 2 2 1 1 2 2 3 3 4 4 1 11 1 7 7 5 5 3 3 1 1 1 16 6 8 8 6 4 6 4 2 2 1 19 9 1 17 7 2 20 0 1 18 8 3 3...

Page 138: ...les 9 Replace pump motor 9 Replace pump motor 8 Replace motor cables 8 Replace motor cables 1 Disconnect battery plug then perform inverter discharging work 1 Disconnect battery plug then perform inve...

Page 139: ...3 3 4 4 CAN CAN 5 5 3 3 4 4 6 6 11 11 9 9 10 10 11 11 12 12 Power Power Power card Power card E 05 E 05 E 16 E 16 E 16 E 16 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case c...

Page 140: ...g onnect steering motor cables from E motor cables from EPS c PS controller ontroller Measur Measure res e resistance istance of motor cables U of motor cables U and and W phas W phases es Less Less t...

Page 141: ...6 63 3 6 61 1 5 59 9 5 55 5 5 53 3 5 51 1 4 49 9 43 43 6 64 4 6 62 2 6 60 0 5 56 6 5 52 2 5 50 0 4 48 8 44 44 E 02 E 02 1 15 1 5 13 1 3 11 1 9 9 5 5 3 3 1 16 6 1 14 4 1 12 2 1 10 0 6 6 4 4 E 01 E 01 5...

Page 142: ...nd c and check heck voltage between voltage between H H 01 3W 01 3W E 38 4W 4 Power and 6 GND E 38 4W 4 Power and 6 GND 5 5 V V 10 10 Outside Outside the the specified specified range range 3 Check co...

Page 143: ...1 10 0 6 6 4 4 E 01 E 01 5 5 53 53 6 6 CAN CAN Life Life Signal Signal E 04 E 04 5 5 3 3 4 4 6 6 11 11 Fuse Fuse Steering Unit Steering Unit Power Power L L L R L R W W L R L R R Y R Y R Y R Y Y B Y B...

Page 144: ...y Continuity No No continuity continuity 4 Perform inverter discharging work 4 Perform inverter discharging work 7 Check continuity between E 02 20 and E 19 6 52 7 Check continuity between E 02 20 and...

Page 145: ...19 6 52 E 19 2 53 Turn on power Turn on power and check and check accelerator voltage with service tool accelerator voltage with service tool 0 0 V V N No ot t 0 0 V V CHAPTER 2 TROUBLESHOOTING FOR C...

Page 146: ...n connector securely 8 Fasten connector securely 12 Repair or replace harness 12 Repair or replace harness 2 Check to see if right traction motor cables U 2 Check to see if right traction motor cables...

Page 147: ...3 3 1 16 6 1 14 4 1 12 2 1 10 0 6 6 4 4 23 23 2 21 1 1 19 9 1 17 1 7 15 5 9 9 7 7 5 5 3 3 1 1 24 24 2 20 0 1 18 8 8 8 6 6 4 4 2 2 7 5 7 5 3 3 1 1 1 16 6 6 4 6 4 2 2 1 19 9 1 17 7 2 20 0 1 18 8 3 3 4 4...

Page 148: ...r securely 6 Fasten connector securely 6 Fasten connector securely 12 Repair or replace harness 12 Repair or replace harness 2 Check to see if left traction motor cables U V and W 2 Check to see if le...

Page 149: ...6 4 4 23 23 2 21 1 1 19 9 1 17 1 7 15 5 9 9 7 7 5 5 3 3 1 1 24 24 2 20 0 1 18 8 8 8 6 6 4 4 2 2 1 1 2 2 1 1 2 2 3 3 4 4 1 11 1 7 7 5 5 3 3 1 1 1 16 6 8 8 6 4 6 4 2 2 1 19 9 1 17 7 2 20 0 1 18 8 3 3 4...

Page 150: ...5 2 5 0 2 V if it 0 2 V if it is not operated is not operated 5 Disconnect battery plug then perform inverter 5 Disconnect battery plug then perform inverter discharging work discharging work 1 11 1...

Page 151: ...9 9 7 7 1 1 2 26 2 6 24 4 2 20 1 0 18 8 1 14 4 8 8 2 2 3 31 1 2 29 9 2 27 7 3 32 2 3 30 0 2 28 8 E 12 E 12 H 04 H 04 E 02 E 02 E 01 E 01 E 12 E 12 CAN CAN Power cord Power cord 23 23 8 8 7 7 2 2 1 1 5...

