TCM FB10-7, Service Manual

Page: 55 / 175

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3. CONTROL SYSTEM
No.
37
[405]
38
[501]
39
45
[407]
60
65
70
[403]
Problem
Load handling contactor
(MP) shorted
Detection circuit harness
defective
Load handling contactor
(MP) drive Tr defective
(Tr 4 inside CPU board)
Load contactor coil stuck
open
Detection circuit harness
defective
Load handling controller
temperature abnormal
Load handling main fuse
(F2) blow out
Detection circuit harness
defective
Load handling controller
temperature rises
abnormally.
Load handling motor
temperature abnormal
(external input signal)
Load handling quick
charge function defective
(Capacitor on load
handling capacitor board
is not properly charged.)
Error
Load handling system
does not work.
Load handling system
does not work.
Load handling system
does not work.
(The error is detected
when the temperature is
115°C and load handling
system does not work.)
Load handling system
does not work.
(MP contactor does not
close.)
Load handling system
works.
(This error is detected
when the temperature
exceeds 110°C, and
the conduction ratio is
restricted.)
Load handling system
does not work.
Usual load handling
operation is possible
(This error is detected
when the error code 30
occurs.)
Contactor ON timing is
late.
Remedy
Proceed with remedy in numerical order of encircled numbers.
①
Check load handling contactor (MP), and repair
or change if needed.
(seized contact points or mechanical hitch)
②
Check harness between CN5-22 (CPU board)
and P11 terminal, and repair or change if needed.
③
Check harness between CN4-10 (CPU board)
and P13 terminal, and repair or change if needed.
①
Check thermo sensor (THP) voltage, and change
if needed.
Check load handling contactor (MP) coil
connectors for disconnection and coil for
breakage, and repair or change if needed.
②
Check harness between contactor coil connector
and CN4-5, 13 (CPU board), and repair or
change if needed.
③
Change CPU board (drive Tr defective).
①
Cool down the controller.
②
Check TMP for loose fitting screws.
③
Check the resistance/voltage of thermo sensor
(THP), and change if needed.
④
Check harness between CN7-6, 12 (CPU board)
and thermo sensor (THP), and repair or change if
needed.
⑤
Check harness between CN9-6 (CPU board) and
CN1R-6, and repair or change if needed.
①
Check load handling fuse (F2), and change if
needed.
②
Check harness between CN5-22 (CPU board)
and P11 terminal, and repair or change if needed.
③
Check harness between CN4-8 (CPU board) and
P1 terminal, and repair or change if needed.
①
Cool down the controller.
②
Check TMP for loose fitting screw.
③
Check the resistance/voltage of thermo sensor
(THP).
④
Check harness between CN7-6, 12 (CPU board)
and thermo sensor (THP), and repair or change if
needed.
⑤
Check harness between CN9-6 (CPU board) and
CN1R-6, and repair or change if needed.
①
Cool down load handling motor.
②
Check the harness of CN1-22 (CPU board).
①
When the load handling system does not work,
check the error code 30 first.
②
Change CPU board (quick charge drive Tr, poor
resistance).
Reset
Turn off
key switch.
Turn off
key switch.
Restore
to normal
when the
temperature
drops below
115°C.
Turn off
key switch.
Restores
to normal
when the
temperature
drops below
100°C.
Restore to
normal.
Turn off
key switch.
Remarks
Thermo sensor (THP)
voltage under normal
condition:
0.2 V to 4.95 V
The resistance/voltage
of thermo sensor under
normal condition
20 k Ω /4.0 V (±10%) at
25°C.
Check for secondary
voltage of fuse (F2).
Thermo sensor (TH)
voltage under normal
condition:
0.1 V to 4.95 V
The resistance/voltage
of thermo sensor under
normal condition:
20 k Ω /4.0 V (±10%) at
25°C.
The error is detected when
the PM thermo switch is
opened (more than 120°C
and released when the
temperature drops (switch
closed).
If the key switch is
turned on with capacitor
improperly charged, the
contactor timing becomes
late. In addition, an arc
occurs when the contactor
is turned on, to promote
the wear of contactor.
Numbers in brackets are error codes that appear on the meter panel.