Sie sind auf Seite 1von 66

CHAPTER 1 CONTROLLER

Chapter 1 CONTROLLER
1. Controller System
1.1 System Layout

The lift truck is controlled by the logic unit and the inverter. The logic unit, the inverter, and meter panel are linked
together by the Controller Area Network (CAN) to
The logic unit is the main part of the control system and
communicate with each other. The logic unit sends the
controls the travel, lifting and safety function systems. The
motor control command to the inverter and the inverter
logic unit is connected to the inverter, meter panel and
sends the sensing data to the logic unit.
other control switches.
The meter panel indicates the lift truck conditions and
The inverter controls the AC induction traction motor and
setting data.
the AC induction pump motor.

Input switch signals


Key switch CAN
Meter panel
Direction lever Logic Unit
Accelerator
Service brake Logic card
Warning buzzer
Parking brake Traveling control
Seat switch Lifting control Contactor control signal
Seat belt switch Safety function
etc. Lift lock solenoid control signal
Brake fluid
Other switches Hydraulic lever input

CAN bus

Sensing data Motor control command Sensing data

Traction Inverter Pump Inverter

Lift cylinder
DSP card DSP card Tilt cylinder
Micro
switches

Steering
Hydraulic motor
Sensors Sensors control valve
assembly
M M Lift lock M
solenoid
3~ 3~ valve
Hydraulic
Traction motor Pump motor pump

Contactor Battery
Electric power

608585

1-1
CHAPTER 1 CONTROLLER
1.2 Controller Area Network (CAN)

Each controller is linked with the lift truck harness to form a If the terminal resistors are not properly connected, a
network as follows: communication failure may occur between the logic unit
and the inverters.
The terminal resistors are built into the traction inverter and
the pump inverter. For details, refer to Traction Inverter Fault (63) and Pump
Inverter Fault (65) in Troubleshooting for Control Circuits.

Traction Logic Meter Pump


inverter unit panel inverter

Built-in CAN H Built-in

CAN L

608586

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

VCAN-L
Kind of
potential

Logic
bit Vdiff
Vdiff

dominant 0 VCAN-H

recessive 1 recessive dominant recessive

500921
Main specifications

Item Specifications
Non-return to zero method
Communication protocol CAN bus 2.0B passive
Broadcast communication protocol
Communication line Dual 2-wire type serial communication
Communication speed 500 kbps
Data length 0 to 8 bytes

1-2
CHAPTER 1 CONTROLLER
1.3 Outline of Logic Unit
Logic unit
The logic unit consists of the logic card and the power The logic unit communicates with the meter panel through
supply card. the CAN bus. The lift truck speed and residual battery power
are monitored and shown on the meter panel. The seat belt
The logic card has the CPU chips and controls all the jobs for
and brake fluid level are also monitored and shown on the
the lift truck.
meter panel.
The logic unit calculates the traction motor control
The logic unit sets the model information and optional
command through the input of the direction lever or
default data into internal memory. The information is
accelerator pedal and sends the command to the traction
secured even if the power supply for the logic unit is turned
inverter. It also monitors malfunctions of the traveling
OFF. This information is set at the factory.
control system.
The following table shows the model information. The
The logic unit calculates the AC induction pump motor
system will not work properly if the actual controller system
control command through the input of the hydraulic levers
is different from the model information.
and sends the command to the pump inverter. It also
monitors malfunctions of the lifting control system.
Model information

Item Description SUO No.


Lift truck model Model set #40
Battery voltage 36 V, 48 V #41
Battery type Battery type #42
Mast type Mast type #44
Valve section Number of valves #45
Battery voltage adjustment Battery voltage adjustment #46
Foot direction Optional equipment #47

The current information is available to confirm and modify.


Refer to 1-24 "Setup Option".
The model information and various features are set by the Setup Option (SUO).
The power supply card changes the battery voltage and supplies power to the logic card and the DSP card.

1-3
CHAPTER 1 CONTROLLER
Logic unit

608587

Logic card

CN1

Main harness side

1)

2) 3) 4)
608588
1) Logic card side CN1 3) Main harness side E-03
2) Main harness side E-02 4) Main harness side E-04

1-4
CHAPTER 1 CONTROLLER
Power supply card

CN1

1) 2)
608589
1) Power supply card side CN1 2) Main Harness side E-01

1-5
CHAPTER 1 CONTROLLER
1.4 Outline of Inverter

The inverter is a motor drive controller that consists of Digital Signal Processor (DSP) card, Insulated Metal Substrate (IMS)
module and their drive boards.
It drives the AC induction motors according to the motor control command from the logic unit. It also monitors malfunctions
of motors and its own condition.
When a malfunction occurs, it stops the motors and informs the logic unit.
The DSP card has the DSP chips that enables high-speed calculation and controls the AC induction motors.
The IMS module has plural MOS-FET modules and converts the battery DC current into AC current for supplying to the traction
and pump motors. Also refer to 1-64 "AC Motor System Basics".
Traction and pump inverters

608590
1. DSP card

Traction and pump inverter DSP card

CN2

1) 2) 608591
1) Traction inverter card side CN2 2) Main harness side, Traction E-06
Pump inverter card side CN2 Main harness side, Pump E-05

1-6
CHAPTER 1 CONTROLLER
2. Traction Controller Feature
The line contactor closes in the following conditions when the key switch is turned ON. This enables the inverter to control the
traction motor.
All the following must be satisfied:
- The seat switch is turned ON.
- The lifting operation is not performed (the hydraulic lever input does not occur).
- The traveling operation is not performed: The direction lever is placed to NEUTRAL and the accelerator pedal is not
pressed.
- Warning related to the traveling and lifting operations does not occur.
2.1 Powering
Normal traveling
Travel speed is controlled by the accelerator pedal depression. The speed is also controlled by the accelerator pedal depression
when descending a grade and it is controlled only in the output torque range of the traction motor.
The controller supplies power to the traction motor according to the acceleration rate and the torque characteristic when the
accelerator pedal is pressed.

Description SUO No.


Acceleration rate Acceleration of traction #8
Powering
Traveling power Max. power, amount of battery consumption #9

Torque
[%]
POWER (3)
100 STANDARD (2)
85
ECONOMY (1)
70
Brake limit *1 (50%)
Thermal, BDI [0] or Service indicator*2
(30%)

Speed
0 5 10 15 (km/h)
500939

*1 Brake limit: Torque value resulting from reduction in current when the service brake or parking brake is applied.
*2 Thermal, BDI Level [0] or Service indicator: Curve of limited torque under a condition of overheating or battery voltage low
or maintenance time over.

1-7
CHAPTER 1 CONTROLLER
Boost
When lift truck travel is blocked by a step, the boost function Fully depress the accelerator pedal for 2 seconds. The boost
prevents stalling of the lift truck. This function allows the lift function increases the motor maximum torque for 5
truck to bypass a step regardless of the value setting of the seconds. If the pressure on the accelerator pedal is reduced
motor maximum torque. or the direction lever is moved, the boost function will be
canceled immediately.

Item Description SUO No.


When the service brake pedal is pressed or the parking brake is applied, the boost function
is not activated.
Boost #9
If the service brake pedal is pressed or the parking brake is applied when the boost
function is being activated, the boost function will be canceled immediately.

Torque [%]
*Torque required to climb over a step

* #9
100 POWER; Full acceleration
85 STANDARD; Full acceleration
70 ECONOMY; Full acceleration

0 Time [sec]
2 7
500931

Note: The lift truck is equipped with a stall timer. If the lift truck travel is blocked by an obstruction or is traveling on too steep
a grade and the accelerator is fully depressed, the stall timer will only allow the boost function to operate for a preset
duration of time to prevent overheating and damage to the traction motor. If the preset stall time is exceeded, diagnostic
code 16 will be present.

Limitation of maximum travel speed


This function limits the maximum travel speed of the lift truck.
The limitation that functions at all times and is used to keep the speed within the limits.

Item Description SUO No.


Maximum travel speed limit Always effective #7

1-8
CHAPTER 1 CONTROLLER
2.2 Regeneration

There are three types of regeneration control: the


accelerator regeneration, lever regeneration, and brake
regeneration.
Amount of accelerator regeneration
Accelerator regeneration
[%]
The accelerator regeneration starts when the accelerator 100
pedal is released with the direction lever shifted into the
FORWARD or REVERSE position during traveling.

0
1 2 3 4 5 6 7 8 9 10
Value of #23
505670

Item Description SUO No.


Accelerator regeneration The amount of regeneration is determined by the
#23
(Auto regeneration) accelerator regeneration characteristic

Lever regeneration
The lever regeneration starts when the direction lever is
shifted into the position opposite of the traveling direction Amount of lever regeneration
with the accelerator pedal depressed during travel.
[%]
100

0
1 2 3 4 5 6 7 8 9 10
Value of #22
505670

Item Description SUO No.


The amount of regeneration is determined by the lever
Lever regeneration #22
regeneration characteristic.

1-9
CHAPTER 1 CONTROLLER

Brake regeneration
Brake regeneration starts when the brake pedal is pressed.
Note: Brake regeneration also starts when the parking brake Amount of brake regeneration
is applied. [%]
100

0
1 2 3 4 5 6 7 8 9 10
Value of #21
505670

Item Description SUO No.


The amount of regeneration is determined by the
Brake regeneration #21
setting value

Controlled roll-back
Descends slowly when accelerator
This function prevents hazardous descending of the lift pedal is released on a grade.
truck on a grade.
The controlled roll-back is activated when the accelerator
pedal is released on a grade with the direction lever shifted
into the FORWARD or REVERSE position.
The descending speed changes with the steepness of grade
and the weight of load.
Note: This is not a function to stop the lift truck when the 608595
accelerator pedal is released on a grade. This function
is activated only in the output torque range of the
traction motor.

1-10
CHAPTER 1 CONTROLLER
3. Lifting Controller Feature
3.1 Setting and Limitation of Lift Work Speed

Each lift work speed can be set. The lift work speed can be limited or stopped when specific switch input occurs.
Triple input signals are selectable and available to set limit value to each signal.
Feature of lifting work speed setting

Item Description SUO No.