Page 152: ...work discharging work 1 13 3 R Re ep pl la ac ce e o ou ut tp pu ut t u un ni it t 1 14 4 R Re ep pa ai ir r o or r r re ep pl la ac ce e h ha ar rn ne es ss s F FC C O OU UT T h ha ar rn ne es ss s 1...

Page 153: ...ATT2B ATT2B ATT2A ATT2A ATT1B ATT1B ATT1A ATT1A TIL TILTB TB TIL TILT TA A LIFTB LIFTB LIFTA LIFTA E E 3 35 5 E E 3 31 1 E E 3 34 4 E E 3 30 0 E E 3 33 3 E E 2 29 9 E E 3 32 2 E E 2 28 8 E E 3 35 5 E...

Page 154: ...signal is not outputted current is more than 0 18 A When signal is not outputted current is more than 0 18 A Checks Checks 5 Repair or replace harness 5 Repair or replace harness 7 Replace related so...

Page 155: ...ATT2B ATT2B ATT2A ATT2A ATT1B ATT1B ATT1A ATT1A TIL TILTB TB TIL TILT TA A LIFTB LIFTB LIFTA LIFTA E E 3 35 5 E E 3 31 1 E E 3 34 4 E E 3 30 0 E E 3 33 3 E E 2 29 9 E E 3 32 2 E E 2 28 8 E E 3 35 5 E...

Page 156: ...1 Move direction lever to neutral and release accelerator pedal 1 Move direction lever to neutral and release accelerator pedal 7 Check direction lever and accelerator sensor operations 7 Check direc...

Page 157: ...52 55 55 53 53 54 54 E 19 E 19 E 19 E 19 Accelerator Accelerator 37 37 36 36 62 62 61 61 106 106 F F R R 8 8 6 6 4 4 Direction Direction lever lever Forward Forward Reverse Reverse Accel idle Accel id...

Page 158: ...fault occ occurre urred d If If this this fault fault occ occurre urred d when when during during running running turning turning on on power power 11 Replace seat switch 11 Replace seat switch 2 Sto...

Page 159: ...replace main harness CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Logics Logics E 03 E 03 E 03 E 03 Logics Logics E 04 E 04 E 04 E 04 64 64 43 43 1 1 3...

Page 160: ...on on power power 2 Sit on seat then stop pump motor operation 2 Sit on seat then stop pump motor operation If If fault fault remains remains Normal Normal 7 Change lift control lever to other normal...

Page 161: ...arness FC IN harness Lift Lift control lever control lever FCspeci cation FCspeci cation E 36 E 36 E 36 E 36 MC speci cation MC speci cation Lift 1 Lift 1 Lift 2 Lift 2 GND GND 68 68 52 52 51 51 2 2 5...

Page 162: ...red when when pump pump motor motor operation operation turning turning on on power power 2 Sit on seat then stop pump motor operation 2 Sit on seat then stop pump motor operation If If fault fault re...

Page 163: ...arness Tilt Tilt control lever control lever FCspeci cation FCspeci cation 50 50 43 43 3 3 6 6 5 5 2 2 4 4 1 1 Logics Logics E 04 E 04 E 04 E 04 E 36 E 36 MC speci cation MC speci cation Tilt Tilt 5 5...

Page 164: ...s this fault fault occurred occurred when when pump pump motor motor operation operation turning turning on on power power 2 Sit on seat then stop pump motor operation 2 Sit on seat then stop pump mot...

Page 165: ...ontrol lever control lever Attachment1 Attachment1 FCspeci cation FCspeci cation MC speci cation MC speci cation 5 5 6 6 R B R B Y B Y B B Y B Y B B 5V 5V GND GND E 36 E 36 49 49 Y L Y L 0 12V 0 12V 4...

Page 166: ...fault occurred occurred when when pump pump motor motor operation operation turning turning on on power power 2 Sit on seat then stop pump motor operation 2 Sit on seat then stop pump motor operation...

Page 167: ...ess control lever control lever Attachment 2 Attachment 2 FCspeci cation FCspeci cation E 36 E 36 MCspeci cation MCspeci cation R B R B L Y L Y Y L Y L B B 5V 5V GND GND 48 48 5 5 6 6 5 5 2 2 4 4 1 1...

Page 168: ...peration Detects seat switch opening when turning on power or during pump operation Checks Checks 1 1 If If this this fault fault occurred occurred during during If If this this fault fault occurred o...

Page 169: ...ac ce e m ma ai in n h ha ar rn ne es ss s CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Logics Logics E 03 E 03 E 03 E 03 Logics Logics E 04 E 04 E 04...

Page 170: ...1 harnesses Place FNR lever in neutral Place FNR lever in neutral Chec Check continuity betw k continuity between een E E 04 43 04 43 and E and E 03 37 03 37 Chec Check continuity betw k continuity be...

Page 171: ...CONTROL CIRCUITS GND GND Logics Logics Back Back buzzer buzzer E 04 and E 03 E 04 and E 03 E 03 E 03 43 43 18 18 19 19 20 20 14 14 F F 2 2 1 1 4 4 3 3 N N R R GND GND Joystick box Joystick box option...

Page 172: ...shorted to other signal 10 Check to see if these are shorted to other signal cables cables Not Not shorted shorted Shorted Shorted 12 Replace display unit 12 Replace display unit If fault remains If...

Page 173: ...3 3 105 105 105 105 105 105 86 86 10 A 10 A Key switch Key switch Fuse holder Fuse holder Emetrgency SW Emetrgency SW Emetrge Emetrgency ncy SW SW Power card Power card Power card Power card E 01 E 01...

Page 174: ...it or output unit Checks Checks 1 Turn off power then turn on power in Setup Option Group 1 Turn off power then turn on power in Setup Option Group3 setting 3 setting 2 Set Setup Option Group 3 data 2...

Page 175: ...ta EEPROM SUM value of logic card is different different from check data from check data Checks Checks 1 Turn off power then turn on power in Setup Option Group 1 Turn off power then turn on power in...

Page 176: ...e connector E 07 2 Remove DSP cover then remove connector E 07 Check the contact face both of connector E 07on harness Check the contact face both of connector E 07on harness side side and E and E 07o...

Page 177: ...step 17 21 After step 17 Connect E 07 Connect E 07 Reconfirm step 16 Reconfirm step 16 Normal Abnormal Normal Abnormal 22 Repair or replace main 22 Repair or replace main harness harness 24 Replace DS...

Page 178: ...4 4 6 6 11 11 9 9 10 10 11 11 12 12 Power Power Power card Power card E 01 E 01 E 01 E 01 E 07 E 07 E 07 E 07 E 17 E 17 E 14 E 14 DSP DSP card card Inside Inside of of cover cover Inside Inside of of...

Page 179: ...n perform inverter discharging work 1 Disconnect battery plug then perform inverter discharging work 2 Remove DSP cover then remove connector E 06 2 Remove DSP cover then remove connector E 06 Check t...

Page 180: ...6 Disconnect battery plug then perform inverter discharging work 17 Replace DSP card of traction inverter 17 Replace DSP card of traction inverter 18 Replace power supply card of logic unit 18 Replace...

Page 181: ...wer card Power card E 01 E 01 E 01 E 01 E 06 E 06 E 06 E 06 E 18 E 18 E 15 E 15 DSP DSP card card Inside Inside of of cover cover Inside Inside of of case case IMS IMS card card P P N N U U V V W W U...

Page 182: ...rm inverter discharging work 6 Disconnect connector E 02 of logics Unit 6 Disconnect connector E 02 of logics Unit Already disconnected E 05 and E 01 Already disconnected E 05 and E 01 Check Check con...

Page 183: ...and E 02 01 and E 02 to logic unit to logic unit then then turn on turn on power power again again 20 Replace power supply card of logic unit 20 Replace power supply card of logic unit If fault remain...

Page 184: ...V W W U U V V W W M M 37 37 36 36 Flat Flat cable cable Pump inverter Pump inverter PW PW PU PU PV PV IU IU IV IV IW IW Pump motor Pump motor Therma Thermal l sensor sensor Fuse Fuse Battery Battery G...

Page 185: ...H 02 of FC of FC IN harness IN harness 9 Measure voltage between H 02 07 12 and H 02 10 10 9 Measure voltage between H 02 07 12 and H 02 10 10 Con Confirm va firm value is lue is 14 14 2 V 2 V Normal...

Page 186: ...Logics Power card Power card Harness Harness 6 6 3 3 5 5 6 6 CAN CAN B B R Y R Y W W L L GND GND 14V 14V 1 15 1 5 13 1 3 11 1 9 9 5 5 3 3 1 16 6 1 14 4 1 12 1 2 10 0 6 6 4 4 23 23 2 21 1 1 19 9 1 17...

Page 187: ...th FC input output output monitor monitor Normal Normal Error Error 6 Disconnect battery plug then replace output unit 6 Disconnect battery plug then replace output unit Turn off power Turn off power...