Start lift speed Start lift speed setting #2
Top lift speed Top lift speed setting #3
Normal Tilt speed Tilt speed setting #4
Auxiliary 1 speed Attachment 1 #5
Auxiliary 2 speed Attachment 2 #6

Refer to 1-24 "Setup Option".

3.2 Lift Stop

This will stop the lifting operations in progress when the


auxiliary SW input can choose close or open.
To release the stop function, bring the lever to the NEUTRAL
position, and start the operation.

Item Description SUO No.


Auxiliary input for lift and drive speed 1 Stops lift when auxiliary input 1 close/open #11
Condition Auxiliary input for lift and drive speed 2 Stops lift when auxiliary input 2 close/open #14
Auxiliary input for lift and drive speed 3 Stops lift when auxiliary input 3 close/open #17

4. Steering Control Features


The steering contactor closes and drives the steering motor when all the conditions for closing the line contactor (described in
the traction control features) are satisfied. This enables the power steering operation.
After the steering contactor is closed, if the key switch is not turned OFF or if warning related to the steering operation does not
occur, the steering contactor will open when the seat switch is opened.

1-11
CHAPTER 1 CONTROLLER
5. Meter Panel
5.1 Configuration of Meter Panel
Meter panel

3 E00880
1. Warning LED 3. Front panel buttons
2. Screen

1. Warning LED
In addition to a text message on the screen, this red warning LED will illuminate in the case of a detected warning, which limits
lift truck operation.
2. Screen
For details, refer to 1-13 "Meter Panel Screen".
3. Front panel buttons
These directional buttons are used to make adjustments to items shown on the screen and to access the main menu where
further set-up options and diagnostics features are housed.

1-12
CHAPTER 1 CONTROLLER
5.2 Meter Panel Screen

4 6

3 7

2 8

1 9

10

12 11 E00881
1. Overheated warning icon 7. Service brake fluid warning icon
2. Parking brake warning icon 8. Service indicator
3. Seatbelt warning icon 9. Slow speed mode icon
4. Travel direction indicator 10. Advisory area
5. Travel speed/Message center 11. Battery discharge indicator
6. Mast interlock indicator icon 12. Battery warning icon

1. Overheated warning icon


The thermometer icon glows if an over temperature condition develops in the traction motor, pump motor, or the controller.
2. Parking brake warning icon
When the brakes are engaged on the traction motors, this icon will be illuminated.
3. Seatbelt warning icon
This warning icon glows when the seat belt is not worn or when the seat belt is not properly buckled.
4. Travel direction icon
Displays the approximate direction of travel during regular driving, based on direction selected.

Item Icon Item Icon

FORWARD NEUTRAL (ON)


N
REVERSE NEUTRAL (OFF)
N
5. Travel speed / Message center
Displays the lift truck speed during normal operation and displays text messages when there is a warning or fault detected. The
travel speed display can be switched between KPH and MPH.

1-13
CHAPTER 1 CONTROLLER

6. Mast interlock indicator icon


The lift and/or tilt lever can not be operated when the operator is not sitting properly in seat for approximately 2 seconds.

7. Service brake fluid warning icon


When the icon is ON, service brake fluid is low level.
8. Service indicator
The wrench icon glows when it is time for planned maintenance.
9. Slow speed mode icon
The turtle icon glows when maximum travel speed has been reduced, due to an over temperature condition, low battery
condition, or when the carriage has been raised above free lift.

10. Advisory area


-Date
Displays the current date. The date display can be switched between the following formats: MM/DD/YYYY, DD/MM/YYYY, or
YYYY/MM/DD.
-Hour meter
The lift truck hour meter will be displayed in this area for approximately 3 seconds after the key switch is turned to the ON
position. This hour meter is helpful to determine the next periodic inspection.
-Clock
Displays the current time. The time can be switched between a 12-hour and a 24-hour clock.

Item Display form


MM/DD/YYYY
Date DD/MM/YYYY
YYYY/MM/DD
Vehicle hours HV 12345.6
Drive hours HD 12345.6
Hour meter
Pump hours HP 12345.6
Steering hours HS 12345.6
HH: MM (24H)
Time
HH: MMA, HH: MMP (12H)

11. Battery discharge indicator


The battery charge status is indicated by the ten element indicator.
When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease
toward the left side. When only one element is ON, the remaining battery charge warning light will glow. When the indicator
completely goes OFF. The remaining battery charge warning light will be continuously lit and the lift truck enters power
reduction mode.
12. Battery warning icon
This icon will glow when there is only one element left on the 10-element battery discharge indicator, indicating that it is time
to charge the current battery.

1-14
CHAPTER 1 CONTROLLER
5.3 Meter Panel Screen Transition

The screen transition on the meter panel and the operation procedures are as follows:
Screen operation procedures
(1) Press r button with the speed data displayed.
When the warning is being displayed, first press M button to display the speed data, then press r button.
(2) Press M or m button to display "Adjustment Menu", then press r button.
(3) Press M or m button to choose from "Date", "Clock", "Speed", "Date format", "Clock format", "Brightness", "Truck mode",
"Software version", and "Exit for setup.
(4) Press M or m button to display "Exit", then press r button.

KEY-ON

1. KEY-Switch ON
1. CAN Connection Check
2. PASSWORD Check (Option)

2. Main Monitor 1
1. SPEED DATA
2. WARNING (s)

3. Main Menu 1
1. Adjustment Menu
2. EXIT

4. Adjustment Menu
1. Date
2. Clock
3. Speed
4. Date format
5. Clock format
6. Brightness
7. Truck mode
8. Software version
9. EXIT

608780

1-15
CHAPTER 1 CONTROLLER
5.4 Diagnostic Code

Diagnostic code display


The diagnostic code is displayed in the indication area when FAULT 63
a malfunction occurs.
3 (sec)
When multiple faults occur simultaneously, the codes are
displayed alternately every three seconds as shown in the FAULT 65
figure.
3 (sec)

608781

Item Description
Diagnostic code Indicates the code assigned to the fault.
Warning R Glows (or blinks) while the fault is occurring.

1-16
CHAPTER 1 CONTROLLER
5.5 Password Entry

How to enter password


Enter the password by using the following procedures:
Confirm 0000 is shown on the password entry screen, and press button to increase or decrease the number. Press button r
to shift to the next digit.

PASSWORD
0000

2. WARNING (s) PASSWORD


1234

OUTLIM Check : OK Check: OK Check : Not OK


PASSWORD PASSWORD PASSWORD
OK NG
OUTLIM OK

1 (sec) (Restricted mode) 1 (sec)


(Normal mode)

0 KM/H

608782

1-17
CHAPTER 1 CONTROLLER
5.6 User Setting Function

User setting function


This function changes the user setting data: Date, Clock, Speed unit, Date format, Clock format, Display brightness,
Truck mode, and Software version.
These data settings are stored in the built-in memory and read to display the data in the format set previously when turning ON
the power.
Press M or m button to change the figure (or selection). Press button r to determine it.
To display these user data settings, perform steps 1 and 2 of the display operation procedures (refer to 1-15 "Screen operation
procedures"), select the required user data settings with button M or m, then press button r.

(1) Date
Adjust date. ADJUSTMENT
(2) Clock 1 *
1/1 / 2004
Adjust clock.
(3) Speed unit
Select MPH or KM/H. ADJUSTMENT
(4) Date format
2 *
0:0
Select US, EU or JPN.

(5) Clock format ADJUSTMENT


Select 24H or 12H. 3 SPEED
MPH ?
(6) Display brightness
Select brightness [0 (dark) thru 10 (light)]. CHANGE
4 DATE FORMAT
US ?
(7) Truck mode display
Truck mode change.
CHANGE
(8) Logic software version
Select software version. 5 CLOCK FORMAT
24H ?

ADJUSTMENT
6 BRIGHTNESS
3

ADJUSTMENT
7 TRUCK MODE
A

ADJUSTMENT
8 SOFTWARE
VERSION ****
608783

1-18
CHAPTER 1 CONTROLLER
6. Other Features
6.1 PDS (Presence Detection System) Feature

This controller is part of the "Presence Detection System" (PDS) of the lift truck. This system features an enhanced, integral
computer based feed back system which provides "certain product intelligence" to the operator. The table shows processes for
traction and lifting. Refer to 1-20 "PDS status transfer chart" for details.

PDS features

Item Protect condition Result Release method


Seat Sit 6 Leave Sit and
Traction control Slowdown and Stop Direction lever: N
Direction lever F or R Accelerator pedal: Release
Sit and
Hydraulic control Seat Sit 6 Leave Stop
Control valve SW: All open

1-19
CHAPTER 1 CONTROLLER

PDS status transfer chart

Seat SW
Traction Control PDS Seat SW flag: ON
Seat SW off time Delay time
2 sec or 3 sec

Seat SW flag: OFF Seat SW flag: OFF


Normal operation
Seat SW : ON
Direction lever: N (Chosen foot direction: no effect)
Seat SW flag: OFF
Slow down and stop Travel speed 0.5km/h
Display: Blinking" N "

Seat SW flag: OFF Seat SW flag: ON Slow down and stop


Display: Blinking " N"

Slow down and stop


Display: " N" Seat SW flag: OFF Seat SW flag: ON

Slow down and stop


Direction lever: N Display: " N "
Accelerator pedal: OFF Travel speed 0.5km/h

Direction lever: N
Accelerator pedal: OFF

Seat SW Seat SW off time Delay time


Seat SW flag: ON
2 sec or 3 sec

Hydraulic Control PDS


Seat SW flag: OFF
Seat SW : ON

Normal operation Seat SW flag: OFF

Lift lock valve: LOCK


Display: Blinking " "

Seat SW flag: ON
Seat SW flag: OFF

Lift lock valve: LOCK


Display: " "

Micro switch for Control valve: All OFF


(LIFT lever doesn't have SW to detect DOWN.) 504190
Note: In the initial state, E, H1, H2, H3 or H4 may appear.