Page 188: ...5 5 4 4 105 105 86 86 10 A 10 A Key switch Key switch Fuse holder Fuse holder EmetrgencySW EmetrgencySW E 21 E 21 E 21 E 21 C 08 C 08 H 02 H 02 FC FC H 02 H 02 FC FC 2 2 1 1 E 37 E 37 MC MC E 37 E 37...

Page 189: ...f logics Unit Already disconnected E 01 and E 08 Already disconnected E 01 and E 08 Chec Check continuity between E 02 5 k continuity between E 02 5 and E 08 21 3 and E 08 21 3 Chec Check continuity b...

Page 190: ...supply card of logic unit If fault remains If fault remains 21 Disco 21 Disconnec nnect t E 03 E 04 E E 03 E 04 E 05 E 06 E 07 E 08 05 E 06 E 07 E 08 Reconfirm step 17 after power on Reconfirm step 1...

Page 191: ...5 5 3 3 1 16 6 1 14 4 1 12 2 1 10 0 6 6 4 4 E 01 E 01 5 5 53 53 6 6 CAN CAN Life Life Signal Signal E 04 E 04 5 5 3 3 4 4 6 6 11 11 Fuse Fuse Steering Unit Steering Unit Power Power L L L R L R W W L...

Page 192: ...tor if found wit y contactor if found with serv h service tool ice tool Line contactor Line contactor St Steering eering contact contactor or 2 Find faulty contactor line contactor or steering 2 Find...

Page 193: ...CIRCUITS 6 63 3 6 61 1 5 59 9 5 55 5 5 53 3 5 51 1 4 49 9 43 43 6 64 4 6 62 2 6 60 0 5 56 6 5 52 2 5 50 0 4 48 8 44 44 Line contactor Line contactor 59 59 105 105 70 70 73 73 63 63 Logics Logics E 04...

Page 194: ...ging work 1 Disconnect battery plug then perform inverter discharging work 2 D 2 Disconnect connec isconnect connector E 04 of logic tor E 04 of logic unit unit 3 Chec 3 Check short circu k short circ...

Page 195: ...L CIRCUITS 1 1 2 2 1 1 2 2 Logics Logics E 04 E 04 E 04 E 04 72 72 105 105 61 61 Lift Lift lock lock valve valve E 13 E 13 W G W G R W R W E 13 E 13 Harness B Harness B Key Switch Key Switch Y Y B B 6...

Page 196: ...und with service tool P PK KB B P PK KB B2 2 2 Find P 2 Find Park arking brake ing brake with input with input output m output monitor onitor 5 Disc 5 Disconnect connector E 04 of logic onnect connect...

Page 197: ...5 59 9 5 55 5 5 53 3 5 51 1 4 49 9 43 43 6 64 4 6 62 2 6 60 0 5 56 6 5 52 2 5 50 0 4 48 8 44 44 4 4 3 3 2 2 1 1 1 1 2 2 3 3 4 4 62 62 71 71 105 105 105 105 71 71 303 303 301 301 302 302 304 304 60 60...

Page 198: ...f PDS buzzer 2 Disconnect connector of PDS buzzer Check c Check circuit between R1 and R ircuit between R1 and R2 2 of of side side N No ot t s sh ho or rt te ed d S Sh ho or rt te ed d 3 Repair or re...

Page 199: ...h 6 63 3 6 61 1 5 59 9 5 55 5 5 53 3 5 51 1 4 49 9 43 43 6 64 4 6 62 2 6 60 0 5 56 6 5 52 2 5 50 0 4 48 8 44 44 E 03 E 03 3 37 3 7 35 3 5 33 3 3 38 8 3 36 6 3 34 4 3 32 2 2 28 8 34 34 PDS buzzer PDS b...

Page 200: ...y battery less less than than 30 30 V V 48 48 V V battery battery less less than than 42 42 V V Checks Checks 1 Disconnect battery plug 1 Disconnect battery plug Measur Measure battery voltage with m...

Page 201: ...OTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 23 23 2 21 1 1 19 9 1 17 1 7 15 5 9 9 7 7 5 5 3 3 1 1 24 24 2 20 0 1 18 8 8 8 6 6 4 4 2 2 E 02 E 02 105 105 19 19 Logics Logic...

Page 202: ...tage is too high Battery voltage is corrected by 46 high Battery voltage is corrected by 46 value value 36 36 V V battery battery more more than than 42 42 V V 48 48 V V battery battery more more than...