1-20
CHAPTER 1 CONTROLLER

Prevention result
Operated item When operator is on seat again
When turning ON power
after leaving seat
Traveling, lifting, and steering stop. Traveling and lifting stop.
Direction lever or accelerator pedal Travel direction N of meter panel
Diagnostic code E glows
glows
Traveling, lifting, and steering stop. Traveling and lifting stop.
Lift lever Mast interlock indicator of meter panel
Diagnostic code H1 glows
glows
Traveling, lifting, and steering stop. Traveling and lifting stop.
Tilt lever Mast interlock indicator of meter panel
Diagnostic code H2 glows
glows
Traveling, lifting, and steering stop. Traveling and lifting stop.
Attachment 1 lever Mast interlock indicator of meter panel
Diagnostic code H3 glows
glows
Traveling, lifting, and steering stop. Traveling and lifting stop.
Attachment 2 lever Mast interlock indicator of meter panel
Diagnostic code H4 glows
glows

1-21
CHAPTER 1 CONTROLLER

Preventing lift down


This function prevents the lift from lowering when the lift lever is operated with the key switch turned OFF.
The lift does not lower as the lift lock valve is closed when the key switch is turned OFF (when the control system is not
controlled by the controller).

Warning buzzer
- Parking brake warning
The buzzer sounds when the key switch is turned OFF or the operator leaves the operator's seat with the parking brake not
applied.
- Seat belt warning
The buzzer sounds when the seat belt is not fastened with the operator on the operator's seat.

6.2 Stall Timer

Traction Motor Stall Timer (Diagnostic code 16) warning occurs to prevent the traction motor from overheating when the lift
truck travel is blocked for several seconds and the accelerator pedal is fully depressed.

Item Description SUO No.


Stall timer The time to shut down the lift truck can be set. #20

6.3 Password Certification

Password effective time can be changed within the preset time range. If the lapse time from key-OFF to key-ON is within the set
time, input of password can be omitted.

Item Description SUO No.


Password certification Effective time can be set within the range of 0 to 90 min. #38

6.4 BDI (Battery Discharge Indicator)

The BDI shows the remaining battery capacity of the current battery voltage with 11 levels from BDI 0 to BDI 10.
Set the BDI by SUO #41 and SUO #42 depending on the installed battery type and voltage.
If the previous indication is BDI 4 or less and the following indication is not BDI 7 or more when turning ON the key switch, the
BDI will show the previous indication.
When the battery voltage lowers, the following output power control is activated by the BDI function to protect the battery:
Control by BDI 1: Traveling is limited.
Control by BDI 0: Traveling and lifting are limited, and simultaneous operations of traveling and lifting are inhibited.

Item Description SUO No.


Battery voltage Selects battery voltage #41
Battery type Selects battery types #42

1-22
CHAPTER 1 CONTROLLER
6.5 Service Indicator

The service indicator starts blinking 20 hours before the set maintenance time, and remains lit when the lift truck hour meter
indication reaches the set time.
If the output power control is selected, the output power control will also be activated at the same time to limit the traveling
and lifting operations.

Item Description SUO No.


Service indicator The maintenance time and the selection of output power control can be set. #10

6.6 Tire Size Speed Adjustment

Tire diameter change resulting from tire wear can be compensated for.
This setting is used to adjust the travel speed indication when it differs from the actual speed by tire wear.

Item Description SUO No.


Tire size speed adjustment Adjust travel speed by tire size. #27

1-23
CHAPTER 1 CONTROLLER
7. Setup Option
7.1 Outline

The logic unit is equipped with a type of memory module to hold recorded data even if the main power is turned OFF.
The model information and various features are set during factory shipment.
The setup options are categorized from Group 1 to Group 3 according to the feature levels.
Setup group

Group Description
Group 1 Basic function (#1 to #10)
Group 2 Detailed function (#11 to #38)
Group 3 Model information (#40 to #47)

The Group 1 and 2 are available to set the default value in a one-step operation and can be customized in accordance with
applications. Since the Group 3 is for model information, it is required to be set to the same value as actual control system. It
will not work properly if the model information is different.
When setting the setup option data for the first time after the assembly is completed or the logic card is replaced, be sure to set
Group 3 data first, then the default data of Group 1 and 2 with service tool in each setup mode.

608778

1-24
CHAPTER 1 CONTROLLER
7.2 Details of Setup Options (Group-1)

#1 Application presets (Lift truck operation mode)


Lift truck operation mode can be selected from A to E, each with preset values for start lift speed, top lift speed, tilt speed,
maximum travel speed, acceleration rate, traveling power, brake regeneration, and accelerator regeneration.
These 8 settings are automatically set by changing the value of this setting.
Preset values for each setting are as follows. The setting range is A to E.

48V type mode setting

SUO#

Mode A B C D E

Feature/ 1
Preset 1 Preset 2 Preset 3 Preset 4 Preset 5
Application
Lift Fast Fast Medium Fast Fast
Tilt Slow Slow Slow Slow Slow
Travel speed Medium Fast Slow Fast Medium
Characteristic
Acceleration Medium Fast Medium Medium Fast
Power Standard Powerful Economy Standard Powerful
Regeneration Medium Medium Medium Medium Medium
Start lift speed 1 1 1 1 1 2
Top lift speed 9 10 8 9 10 3
Tilt speed 1 1 1 1 1 4
Maximum travel
15 18 12 17 15 7
Default value speed
(Standard) Acceleration rate 3 5 2 3 5 8
Traveling power 2 3 1 2 3 9
Brake regeneration 7 7 7 7 7 21
Accelerator
7 7 7 7 7 23
regeneration
Start lift speed 1 1 1 1 1 2
Top lift speed 8 8 8 8 8 3
Tilt speed 1 1 1 1 1 4
Maximum travel
14 14 14 14 14 7
Default value speed
(EE) Acceleration rate 2 2 2 2 2 8
Traveling power 1 1 1 1 1 9
Brake regeneration 7 7 7 7 7 21
Accelerator
7 7 7 7 7 23
regeneration

You can modify these 8 settings afterwards individually.


When settings are changed the indication (A to E) will blink
to indicate that the settings are modified.

1-25
CHAPTER 1 CONTROLLER
36V type mode setting

SUO#

Mode A B C D E 1

Feature/
Preset 1 Preset 2 Preset 3 Preset 4 Preset 5
Application
Lift Fast Fast Medium Fast Fast
Tilt Slow Slow Slow Slow Slow
Travel speed Medium Fast Slow Fast Medium
Characteristic
Acceleration Medium Fast Medium Medium Fast
Power Standard Powerful Economy Standard Powerful
Regeneration Medium Medium Medium Medium Medium
Start lift speed 1 1 1 1 1 2
Top lift speed 9 10 8 9 10 3
Tilt speed 1 1 1 1 1 4
Maximum travel
15 17 12 17 15 7
Default value speed
(Standard) Acceleration rate 3 5 2 3 5 8
Traveling power 2 3 1 2 3 9
Brake regeneration 7 7 7 7 7 21
Automatic
7 7 7 7 7 23
regeneration
Start lift speed 1 1 1 1 1 2
Top lift speed 8 8 8 8 8 3
Tilt speed 1 1 1 1 1 4
Maximum travel
12 12 12 12 12 7
Default value speed
(EE) Acceleration rate 2 2 2 2 2 8
Traveling power 1 1 1 1 1 9
Brake regeneration 7 7 7 7 7 21
Automatic
7 7 7 7 7 23
regeneration

#2 Start lift speed


This setting affects pump speed when you start the lifting operation.
Speed when lift switch 1 is turned ON
Lift speed of the rise direction will become faster if the setting value is increased.
The setting range is 1 to 10 for all models.

1-26
CHAPTER 1 CONTROLLER

#3 Top lift speed


This setting affects pump speed when you pull the lift lever. Pump motor
If you set a smaller value than #2, then the #2 setting will be output [%]
SUO #3
ignored.
100
Speed when lift switch 2 is turned ON
10
Lifting speed will become faster if the value setting is 9
8
increased.
SUO #2
The setting range is 1 to 10 for all models.

2
1

0
SW1 SW2 Lever operation
close close
608597

Pump motor output characteristics (lift-up operation)

#4 Tilt speed
This setting affects pump speed when you pull the tilt lever.
Pump motor
Speed when tilt switch is turned ON. output [%]

Tilting speed will become faster if the value setting is


increased. SUO #4
100 10
The setting range is 1 to 10 for all models.

2
1

0 SW Close
608596

1-27
CHAPTER 1 CONTROLLER

#5 Auxiliary 1 speed
This setting affects pump speed when you operate the attachment 1 lever.
Speed when attachment 1 switch is turned ON
Attachment 1 speed will become faster if the value setting is increased. The range setting is 1 to 10 for all models.

#6 Auxiliary 2 speed
This setting affects pump speed when you operate the attachment 2 lever.
Speed when attachment 2 switch is turned ON
Attachment 2 speed will become faster if the value setting is increased. The range setting is 1 to 10 for all models.

#7 Maximum travel speed limit


This setting affects maximum lift truck speed without load. Travel speed with load will be less than this setting. This setting
affects top speed, and does not affect traveling on a grade or acceleration.
The range setting is 5 to 18 [km/h].
[When #41 is set for 36 volts: 5 to 17.]
[When #40 is set for EE type, #41 is set for 36 volts: 5 to 12 and when #41 is set for 48 volts (EE type): 5 to 14.]

#8 Acceleration rate
This setting affects response time to calculate speed order from accelerator pedal position.
Acceleration of lift trucks becomes faster if the value setting is increased.
The range setting is 1 (slowest) to 5(fastest).
(When #40 is set for EE type: 1 to 2.)

1-28
CHAPTER 1 CONTROLLER

#9 Traveling power mode


This setting affects the required torque which is calculated from the accelerator pedal position.
The values are selected from three types: ECONOMY, STANDARD, and POWER.
The figure shows the torque characteristic to the speed.

Torque
[%]
POWER (3)
100 STANDARD (2)
85 ECONOMY (1)
70
Brake limit *1 (50%)
Thermal, BDI [0] or Service indicator*2
(30%)

Speed
0 5 10 15 (km/h)

500939

*1 Brake limit: Torque value resulting from *2 Thermal, BDI [0], or BDI [0] or Service indicator: Curve
reduction in current when the Service indicator: of limited torque under a condition
brake is applied. of overheating or battery voltage
low or maintenance time over.