Page 203: ...OTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 23 23 2 21 1 1 19 9 1 17 1 7 15 5 9 9 7 7 5 5 3 3 1 1 24 24 2 20 0 1 18 8 8 8 6 6 4 4 2 2 E 02 E 02 105 105 19 19 Logics Logic...

Page 204: ...ess than 22 V ry voltage is less than 22 V Battery voltage is corrected by 46 value Battery voltage is corrected by 46 value Checks Checks 1 Disconnect battery plug 1 Disconnect battery plug 2 Check b...

Page 205: ...OTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 23 23 2 21 1 1 19 9 1 17 1 7 15 5 9 9 7 7 5 5 3 3 1 1 24 24 2 20 0 1 18 8 8 8 6 6 4 4 2 2 E 02 E 02 105 105 19 19 Logics Logic...

Page 206: ...r and Sensor 3 GND Sensor 3 GND 5 5 V V 10 10 Out Outside side ac acce cept ptable able ran range ge 2 Dis 2 Disconne connect E 02 or E ct E 02 or E 03 03 cable of logic and tilt angle cable of logic...

Page 207: ...6 29 29 25 25 2 2 3 3 5V 5V GND GND 10 10 4 4 2 2 1 1 9 9 11 11 3 3 12 12 100 100 46 46 44 44 45 45 Logics Logics 5 5 VL VL GND GND GND GND R W R W W R W R B B B B E 03 E 03 E 02 E 02 23 23 2 21 1 1 1...

Page 208: ...eck Check voltage between voltage between E 20 3 Power E 20 3 Power and and E 20 1 GND E 20 1 GND 5 5 V V 10 10 Out Outside side acce accepta ptable ble range range 2 Disconnect cable of logic and loa...

Page 209: ...2 E 02 Logics Logics Logics Logics E 03 E 03 E 03 E 03 E 02 E 02 3 37 3 7 35 3 5 33 3 3 38 8 3 36 6 3 34 4 3 32 2 2 28 8 23 23 2 21 1 1 19 9 1 17 1 7 15 5 9 9 7 7 5 5 3 3 1 1 24 24 2 20 0 1 18 8 8 8 6...

Page 210: ...han 8 degrees Checks Checks 1 Disconnect battery plug 1 Disconnect battery plug 4 Replace harness 4 Replace harness 3 Connect power steering controller connector and 3 Connect power steering controlle...

Page 211: ...1 14 4 1 12 2 1 10 0 6 6 4 4 E 01 E 01 5 5 53 53 6 6 CAN CAN Life Life Signal Signal E 04 E 04 5 5 3 3 4 4 6 6 11 11 Fuse Fuse Steering Unit Steering Unit Power Power L L L R L R W W L R L R R Y R Y R...

Page 212: ...A t A4 4 Error code A4 Error code A4 Situation Situation Display A4 All Display A4 All truck operations inhibited Line contactor OPEN and ST contactor OPEN truck operations inhibited Line contactor OP...

Page 213: ...f of case case IMS IMS card card P P N N U U W W U U W W M M Flat Flat cable cable EPScontroller EPScontroller TWR TWR TUR TUR IUR IUR IWR IWR PS motor PS motor Fuse Fuse Battery Battery 12V 12V 14V 1...

Page 214: ...y and terminal for burning and small Normal Abnormal Normal Abnormal 4 Replace EPS motor 4 Replace EPS motor 9 Replace EPS motor or 9 Replace EPS motor or cables cables 3 Chec 3 Check motor terminal U...

Page 215: ...f of case case IMS IMS card card P P N N U U W W U U W W M M Flat Flat cable cable EPScontroller EPScontroller TWR TWR TUR TUR IUR IUR IWR IWR PS motor PS motor Fuse Fuse Battery Battery 12V 12V 14V 1...

Page 216: ...rrent FB 0 16A 0 16A Overcurre Overcurrentdetectedby ntdetectedby overcurren overcurrentdetectioncircuit tdetectioncircuit Checks Checks 1 Disconnect battery plug 1 Disconnect battery plug 4 Replace h...

Page 217: ...4 1 12 2 1 10 0 6 6 4 4 E 01 E 01 5 5 53 53 6 6 CAN CAN Life Life Signal Signal E 04 E 04 5 5 3 3 4 4 6 6 11 11 Fuse Fuse Steering Unit Steering Unit Power Power L L L R L R W W L R L R R Y R Y R B R...

Page 218: ...Disconnect battery plug 1 Disconnect battery plug 4 Check 4 Check for Int for Interference between battery cover andswit erference between battery cover andswitch ch N No o i in nt te er rf fe er re...

Page 219: ...OTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 6 63 3 6 61 1 5 59 9 5 55 5 5 53 3 5 51 1 4 49 9 43 43 6 64 4 6 62 2 6 60 0 5 56 6 5 52 2 5 50 0 4 48 8 44 44 Interlock SW Int...

Page 220: ...e error the error code code Corrected batter Corrected battery voltage is less y voltage is less than 25 V than 25 V Battery voltage is corrected by 46 value Battery voltage is corrected by 46 value C...

Page 221: ...OTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 23 23 2 21 1 1 19 9 1 17 1 7 15 5 9 9 7 7 5 5 3 3 1 1 24 24 2 20 0 1 18 8 8 8 6 6 4 4 2 2 E 02 E 02 105 105 19 19 Logics Logic...

Page 222: ...itch installed condition 3 Check brake fluid switch installed condition Normal Normal Abnormal Abnormal 2 Check brake fluid level 2 Check brake fluid level Normal Normal Too low Too low 5 Disconnect c...

Page 223: ...38 43 43 1 1 2 2 63 63 64 64 Logics Logics E 03 E 03 Logics Logics E 04 E 04 B B Br B Br B GND GND C 01 C 01 C 01 C 01 C 01 C 01 1 1 2 2 E 03 E 03 E 04 E 04 3 37 3 7 35 3 5 33 3 3 38 8 3 36 6 3 34 4 3...

Page 224: ...ti io on n F Fl la as sh hi in ng o g on h n ho ou ur m r me et te er r Possible Possible cause cause Battery voltage for calendar IC is Battery voltage for calendar IC is low low Trigger of Trigger o...

Page 225: ...502878 502878 CHAPTER 3 MOTOR CHAPTER 3 MOTOR C Ch ha ap pt te er r 3 3 M MO OT TO OR R 1 1 Mo Moto tor I r Ins nsta tall llat atio ion P n Pos osit itio ions ns 3 Wheel model 3W 3 Wheel model 3W 3 3...

Page 226: ...tor ors s 2 2 El Elec ectr tro o ma magn gnet etic ic br brak ake e 3 3 P Pu um mp m p mo ot to or r 4 4 E EP PS m S mo ot to or r 502714 502714 CHAPTER 3 MOTOR CHAPTER 3 MOTOR 4 Wheel model 4W 4 Whee...

Page 227: ...on motor or Type Type Induction three Induction three phase AC phase AC V Vo ol lt ta ag ge e V V 4 48 8 V V O Ou ut tp pu ut t W W 4 4 5 5 k kW W W We ei ig gh ht t 3 37 7 k kg g 8 82 2 l lb b Pump m...

Page 228: ...AC motors as the Traction motors and motors as the Traction motors and pump motor pump motor For the feature and speed control of AC motors see AC Motor Syste For the feature and speed control of AC...

Page 229: ...APTER 3 MOTOR 3 3 2 2 P Pu um mp p m mo ot to or r 1 1 W t W te er rm mi in na al l 2 2 V t V te er rm mi in na al l 3 3 U t U te er rm mi in na al l 4 4 Th Ther erma mal l co conn nnec ecto tor r 502...

Page 230: ...pumpassembly assembly 4 W 4 W 2 2 To Tobo bod dy y ha har rne ness ss 502718 502718 1 1 2 2 EPS motor is the DC motor EPS motor is the DC motor The motor moves the rear wheel The motor moves the rear...

Page 231: ...eManual ServiceManual 2 2 Remo Remove all the e ve all the elect lectric wir ric wirings so ings solenoi lenoid brake c d brake cable able and hydraulic lines connected to the motor and and hydraulic...

Page 232: ...act ctio ion m n mot otor or 5 5 1 1 D Di is sa as ss se em mb bl ly S y Se eq qu ue en nc ce e CAUTION CAUTION Ball bea Ball bearing rings at both en s at both ends are of ma ds are of mainten intena...

Page 233: ...rn replace it extremely worn replace it Inspection of ball bearing Inspection of ball bearing Check fitting part of the bearing in Check fitting part of the bearing in the cover end and the the cover...

Page 234: ...e 4P to t t type 4P to the conne he connector of t ctor of the spee he speed senso d sensor in the mot r in the motor or water resistant type 4P water resistant type 4P The left side The left side Con...