#10 Service indicator


This setting sets the maintenance time. The time set here is You can reduce the traveling power when the service
added to the lift truck hour meter and that value is stored in indicator icon on the meter panel glows by setting the
memory as the "maintenance time." service indicator selection. You can also set the demo-mode,
which shows the service Indicator function in a short period
When the lift truck hour meter reaches maintenance time,
of time.
the service indicator icon on the meter panel turns ON.
The setting value is as follows:
It will glow 20 hours before the time.

6 min In increments
Maintenance time [hour] - 100 150 950 1000
(test) of 50
Invalid 0
Set data on
Only warning 0.1 100 150 ----- 950 1000
meter panel
Torque limit =0.1 =100 =150 ----- =950 =1000

1-29
CHAPTER 1 CONTROLLER
7.3 Details of Setup Options (Group-2)

#11 Auxiliary input for lift and drive speed 1


(Harness pin No. 40)
This setting defines the function of "Auxiliary 1" switch. This
value has an effect on #12 and #13 when 2, 3, 5, or 6 is
selected.
The setting value is as follows:

Value Lift Travel


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

*1 Place the lever in NEUTRAL. Lift starts moving by operating the lever again.

#12 Auxiliary travel speed limit 1


(Harness pin No. 40)
This setting defines maximum speed when the Auxiliary 1 switch is closed or opened.
The setting range is 5 to 18 [km/h]. Effective when the data of #11 is 2 or 5.

#13 Auxiliary power reduction rate 1


(Harness pin No. 40)
This setting defines traction power reduction when the Auxiliary 1 switch is closed or opened.
The setting range is 0 to 100 [%]. Effective when the data of #11 is 3 or 6.

#14 Auxiliary input for lift and drive speed 2


(Harness pin No. 41)
This setting defines the function of Auxiliary 2 switch. This value has an effect on #15 and #16 when 2, 3, 5, or 6 is selected.
The setting value is the same as that of #11.

#15 Auxiliary travel speed limit 2


(Harness pin No. 41)
This setting defines maximum speed when the Auxiliary 2 switch is closed or opened.
The setting range is 5 to 18 [km/h]. Effective when the data of #14 is 2 or 5.

#16 Auxiliary power reduction rate 2


(Harness pin No. 41)
This setting defines traction power reduction when the Auxiliary 2 switch is closed or opened.
The setting range is 0 to 100 [%]. Effective when the data of #14 is 3 or 6.

1-30
CHAPTER 1 CONTROLLER

#17 Auxiliary input for lift and drive speed 3


(Harness pin No. 30)
This setting defines the function of Auxiliary 3 switch. This value has an effect on #18 and #19 when 2, 3, 5, or 6 is selected.
The setting value is the same as that of #11.

#18 Auxiliary travel speed limit 3


(Harness pin No. 30)
This setting defines maximum speed when the Auxiliary 3 switch is closed or opened.
The setting range is 5 to 18 [km/h]. Effective when the data of #17 is 2 or 5.

#19 Auxiliary power reduction rate 3


(Harness pin No. 30)
This setting defines traction power reduction when the Auxiliary 3 switch is closed or opened.
The setting range is 0 to 100 [%]. Effective when the data of #17 is 3 or 6.

#20 Stall timer


This setting shuts down the lift truck when the traction motor torque is very high (about 90% of maximum) and the wheels are
not turning. This function is used to detect pulse sensor faults and to prevent the controller from overheating.
The setting range is 2 to 10 seconds for all models.

#21 Brake regeneration


This works when the brakes are applied.
When the setting value is higher than #23, regenerative power will increase by stepping on the brake.
When the setting value is lower than #23, the regenerative rate will be the same as the #23.

#22 Lever regeneration


This setting defines the Lever regeneration characteristic.
When the direction lever is shifted into the position Amount of lever regeneration
opposite to the traveling direction, the Lever regeneration [%]
function is activated. The Lever regeneration characteristic 100
is shown in the diagram. The setting range is 1 to 10.

0
1 2 3 4 5 6 7 8 9 10
Value of #22
505670

1-31
CHAPTER 1 CONTROLLER

#23 Accelerator regeneration


This setting defines amount of deceleration when
"Accelerator regeneration" is activated. The setting range is Amount of lever regeneration
1 to 10 for all models.
[%]
100

0
1 2 3 4 5 6 7 8 9 10
Value of #23
505670

#24 Chat timer


This setting turns OFF power when the lift truck is not operated in order to cut down electric power consumption.
Time setting is available from 0 to 40 seconds.

#26 Speed alarm 1


(Harness pin No. 61)
This setting defines speed of turning on the "Speed alarm 1" light.
The setting range is 5 to 18 [km/h].

#27 Tire size speed adjustment


This setting is used to adjust the travel speed indication when it differs from the actual speed by tire wear. Tire diameter change
resulting from tire wear can be compensated for.
The setting value is -20, 0, or 20 [mm].

#30 Auxiliary input for travel speed (Harness pin No. 31)
When the speed limit signal is ON, travel speed or power is limited to set value. The amount of maximum speed is defined at
#31. The amount of power reduction is defined at #32.
The setting range is 0 or 1. (0: Disable, 1: Enable)

#31 Auxiliary maximum travel speed setting (Harness pin No. 31)
This setting defines the truck speed limit set up by #30.
The setting range is 5 to 18 [km/h].

#32 Auxiliary output power limit


(Harness pin No. 31)
This setting defines the traction power reduction ratio set up by #30.
The setting range is 0 to 100 [%].

#38 Password certification


This defines the password certification ON/OFF after key switch OFF.
The setting range is 0 to 90 [min].

1-32
CHAPTER 1 CONTROLLER
7.4 Details of Setup Options (Group-3)

#40 Truck model


This setting defines the type of lift truck.
The setting value is as follows.

Display Model
1 EC22N2
2 EC22N2EE
3 EC25N2
4 EC25N2EE
5 EC25EN2
6 EC25N2EE
7 EC25LN2
8 EC25LN2EE
9 EC30N2
10 EC30N2EE
11 EC30LN2
12 EC30LN2EE

R CAUTION
If the lift truck model setting is incorrect, the lift truck may show unexpected movement.

#41 Battery voltage


This setting defines the voltage of battery installed in the lift truck.
The setting value is 36 or 48 [V].

1-33
CHAPTER 1 CONTROLLER

#42 Battery type


This setting defines the type of battery carried in the lift truck.
The setting value is 0, 1, or 2.
0: Normal BDI 1: Tubular BDI 2: Gel BDI
This value selects Battery Discharge Indicator (BDI) table. The table is as follows:

Normal BDI Tubular BDI


BDI# 36V 48V BDI# 36V 48V
0 - 34.4 - 45.9 0 - 35.2 - 46.9
1 34.5 - 34.8 46.0 - 46.4 1 35.3 - 35.5 47.0 - 47.3
2 34.9 - 35.2 46.5 - 46.9 2 35.6 - 35.8 47.4 - 47.7
3 35.3 - 35.6 47.0 - 47.4 3 35.9 - 36.1 47.8 - 48.1
4 35.7 - 36.0 47.5 - 47.9 4 36.2 - 36.4 48.2 - 48.5
5 36.1 - 36.4 48.0 - 48.4 5 36.5 - 36.7 48.6 - 48.9
6 36.5 - 36.7 48.5 - 48.9 6 36.8 - 37.0 49.0 - 49.2
7 36.8 - 37.0 49.0 - 49.8 7 37.1 - 37.2 49.3 - 49.5
8 37.1 - 37.3 49.4 - 49.7 8 37.3 - 37.4 49.6 - 49.8
9 37.4 - 37.6 49.8 - 50.1 9 37.5 - 37.6 49.9 - 50.1
10 37.7 - 50.2 - 10 37.7 - 50.2 -

Gel BDI
BDI# 36V 48V
0 - 32.9 - 43.8
1 33.0 - 33.5 43.9 - 44.7
2 33.6 - 34.0 44.8 - 45.4
3 34.1 - 34.5 45.5 - 46.1
4 34.6 - 35.0 46.2 - 46.7
5 35.1 - 35.5 46.8 - 47.3
6 35.6 - 35.9 47.4 - 47.8
7 36.0 - 36.2 47.9 48.3
8 36.3 - 36.5 48.4 - 48.7
9 36.6 - 36.7 48.8 - 48.9
10 36.8 - 49.0 -

#44 Mast type


This setting defines the type of the mast. The setting value is 0, 1, or 2.
0: 2FF (2-stage full-free)
1: 3FF (3-stage full-free)
2: 2SP (2-stage panorama)

1-34
CHAPTER 1 CONTROLLER

#45 Valve section


This setting defines the number of valve sections. The setting value is 1 or 2.
1: 3-way (lift, tilt, attachment 1)
2: 4-way (lift, tilt, attachment 1, 2)

#46 Battery voltage adjustment


This setting corrects the difference between the actual Measure actual battery voltage using a tester (or a multi-
battery voltage and controller-recognized battery voltage. meter) and operate service tool.
The meter panel shows battery voltage which the controller
Refer to the Measurement of battery voltage below.
recognizes.