Page 235: ...Se eq qu ue en nc ce e Follow the disassembling in Follow the disassembling in reverse reverse 1 1 Apply Applysilic silicone oneadhe adhesive sive Tor Toray D ay Dow C ow Cornin orning SE g SE9188 91...

Page 236: ...r fore re e remov moval al Turn th Turn the key swit e key switch to the of ch to the off positi f position and ope on and operate hy rate hydrau draulic leve lic levers a few tim rs a few times to re...

Page 237: ...3 1 1 2 2 Tightening torque for flange nut Tightening torque for flange nut 10 9 to 13 3 N m 1 1 to 1 4 kgf m 8 0 to 9 8 lbf ft 10 9 to 13 3 N m 1 1 to 1 4 kgf m 8 0 to 9 8 lbf ft 6 6 Remov Remove the...

Page 238: ...pairi pairing the mo ng the motor th tor the e bearings and seals must be replaced bearings and seals must be replaced If a bear If a bearing wh ing which is to b ich is to be repl e replaced h aced h...

Page 239: ...replace it extremely worn replace it Inspection of ball bearing Inspection of ball bearing Check fitting part of the bearing in Check fitting part of the bearing in the cover end and the the cover end...

Page 240: ...o otor r Con Connec nect the t theV2 ca V2 cable f ble from romthe thecha chassi ssis to th s to the V2 te e V2 term rmina inal on th l on the mot e motor or Con Connec nect the t theW2 ca W2 cable f...

Page 241: ...y Se Sequ quen ence ce Follow the disassembling in Follow the disassembling in reverse reverse 1 1 Apply Applysilic silicone oneadhe adhesive sive Tor Toray D ay Dow C ow Cornin orning SE g SE9188 91...

Page 242: ...2713 502713 CHAPTER 3 MOTOR CHAPTER 3 MOTOR 12 12 Tight Tightening eningof Hi of High pow gh power Ca er Cable ble Term Terminals inals CAUTION CAUTION If the high power cable terminals of the battery...

Page 243: ...ord plac laces of h es of har arnes ness con s connec nectio tions be ns befor fore dis e discon connec nectin ting g Be Be su sure re to to di disc scon onne nect ct th the b e bat atte tery ry pl pl...

Page 244: ...al ll b l be ea ar ri in ng g 502732 502732 1 1 4 4 6 6 7 7 7 7 CHAPTER 3 MOTOR CHAPTER 3 MOTOR 4 Wheel model 4 W 4 Wheel model 4 W 1 1 B Bo ol lt t 2 2 E En nd d c co ov ve er r C C 3 3 Y Yo or rk a...

Page 245: ...ne Check for wear of spline If it is If it is extremely worn replace it extremely worn replace it Inspection of ball bearing Inspection of ball bearing Check fitting part of the bearing in Check fitti...

Page 246: ...tor commutator 0 8 to 0 85 mm 0 8 to 0 85 mm 0 032 to 0 034 in 0 032 to 0 034 in How to repair of commutator How to repair of commutator 1 1 Grin Grind or d orpolish polishthe the Comm Commutat utator...

Page 247: ...de el l 5 5N N 4 4 W W 5 5N N CAUTION CAUTION If the SPRING and or the brush If the SPRING and or the brush holder were rusted replace them holder were rusted replace them Inspect with the Inspect wi...

Page 248: ...of connector plug each terminal of connector plug 1 1 Me Megg gger er 2 2 Con Connec nector tor 3 3 End Endcov cover er 502739 502739 1 1 2 2 3 3 T To oo ol l S Sp pe ec ci if fi ic c R Re es si is s...

Page 249: ...ckness of b ness of brush rush 1 1 1 1 1 1 3 3 502740 502740 2 2 I It te em m S St ta an nd da ar rd d L Li im mi it t Thickness of brush Thickness of brush 3 W 3 W 1 3 to 1 6 ton model 1 3 to 1 6 ton...

Page 250: ...ep pa ai ir r o or r r re ep pl la ac ce e B Br ro ok ke en n w wi ir re e i in n f fi ie el ld d d de ev vi ic ce e R Re ep pa ai ir r o or r r re ep pl la ac ce e B Br ro ok ke en n w wi ir re e i...

Page 251: ...ates the pow indicates the power circuit i er circuit including the batte ncluding the battery fuse ignition sw ry fuse ignition switch etc itch etc GND circuit diagram GND circuit diagram The GND cir...