Measurement of battery voltage

- +
1
49.6V
V

- +

3
4

505685
1. Battery 3. Tester or multi-meter
2. Line contactor (POSITIVE) 4. Traction inverter (NEGATIVE)

#47 Foot direction


This setting defines the foot direction option. This setting is 1 or 2.
1: Standard direction lever
2: Foot Direction Control (FoDiCo)

1-35
CHAPTER 1 CONTROLLER
7.5 Setup Options (Group 1)

Option Default
Title Description Range
# Value
The value setting of the following 8 items are 1: A
registered beforehand: 2: B
Application presets
Start lift speed, top lift speed, tilt speed, maximum 3: C
#1 (Lift truck operation 1 (3)
travel speed, acceleration rate, traveling power, 4: D
mode)
brake regeneration, and accelerator regeneration. 5: E
Refer to the explanation for details See note (1)
Beginning lift speed
#2 Start lift speed 1 (Slow) to 10 (Fast) 1
Start lift speed cannot exceed top lift speed.
#3 Top lift speed Lift speed when operating the lever at maximum 1 (Slow) to 10 (Fast) 9 (3)
#4 Tilt speed Speed setting for tilt 1 (Slow) to 10 (Fast) 1
#5 Auxiliary 1 speed Speed setting for attachment 1 1 (Slow) to 10 (Fast) 3
#6 Auxiliary 2 speed Speed setting for attachment 2 1 (Slow) to 10 (Fast) 3
5 to 18 [km/h] or
Maximum travel speed
#7 Maximum travel speed 5 to 17 [km/h] 15 (3)
limit
See note (2), (3)
1 to 5 See note (3)
#8 Acceleration rate Choice of acceleration rate (1: Slowest, 2: Slow, 3: 3 (3)
Middle, 4: Fast, 5: Fastest)
1, 2, 3 See note (3)
#9 Traveling power Choice of powering characteristic (1: ECONOMY, 2: 2 (3)
STANDARD, 3: POWER)
This function notifies service personnel that
maintenance time is approaching or has passed. 0, 0.1,
100, 150, ...950, 1000,
It means the lapsed time when setting up. =0.1 (6 min.),
#10 Service indicator Service indicator icon on meter =100, =150, =950, =1000 0
Approached: (In increments of 50 [hour])
panel blink (20 hour)
=: power reduction
The icon glows and power 0: no action
Passed :
reduction (selected)

Note:
(1) Before changing, when parameter data are different from the values of the selected mode, the lift truck operation mode
indicator (A to E) blinks. When the lift truck operation mode is changed, all parameter data is replaced by the set values of
the selected mode.
(2) When #41 is set for 36 volts, the setting range is 5 to 17 [km/h].
For setting other than above, the setting range is 5 to 18 [km/h].
(3) When #40 is set for EE type, the setting range and default value of each Setup Option data are as follows:

Option# Range Default Value


#1 A to E C
#3 1 to 10 8
#41 36 volts 5 to 12 12
#7
#41 48 volts 5 to 14 14
#8 1 to 2 2
#9 1 only 1

1-36
CHAPTER 1 CONTROLLER
7.6 Setup Options (Group 2)

Op- Default Harness


Title Description Range
tion# Value Pin No.
When the auxiliary
input 1 signal is ON,
0: Disable
travel speed or lift
1: Disable lift (switch closed)
speed is limited to the
Auxiliary input for 2: Speed limit (switch closed)
set value.
#11 lift and drive 3: Power reduction (switch closed) 0 40
The maximum speed is
speed 1 4: Disable lift (switch opened)
defined at #12.
5: Speed limit (switch opened)
The amount of power
6: Power reduction (switch opened)
reduction is defined at
#13.
Auxiliary travel Travel speed limit for
#12 5 to 18 [km/h] 12 40
speed limit 1 #11
Auxiliary power Traction power
#13 0 to 100 [%] 70 40
reduction rate 1 reduction ratio for #11
When the auxiliary
input 2 signal is ON,
0: Disable
travel speed or lift
1: Disable lift (switch closed)
speed is limited to set
Auxiliary input for 2: Speed limit (switch closed)
value.
#14 lift and drive 3: Power reduction (switch closed) 0 41
The maximum speed is
speed 2 4: Disable lift (switch opened)
defined at #15.
5: Speed limit (switch opened)
The amount of power
6: Power reduction (switch opened)
reduction is defined at
#16.
Auxiliary travel Travel speed limit for
#15 5 to 18 [km/h] 12 41
speed limit 2 #14
Auxiliary power Traction power
#16 0 to 100 [%] 70 41
reduction rate 2 reduction ratio for #14
When the auxiliary
input 3 signal is ON,
0: Disable
travel speed or lift
1: Disable lift (switch closed)
speed is limited to set
Auxiliary input for 2: Speed limit (switch closed)
value.
#17 lift and drive 3: Power reduction (switch closed) 0 30
The maximum speed is
speed 3 4: Disable lift (switch opened)
defined at #18.
5: Speed limit (switch opened)
The amount of power
6: Power reduction (switch opened)
reduction is defined at
#19.
Auxiliary travel Travel speed limit for
#18 5 to 18 [km/h] 12 30
speed limit 3 #17
Auxiliary power Power reduction ratio
#19 0 to 100 [%] 70 30
reduction rate 3 for #17
This setting allows to
shut down lift truck
when the traction
#20 Stall timer 2 to 10 [sec] 5
motor torque is very
high and the wheels
are not turning.
Brake 10 steps to set for 1 to 10
#21 7
regeneration brake regeneration (1: SLOW to 10: FAST)

1-37
CHAPTER 1 CONTROLLER

Op- Default Harness


Title Description Range
tion# Value Pin No.
Lever 10 steps to set for lever 1 to 10
#22 7
regeneration regeneration (1: SLOW to 10: FAST)
10 steps to set for
Accelerator 1 to 10
#23 accelerator 7
regeneration (1: SLOW to 10: FAST)
regeneration
Sets the time for chat
#24 Chat timer 0 to 40 [sec] 20
timer
Sets speed for turning
#26 Speed alarm 1 5 to 18 [km/h] 12 61
on alarm 1 light.
Adjusts the amount of
0: -20 mm
Tire size speed tire wear. It changes
#27 20: 0 mm 20
adjustment travel speed
40: +20 mm
recognition.
This setting defines the
function of speed limit
switch.
Auxiliary input for 0: Disable
#30 According to the 0 31
travel speed 1: Enable
combination of #30
and #31, you can
reduce travel speed.
Auxiliary
Travel speed limit for
#31 maximum travel 5 to 18 [km/h] 12 31
#30
speed setting
Auxiliary out put Traction power
#32 0 to 100 [%] 70 31
power limit reduction ratio for #30
0: 0 [min]
3: 3 [min]
Password certification 10: 10 [min]
Password
#38 ON/OFF after key 30: 30 [min] 255
certification
switch OFF. 60: 60 [min]
90: 90 [min]
255: Disable

1-38
CHAPTER 1 CONTROLLER
7.7 Setup Options (Group 3)

Option Default
Title Description Range
# Value
This option is used to set the size 12 patterns (Refer to 1-33 "Details of
#40 Truck model and type of the lift truck. Setup Options (Group-3)" for model
Refer to the explanation for details. names.
This option is used to set the voltage
#41 Battery voltage 36, 48 [V]
of the battery.
This option is used to set the type of
the battery. 0: Normal BDI
#42 Battery type The electric discharge characteristic 1: Tubular BDI
of a battery changes with battery 2: Gel BDI
type.
0: 2FF (2-stage full-free / Duplex mast)
This option is used to set the type of 1: 3FF (3-stage full-free / Triplex mast)
#44 Mast type
the mast. 2: 2SP (2-stage panorama / Simplex
mast)
This option is used to set the 1: 3V (Lift, tilt, and attachment1)
#45 Valve section
number of valve section 2: 4V (Lift, tilt, and attachment1,2)
This setting corrects the gap of the
battery voltage which the controller
recognizes, and actual battery
Battery voltage voltage.
#46 5.0 to 120.0 [V]
adjustment Measure actual battery voltage and
use service tool in order to adjust the
value which is shown on the service
tool actual battery voltage.
This option is used to enable the 1: Standard direction lever
#47 Foot direction
function for foot direction option. 2: Foot Directional Control (FoDiCo)

Note:
(1) The data of group 3 have no default value, but it needs to set data by the actual lift truck model. If the value and the lift
truck model are not in agreement, the lift truck does not operate normally.
(2) When you set up for the first time, set up group 3 first, and then set default data of group 1 and 2.
(3) This value was adjusted at the time of LOGIC CARD inspection. Adjust the value if the value shown on the service tool is
different from actual battery voltage.
(4) Use this option to achieve the lift lockout at the designed battery voltage.
(5) Setting volts lower than battery volts will activate lift lock out at a higher voltage.
(6) Setting higher than battery voltage will discharge the battery to a deeper level.

1-39
CHAPTER 1 CONTROLLER
8. Diagnostics
8.1 Outline

The controller monitors status of various input/output equipment to allow diagnostics of lift trucks malfunction.
There is a diagnostics called Self Diagnostics, which performs an equipment check during maintenance.
Diagnostics

Mode Description
Diagnostics Self diagnostics Checks function of electrical systems.

Self diagnostics that exclusively checks the power steering system is also available.

8.2 Operation Procedure

Turn ON the key switch and enter the diagnostics mode using the service tool.
Perform diagnostics by following the procedure below.

Preparatory operations (excluding steering) (4) Discharge all inverters. Refer to 1-48 "Inverter
Discharging Procedure".
(1) Place the parking brake lever in the locked position. (5) Place the direction lever in the NEUTRAL position.
(2) Turn OFF the key switch. (6) Remove the fuses (500 A) on traction and pump
(3) Disconnect the battery plug/connector. inverters and steering fuse (60 A).
(7) Connect the battery plug/connector.

Diagnostics procedure
Perform the procedure using the Self-Diagnostics table (refer to 1-41 "Self-Diagnostics") in accordance with the following
guide.
(1) Start diagnostics with the Step 0 in the table. Without sitting in the seat, turn ON the key switch according to the
instruction in the Action column on the Step 0 line. If the item passes the check without any problem, the next Step 01
appears on the meter panel.
If the item involves any problem and fails in the check, dd is shown on the meter panel. The meter panel also shows dd
when diagnostics is started without removing the fuse. In this case, diagnostics is prohibited from going even to the first
step.

(2) When the Step 0 has passed the check, diagnostics may
advance the Step 1 (seat switch). Cycle the seat
switch OFF 6 ON 6 OFF according to the instruction in 1
the Action column on the Step 1 line. If the item
passes the check, the next step number 02 appears on
the meter panel.
Do likewise for the succeeding items, following the
instructions in the Action column boxes. If the step
fails in the check, diagnostics does not advance
automatically. In this case, diagnostics can be forcibly
advanced to the next step by pressing the next button
on the service tool.
Note: Diagnostic items can be skipped by pressing the Skip 500946
button on the service tool.
1. Diagnostics result indication

(3) When all the steps have been checked through, turn OFF the key switch. Be sure to install the 500 A fuses and 60 A steering
fuse.
- Turn OFF the key switch to exit from the diagnostics mode.
- Repair all faults found immediately after diagnostics.
Follow the instructions in the diagnostics procedure guide above as well as Self-Diagnostics table in the applicable Action
column.

1-40
CHAPTER 1 CONTROLLER
8.3 Self-Diagnostics

Controller check Contactor


Step Item Action Result Display
this operation
Close line Pass 01
contactor and
Line contactor and
Line voltage steering
0 Turn ON key switch dd steering contactor
(Fuse check) contactor, and Fail
See note 1) close and open.
check power line
voltage.

Release, press, and release seat Input Pass 02


1 Seat SW
SW OFF - ON - OFF Fail 01

Direction Cycle direction lever. Input Pass 03


2
change SW N-R-N-F-N N-R-N-F-N Fail 02
Input Pass 04
Parking brake Apply and release parking
3 Release - Apply -
SW brake Fail 03
Release
Input Pass 05
Service brake Release and depress service
4 Release - Depress -
SW brake Fail 04
Release
Depress and release Pass See note 2)
accelerator and see meter
5 Accel SW panel Fail -

Skip button - 07

Battery Check battery Pass 08


7 Automatic
voltage voltage: (34V-51V) Fail 07
Input Pass 09
8 Lift lever SW Pull and release lift lever. Release - Pull (lift
up)-Release Fail 08

Input Pass 10
9 Tilt lever SW Pull and release tilt lever. Release - Pull -
Release Fail 09

Input Pass 11
Attachment Pull and release Attachment1
10 Release - Pull -
lever 1 switch lever. Fail 10
Release
Input Pass 13
Attachment Pull and release Attachment 2
11 Release - Pull -
lever 2 switch lever. Fail 11
Release

Pull any lever and see meter Pass See note 3)


Hydraulic
13 pump speed panel. Fail -
check
Skip button - 14
Pass 14 Contactor closes.
See line contactor close Contactor does not
Fail 14
closes.
14 Line contactor
Pass 16 Contactor opens.
Skip button Fail 16 Contactor does not
open.

1-41
CHAPTER 1 CONTROLLER

Controller check Contactor


Step Item Action Result Display
this operation
Pass 16 Contactor closes.
See steering contactor close Contactor does not
Fail 16
Steering closes.
16
contactor Pass 17 Contactor opens.
Skip button Contactor does not
Fail 17
open.

Release, fasten, and release Input Pass OK


17 Seatbelt SW -
seatbelt OFF - ON - OFF Fail 16

Note:
(4) Input (ON/OFF) to the accelerator switch and travel of the accelerator pedal (0 to100%) appears.
(5) Setting of hydraulic speed (0 to 10) appears when any lever is pulled.
(1) dd indicates the fuse needs to be removed.

1-42
CHAPTER 1 CONTROLLER
8.4 Run Time Diagnostics

Availability of operation:
z: Yes, 9: No, *: Applicable

Meter panel

Steering operation
Icon

Memory
Return

Driving interlock
Mast interlock
Parking brake

Over temp.
Code Fault How to detect

Battery low
Result to

Brake fluid

Code
Warning
normal

Traction motor, Power


E0 Thermistor (150C, -25C) * - z Cool *
Overheating reduction
Pump motor, Power
E2 Thermistor (150C, -25C) * - z Cool *
Overheating reduction
Traction Thermistor
Power
E5 Inverter, (IMS 100C, -25C) * - z Cool *
reduction
Overheating Capacitor (110C, -25C)
Power
Thermistor
Pump Inverter, reduction
E7 (IMS 100C, -25C) * - z Cool *
Overheating (Transistor
Capacitor (110C, -25C)
Control Type)
Line contactor
Traction motor,
OFF(*) Turn OFF
14 Current sensor Out of normal range * 14 z *
Steering key
fault
contactor Hold
Line contactor
More than 985 Arms (1.6
Traction motor, OFF Turn OFF
15 ms), 990 Arms (1 ms), 1018 * 15 z *
Over-current Steering key
Arms (a moment)
contactor Hold
Line contactor
Traction motor, Measures time (set by OFF Turn OFF
16 * 16 z *
Stall timer SUO#20) while stalling Steering key
contactor Hold
Line contactor
Pump motor,
OFF(*) Turn OFF
34 Current sensor Out of normal range * 34 z *
Steering key
fault
contactor Hold
Line contactor
More than 985 Arms (1.6
Pump motor, OFF Turn OFF
35 ms), 990 Arms (1 ms), * 35 z *
Over-current Steering key
1018 Arms (a moment)
contactor Hold
Line contactor
Line contactor, Checks voltage of power OFF(*) Turn OFF
40 * 40 z *
Fault circuit. Steering key
contactor Hold
Line contactor
Traction motor, OFF Turn OFF
45 Traction motor open * 45 z *
Open Steering key
contactor Hold

1-43
CHAPTER 1 CONTROLLER

Meter panel

Steering operation
Icon

Memory
Return

Driving interlock
Mast interlock
Parking brake

Over temp.
Battery low
Code Fault How to detect Result to

Brake fluid

Code
Warning
normal

Line contactor
Pump motor, OFF Turn OFF
47 Pump motor open * 47 z *
Open Steering key
contactor Hold
Line contactor
Steering motor, Steering motors warning OFF Turn OFF
49 * 49 9 *
Fault signal is open (high) Steering key
contactor OFF
- Accel sensor voltage 1 is
out of range from 0.15 to
4.2 V.
- Accel sensor 2 input value
Line contactor
when multiplied by two is
Accelerator OFF Turn OFF
51 out of range from 0.15 to * 51 z *
sensor, Fault Steering key
4.2 V.
contactor Hold
- Difference in input
between accelerator
sensors 1 and 2 (multiplied
by two) is 0.4 or more.
Line contactor
Traction motor, Out of normal range OFF Turn OFF
52 * 52 z *
Pulse input fault (5800 min-1) Steering key
contactor Hold
- Out of normal range Line contactor
Pump motor, (-200 min-1) OFF Turn OFF
57 * 57 z *
Pulse input fault - Out of normal range Steering key
(5800 min-1) contactor Hold
Line contactor
FNR lever/accel is not Seat
OFF
NEUTRAL at power-ON and E 9 switch ON
Direction lever Steering
seat SW ON Direction
E or accelerator, contactor OFF
lever is in
Faulty setting Slow down and NEUTRAL
Seat SW is turned ON after
* - z Line contactor accel OFF
lever/accel is operated
OFF
Line contactor
OFF Seat
Seat SW is OFF at power-ON - 9 switch ON
Seat switch, Steering
contactor OFF Direction
(E) Faulty setting
lever is in
for traction Slow down and NEUTRAL
Seat SW is OFF * - z Line contactor accel OFF
OFF

1-44
CHAPTER 1 CONTROLLER

Meter panel

Steering operation
Icon

Memory
Return

Driving interlock
Mast interlock
Parking brake

Over temp.
Battery low
Code Fault How to detect Result to

Brake fluid

Code
Warning
normal

Line contactor
OFF Seat
Seat switch, Seat SW is OFF at power-ON - 9
Steering switch ON
(L) Faulty setting contactor OFF Lever is in
for hydraulic
Disables lever NEUTRAL
Seat SW is OFF - z
operation
Line contactor
Lever is not NEUTRAL at OFF Seat
H1 9
Lift lever, Faulty power-ON and seat SW ON Steering switch ON
H1 contactor OFF
setting Lever is in
Seat SW is turned ON after Disables lever NEUTRAL
* - z
lever is operated operation
Line contactor
Lever is not NEUTRAL at OFF Seat
H2 9
Tilt lever, Faulty power-ON and seat SW ON Steering switch ON
H2 contactor OFF
setting Lever is in
Seat SW is turned ON after Disables lever NEUTRAL
* - z
lever is operated operation
Line contactor
Lever is not NEUTRAL at OFF Seat
Attachment 1 H3 9
power-ON and seat SW ON Steering switch ON
H3 lever, Faulty contactor OFF Lever is in
setting
Seat SW is turned ON after Disables lever NEUTRAL
* - z
lever is operated operation
Line contactor
Lever is not NEUTRAL at OFF Seat
Attachment 2 H4 9
power-ON and seat SW ON Steering switch ON
H4 lever, Faulty contactor OFF Lever is in
setting
Seat SW is turned ON after Disables lever NEUTRAL
* - z
lever is operated operation
Meter panel, When serial
Comn fault is Turn OFF
60 Communication communication is not * - - *
displayed key
fault going on
Line contactor
- SUO Group #3 and default
Logic card, OFF Turn OFF
61 setting are not set * 61 9 *
Initialize failure Steering key
- Inverter setting warning
contactor OFF
- Sum check of ROM Line contactor
- Memory check of RAM OFF Turn OFF
62 Logic unit, Fault * 62 9 *
- Sum check of SUO data Steering key
(EEPROM) contactor OFF

1-45
CHAPTER 1 CONTROLLER

Meter panel

Steering operation
Icon

Memory
Return

Driving interlock
Mast interlock
Parking brake

Over temp.
Battery low
Code Fault How to detect Result to

Brake fluid

Code
Warning
normal

- Sum check of ROM


- Memory check of RAM
Line contactor
- Initial mode SW setting
Traction OFF Turn OFF
63 fault * 63 9 *
inverter, Fault Steering key
- When CAN
contactor OFF
communication is not
going on
- Sum check of ROM
- Memory check of RAM
Line contactor
- Initial mode SW setting
Pump inverter, OFF Turn OFF
65 fault * 65 9 *
Fault Steering key
- When CAN
contactor OFF
communication is not
going on
- Contactor coil current Line contactor
Contactor, Coil sensor OFF Turn OFF
72 * 72 9 *
fault - Line contactor Steering key
- Steering contactor contactor OFF
Hydraulic lock Checks current of lift lock Disables lever Turn OFF
74 * 74 z *
solenoid, Fault valve power circuit. operation key
Line contactor
Electromagnetic Checks current of
OFF Turn OFF
75 brake solenoid, electromagnetic brake * 75 z *
Steering key
Fault valve power circuit.
contactor Hold
Only warning
PDS buzzer, PDS buzzer short-circuit display and Turn OFF
76 * 76 z *
Fault protection is activated buzzer key
stoppage
Line contactor
Battery, Voltage OFF Turn OFF
78 Voltage class is not correct. * 78 9 *
too low Steering key
contactor OFF
Line contactor
Battery, Voltage OFF Turn OFF
79 Voltage class is not correct. * 79 9 *
too high Steering key
contactor OFF
Line contactor
Battery, OFF (*)
Too much consumption Turn OFF
Lo Consumption * (Lo) 9 Steering
with small capacity battery key
too much contactor
OFF (*)
Power
Battery,
Much consumption with reduction Charge
(Lo) Consumption * - z
small capacity battery (economy battery
much
table)