Page 252: ...tem from fuse to GND earth is indicated The circuits indicate the The circuit of each system from fuse to GND earth is indicated The circuits indicate the direction of signal flow In figures it direct...

Page 253: ...Indica icate sam te same conn e connect ector or 13 13 Indic Indicate co ate connect nnection wi ion with GND th GNDcirc circuit uit 14 14 Shee Sheet nu t number mberof of GND GND circu circuit it 15...

Page 254: ...BO OL L N NA AM ME E RESISTOR RESISTOR VALIABLERESISTOR VALIABLERESISTOR S SY YM MB BO OL L N NA AM ME E 4 4 Semi Semicond conducto uctors an rs and el d electr ectronic onictube tubes s S SY YM MB BO...

Page 255: ...N NA AM ME E SWITCH SWITCH N O N O SWITCH SWITCH N C N C TWO POSITION SWITC TWO POSITION SWITCH H EMERGENCYSWITCH EMERGENCYSWITCH PUSH BUTTONSWITCH PUSH BUTTONSWITCH SWITCH AUTO RETURN SWITCH AUTO RET...

Page 256: ...No No 1 1 and and No No 3 3 terminals terminals are are connected when the switch position is placed in connected when the switch position is placed in N position N position 1 1 S Sw wi it tc ch h p...

Page 257: ...uit it number wire diameter and wire color For the number wire diameter and wire color For the connecting lines of 0 5 mm connecting lines of 0 5 mm2 2 0 02 in 0 02 in2 2 wire size the wire wire size...

Page 258: ...e The items listed under the d under theitem categ item category symbol have a ory symbol have aspecific symbol specific symbol equipment num equipment number for classific ber for classification of i...

Page 259: ...ay coil c y coil conta ontactor c ctor coil t oil the shee he sheet symb t symbol in ol in which its contact is represented is provided so that you which its contact is represented is provided so that...

Page 260: ...nnec ecti ting ngLi Line ne 2 2 8 8 In Ind dic icat ati ion onof ofGN GND D E Ea art rth h 1 1 When a co When a connec nnecting wi ting wire cro re crosses to ot sses to other she her sheet it is et...

Page 261: ...inatio nation sheet symbo n sheet symbol l 3 3 Thisind Thisindicate icatestheconnecti stheconnectionto onto GND circuit GND circuit 4 4 Thisindi Thisindicatestheconne catestheconnectionto ctionto nega...

Page 262: ...nts and terminal shapes plug or For all connectors included in the circuit diagrams the connector shapes terminal arrangements and terminal shapes plug or socket are indicated socket are indicated Soc...

Page 263: ...ented by blackening to distinguish from the socketterminal female socketterminal female 501966 501966 CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS 5 5 Unus Unused ter...

Page 264: ...4 13 4 13...

Page 265: ...CHAPTER 5 CIRCUIT DIAGRAM CHAPTER 5 CIRCUIT DIAGRAM Ch Chap apte ter 5 r 5 C CIR IRCU CUI IT DI T DIA AGR GRAM AM...

Page 266: ...5 1 5 1...

Page 267: ...5 2 5 2...

Page 268: ...5 3 5 3...

Page 269: ...5 4 5 4...

Page 270: ...5 5 5 5...

Page 271: ...5 6 5 6...

Page 272: ...5 7 5 7...

Page 273: ...5 8 5 8...

Page 274: ...5 9 5 9...

Page 275: ...5 10 5 10...

Page 276: ...5 11 5 11...

Page 277: ...5 12 5 12...

Page 278: ...5 13 5 13...

Page 279: ...5 14 5 14...

Page 280: ...5 15 5 15...

Page 281: ...5 16 5 16...

Page 282: ...5 17 5 17...

Page 283: ...5 18 5 18...

Page 284: ...5 19 5 19...

Page 285: ...5 20 5 20...

Page 286: ...5 21 5 21...

Page 287: ...5 22 5 22...

Page 288: ...5 23 5 23...

Page 289: ...5 24 5 24...

Page 290: ...5 25 5 25...

Page 291: ...i i s s h h i i F F o o r r k k l l i i f f t t T T r r u u c c k k s s S S e e r r v v i i c c e e M M a a n n u u a a l l F F B B 1 1 3 3 P P N N T T F F B B 2 2 0 0 P P N N T T F F B B 1 1 6 6 C C...

Page 292: ...9 9 9 9 7 7 5 5 9 9 5 5 M M 3 3 0 0 0 0 P P N N F F o o r r k k l l i i f f t t T T r r u u c c k k s s...

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