1-46
CHAPTER 1 CONTROLLER

Meter panel

Steering operation
Icon

Memory
Return

Driving interlock
Mast interlock
Parking brake

Over temp.
Battery low
Code Fault How to detect Result to

Brake fluid

Code
Warning
normal

Brake fluid, Low Turn OFF


- Level sensor (Contact) * - z -
level key
RTC battery, Battery voltage for calendar Calendar date Turn OFF
- * - z
Low IC is low is wrong key

Note:
- E0, E2, E5, and E7 do not appear on the meter panel, but are stored in the memory.
- Line contactor OFF (*)/Steering contactor OFF (*) means that the contactor will open immediately when a fault is
detected.
Line contactor OFF means that the contactor will open when current goes to 0.
- Contactor hold means no change. When a warning occurs while the contactor is turned ON, it stays ON.

1-47
CHAPTER 1 CONTROLLER
9. Removal and Installation
9.1 Inverter Discharging Procedure

Discharge electric charges stored in the inverters by using


the following procedure.
(1) Turn OFF the key switch.
(2) Disconnect the battery plug/connector.
(3) Remove the rear cover.

1 608606
1. Rear cover

(4) Place a 150 /25 W resistor between P and N terminals


in the traction inverter to discharge electric charges
stored in the inverter.
(5) After touching the resistor to the P and N terminals for
approx. five seconds, measure the voltage between the P
N
terminals with a multimeter and confirm a reading of
5V or less. W
(6) Perform the same procedure for the pump inverter in V
order to discharge electric charges from all inverters. F
U

608607

Check whether the resistance between + and - of the


battery plug/connector on the lift truck side is 1 k or more
when connecting the battery plug/connector for the first
time after maintenance.
Note: Discharge electric charges completely before
measuring. Longer measurement time reduces
resistance value.

Item Part No.


Discharge tool 16A68-02600

1-48
CHAPTER 1 CONTROLLER
9.2 Replacing Inverter

Removal
(1) Raise the front wheels.
(2) Perform Steps (1) through (6) in Inverter Discharging Procedure.

R CAUTION
Be sure to discharge electric charges from all inverters before working on the electrical system.

(3) Disconnect all five power cables from F, N, U, V and W


terminals.
(4) Disconnect the connector.
N F

V F

608608

R CAUTION
When disconnecting the connector, hold the connector housing and plug, and unlock the connector.
Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage.

(5) Remove M8 nuts (five places) fixing the inverter, then remove the inverter.

1-49
CHAPTER 1 CONTROLLER
9.3 Insuring Proper Thermal Transfer

Mounting Instructions for DC/AC Inverters


DSP Card
In the design of this family of DC/AC Inverters,
performance assumptions were made based on heat
transfer between the inverter and the ambient
environment. The lift truck mounting surface acts as a heat
sink, which increases the effective surface area for heat
dissipation. If this assumed heat transfer is not achieved
during inverter installation and operation, the inverters will
fall short of their anticipated performance. It should be
noted that the condition of the mounting surface, and the
quality of the resulting interface between the control and
608609
the lift truck, can significantly hinder heat transfer from the
inverter. This is why each inverter has a heat sink between Traction and hydraulic inverter
the inverter and the frame of the lift truck.

The presence of contaminants or air voids created by surface inconsistencies in either the lift truck or the heat sink will degrade
the inverters capacity for heat transfer. The inverters performance is de-rated proportionally as its own thermal sensors reduce
its operation to protect it from damage due to excessive heating.
Contained within the software of the controls are several diagnostic status codes related to controller thermal performance.
Failure to follow these mounting recommendations increases the likelihood of encountering these status codes.
Careful surface preparation, including adequate application of thermal compound, as detailed in the following paragraphs,
must be completed during the installation of the controls. There are many techniques for applying thermal compound. One
approach is outlined below that has shown to apply a consistent thickness of material.

Necessary tools
Recommended use of the following components, or equivalent substitutions, during the control installation process:
(1) Thermal compound, (5P9837), maintained per the manufacturers recommendations and free of contaminants
(2) 3/32" notched trowel, such as an adhesive spreader, P/N SE000049
(3) Calibrated torque wrench (0 15 ft-lbs)

The inverters
During the manufacture of the control, the surface flatness is maintained at 0.005" per linear inch (not to exceed 0.025" per 10.0
inches). The surface finish of the control has a Ra (average roughness) of 64 (micro inches), or better. This finish is consistent
with cold rolled or extruded aluminum. Care should always be taken in the handling and storage of controllers. The base of the
control should be free from nicks, bumps, protrusions, or any other foreign object that would prevent the control from sitting
flush with the lift truck mounting surface. Examine the base of the control to verify that it is in good condition and free from
damage or contamination.

Lift truck mounting surface


The quality of the lift truck mounting surface is critical for optimum heat transfer between the inverter and the ambient
environment. Conduction through the base of the inverter is the inverters only means of heat rejection. While the inverters are
highly efficient, a few percent of the electrical energy will be converted into heat. As previously mentioned, if this energy is not
dissipated through the base of the inverter, a thermal protector will reduce the performance of the inverter until the
temperature stabilizes. For optimal heat transfer from control to lift truck, the flatness of the lift truck mounting surface should
be equivalent to the flatness of the control surface (0.005" per linear inch). Use a straight edge or dial indicator to verify the
mounting surface. The biggest hindrance to heat transfer is the presence of rust, scale, weld splatter or paint on the lift truck
mounting surface. If any of these items are noted, prepare the surface per the following guidelines:
(1) Clean the mounting surface with a rotary wire brush until the metal surface is exposed.
(2) Using 80-100 grit emery paper, sand the surface until the metal shines.
(3) Flush the surface clean with an appropriate liquid de-greaser or parts cleaner.

R CAUTION
Apply thin and even heat sink grease since it works to release generated heat from the inverter to the lift truck body.

1-50
CHAPTER 1 CONTROLLER

Application of thermal compound


Due to the small differences in the inverter mounting
surface and the lift truck mounting surface, small pockets of
air will be created. These air pockets will add to the overall
thermal resistance of the interface. To avoid these air
pockets and improve thermal conductivity, thermal
compound must be applied between the control base plate
and the lift truck mounting surface. The function of this
compound is to conform to surface discrepancies, filling
gaps and optimizing the metal-to-metal contact of the Adhesive Spreader model SE000049
inverter and the lift truck. 608610

(1) Prepare the two mounting surfaces (Inverter and lift


truck) as indicated above.
(2) Using a triangular notched trowel of 3/32" (.09" +/- .01),
apply the grease to the lift truck mounting surface.
(3) Use straight, non-crossing strokes of the trowel to apply
the compound.
(4) Make multiple vertical passes until a uniform
consistency is achieved.

Truck mounting surface after proper grease application


608611

Mounting the inverter


After inverter mounting surface is prepared with heat sink
grease
(1) Prepare mounting surface of lift truck using the same
procedure as the inverter heat sink.
(2) Place the inverter with desired orientation on
mounting surface of lift truck with mounting holes
aligned.
(3) Move the inverter slightly in all directions to eliminate Calibrated torque wrench for hardware installation
voids and enhance the distribution of the thermal
compound. 608612
(4) Insert all of the mounting hardware 10 mm, 1.25 thread
pitch, with washers (4 bolts necessary for the mounting
of the respective inverter).
(5) Tighten these bolts to half of the nominal torque value
34.8 N-m (3.5 kgf-m) 34.8 ft-lb.
(6) Lastly, tighten the bolts to the nominal torque value
69.6 N-m (7.1 kgf-m) 51.4 ft-lb.
(7) Torque wrench, extension and socket required to
complete installation.

1-51
CHAPTER 1 CONTROLLER

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

R CAUTION
Apply thin and even heat sink grease since it works to release generated heat from the inverter to the lift truck body.

(3) Attach the inverter with M8 bolts.


(4) Connect the power cables to F, N, U, V, and W terminals. Proper stack method is: Cable, flat washer, Belleville washer and
nut.
Note: Retighten bolts of the cables one month after delivery or one month after the cable installation.

R CAUTION
Use the correct power cables and terminate marked cable ends to the correct terminals marked on the motor.
Cables terminated at the wrong terminals on the motor may cause the motor to rotate in the opposite direction when
activated.

Item Tightening torque


P, N, U, V, W 16 1.0 Nm (1.63 0.10 kgfm) [11.80 0.74 lbfft]
Power cables
F 10 1.0 Nm (1.02 0.10 kgfm)[7.38 0.74 lbfft]

(5) Connect the main harness connector to the inverter.

R CAUTION
You need to hold the DSP card connector when installing the harness connector to prevent any damages to the DSP card.
Ensure the connector is seated and the latch is locked.
Forcibly pressing the connector may cause damage to the DSP card. Hold the connector housing and press the connector, it
may not be easy to lock.

Note:
- It is recommended to check or replace the inverters every 10,000 hours of service operation.
- It is recommended to torque the U, V, W, P, N, and F terminals after 30 days service and at 1000 hour intervals.

1-52
CHAPTER 1 CONTROLLER
9.4 Replacing DSP (Digital Signal Processor) Card

Removal
(1) Perform Steps 1 through 6 in Inverter Discharging Procedure.

R CAUTION
Make sure to discharge inverters before working on the electrical system.

(2) Push and lift up at the four corners of the card cover to
remove the cover.
(3) Disconnect the connector.

608613

R CAUTION
When disconnecting the connector, hold the connector housing and plug, and unlock the connector.
Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage.

(4) Unlock the connector that is connected to the flat


cable. Hold the both ends of the white part of the
connector and pull it straight up.
(5) Pull the flat cable to disconnect it. If it cannot be
disconnected smoothly, raise the lock again to unlock.
(6) Pinch the plastic spacers at the four corners of the DSP
card with pliers to unlock and remove the card.

608614

R CAUTION
Be careful not to damage mounted parts with the pliers since the card has a number of fragile parts.

1-53
CHAPTER 1 CONTROLLER

Installation
(1) Align the four mounting holes of the new DSP card with the plastic spacer positions and press it into place.

R CAUTION
Press at the card edges.
Make sure that the spacer lock works completely and the card cannot be removed.

(2) Confirm that the flat cable connector is unlocked by


raising the connector lock.
(3) Insert the flat cable into the connector. Press down the
connector lock.

608615

R CAUTION
Do not forcibly bend the flat cable. Insert its conductive surface in the direction shown in the illustration.
Also, confirm that the cable is not tilted.

(4) Connect the main harness connector to the inverter.

R CAUTION
Do not push the flat cable by the inside of the inverter cover. Do not forcibly bend the flat cable.
Make sure that the cable will not be pinched underneath the cover. Confirm that the cover is completely locked.

(5) Install the cover while pushing the flat cable toward the
card side slightly.

608616

R CAUTION
Forcibly pressing the connector may cause damage to the DSP card. Hold the connector housing and press the connector, it
may not be easy to lock. Insert connectors surely until they are locked.

1-54
CHAPTER 1 CONTROLLER
9.5 Replacing Logic Unit

Removal
(1) Turn OFF the key switch.
(2) Disconnect the battery plug.

505635
1. Meter panel 3. GSE connector cap
2. Cup holder

(3) Disconnect the connector (CN1, CN2, CN3) from the logic card and the connector (CN4) from the power supply card.

4) 1

2
1) 2) 3)
505636
1. Logic unit 1) CN 1
2. MC main harness 2) CN 2
3) CN 3
4) CN 4

R CAUTION
When disconnecting the connector, hold the connector housing and plug, and unlock the connector.
Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage.

1-55
CHAPTER 1 CONTROLLER

(4) Remove M8 bolts (two places) and remove the logic


unit.

1 608618
1. Bolt, Washer (2 pcs)

Installation
Follow the removal sequence in reverse.

1-56
CHAPTER 1 CONTROLLER
9.6 Replacing Logic Card

Note: When replacing the logic card, it is recommended to


replace the logic unit as an assembly.
1
When the cover is removed from the logic unit case,
its tapped holes may be damaged. Replace the cover
if the tapped holes of the cover are damaged.
Removal
(1) Perform Steps (1) through (4) in Replacing Logic Unit.
(2) Remove M3 flat head screws (four places) from the
bottom, and M3 screws (five places) from the side of the
logic unit to remove the cover.
(3) Remove M3 screws with washers (five places) fixing the
logic card to the logic unit case to remove the logic
card.
(4) Remove the grommet from the logic card. 2
608619
1. Cover 2. Logic unit case

Installation 2
Follow the removal sequence in reverse. 1

608620
1. Heat sink 2. Logic card

1
608621
1. Grommet 2. Logic card

R CAUTION
When installing the logic card onto the logic unit case, carefully tighten the logic card and heat sink fixing screws to the
specified torque to avoid excessive stresses. Repair the heat sink first.

Item Tightening torque


M3 screw 0.98 0.20 Nm {0.10 0.02 kgfm} [0.72 0.15 lbfft]
M3 flat head screw 0.30 0.10 Nm {0.03 0.01 kgfm} [0.22 0.074 lbfft]

Note: Apply LOCTITE No.242 to M3 screws (five places) on the side of the logic unit when installing.

1-57
CHAPTER 1 CONTROLLER
9.7 Replacing Power Supply Card

Note: When replacing the power supply card, it is


recommended to replace the logic unit as an
1
assembly.
When the cover is removed from the logic unit case,
its tapped holes may be damaged. Replace the cover
if the tapped holes of the cover are damaged.
Removal
(1) Perform Steps (1) through (4) in Replacing Logic Unit.
(2) Remove M3 flat head screws (four places) from the
bottom and M3 screws (five places) from the side of the
logic unit to remove the cover.
(3) Remove M3 screws with washers (four places) fixing the
power supply card to the logic unit case to remove the
power supply card. 2
(4) Remove the grommet from the power supply card. 608619

1. Cover 2. Logic unit case

Installation
1 2
Follow the removal sequence in reverse.

608622
1. Heat sink 2. Power supply card

608623
1. Grommet 2. Power supply card

R CAUTION
When installing the power supply card onto the logic unit case, carefully tighten the power supply card and heat sink fixing
screws to the specified torque to avoid excessive stresses. Apply a small amount of heat sink compound before installing.

Item Tightening torque


M3 screw 0.98 0.20 Nm {0.10 0.02 kgfm} [0.72 0.15 lbfft]
M3 flat head screw 0.30 0.10 Nm {0.03 0.01 kgfm} [0.22 0.074 lbfft]

Note: Apply LOCTITE No.242 to M3 screws (five places) on the side of the logic unit when installing.

1-58
CHAPTER 1 CONTROLLER
10. Basic Check
Always follow basic troubleshooting steps.
- Talk to the operator.
- Confirm his description of the problem with an operational check.
- Visually inspect cables, connectors, contactor tips, etc.
- Perform basic battery cables to frame resistance test. (at least 20 k ohm)
- Check battery condition.
Always check each option and write down the reading.

10.1 Testing Tools

Note: The illustrations show digital circuit testers. In these


testers, the positive (+) terminal is applied with 2
positive charge, and the negative () terminal with
negative charge. It should be noted that the terminals 1
must be connected inversely when using an analog
meter tester. 3

608624
1. Circuit tester 3. IC clip
2. Clamp meter

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

10.2 Measurement of Card Voltage

R WARNING
To prevent accidental movement of the lift truck, place wood blocks under the lift truck to lift the front wheels off the ground.
Do not place wood blocks close to the front wheels.

(1) Tilt the mast fully BACKWARD. Place blocks under the mast, and tilt the mast FORWARD.
(2) Turn the key switch OFF.
(3) Disconnect the battery plug. Remove the cover.
(4) Reconnect the battery plug.
(5) Turn the key switch ON. Connect the negative terminal of the circuit tester to the V GND terminal of the card.
(6) Set the circuit tester to the 100-VDC range.
(7) Connect the positive terminal of the circuit tester to each pin of connectors.

Note: Be careful not to short-circuit pins. For normal voltage1-60 "Logic card voltage chart".

1-59
CHAPTER 1 CONTROLLER
Logic card voltage chart
Card side connector No.: CN1, Main harness side connector No.: E-02, E-03, and E-04

No. Name Note No. Name Note


1 GND-L E-02 33 Seat E-03
2 +15VL E-02 34 Parking brake E-03
3 GND-L E-02 35 Service brake E-03
4 +5VL E-02 36 Reverse E-03
5 CAN_H E-02 37 Forward E-03
6 CAN_L E-02 38 Brake fluid E-03
7 Boot E-02 39
8 FWE E-02 40 Lift limit SW 1 E-03
9 GND (GSE) E-02 41 Lift limit SW 2 E-03
10 42
11 43 GND E-04
12 44 PDS buzzer E-04
13 45
14 46
15 KEY OFF 2 E-02 47
16 48 Attachment 2 E-04
17 TxD (GSE) E-02 49 Attachment 1 E-04
18 RxD (GSE) E-02 50 Tilt E-04
19 POS Voltage E-02 51 Lift 2 E-04
20 Accelerator analog input 1 E-02 52 Lift 1 E-04
21 53
22 54
23 55
24 +5V (Power out) E-02 56 Steering motor fault E-04
25 GND (Power out) E-02 57 Lift lock valve + E-04
26 58 Lift lock valve - E-04
27 59 Line contactor E-04
28 Accelerator analog input 2 E-03 60 Steering contactor E-04
29 61 Alarm 1 E-04
30 Lift limit SW3 E-03 62 Steering motor enable E-04
31 Speed limit SW E-03 63 Con VE E-04
32 Seatbelt E-03 64 Electromagnetic brake E-04

1-60
CHAPTER 1 CONTROLLER
Power supply card voltage chart
Card side connector No.: CN1, Main harness side connector No.: E-01

No. Name Note No. Name Note


1 9 +VL (Logic unit) E-01
2 10 +5V (Logic unit) E-01
3 +VL (Inverter) E-01 11 GND (Logic unit) E-01
4 +8V (Inverter) E-01 12 GND (Logic unit) E-01
5 +VG (Inverter) E-01 13 V POW E-01
6 GND (Inverter) E-01 14 V POW E-01
7 15 V GND E-01
8 16 V GND E-01

DSP card voltage chart


Card side connector No.: CN2, Main harness side connector No.: E-05 and E-06

No. Name Note No. Name Note


1 Motor thermal + E-05,06 11 GND E-05,06
2 Motor thermal - E-05,06 12 TxD (GSE)
3 CAN_H E-05,06 13 TxR (GSE)
4 CAN_L E-05,06 14 CAN_L E-05,06
5 Rotary sensor +12V E-05,06 15 CAN_H E-05,06
6 Rotary sensor A E-05,06 16 +VG (Power IN) E-05,06
7 Rotary sensor B E-05,06 17 +VL (Power IN) E-05,06
8 18 +8V (Power IN) E-05,06
9 Mode 2 E-05,06 19 Rotary sensor GND E-05,06
10 Boot 20 GND (Power IN) E-05,06

1-61
CHAPTER 1 CONTROLLER
10.3 Checking Contactor Coil

R CAUTION
Disconnect the battery plug and discharge the inverter before working on electrical system.

(1) Disconnect the lead wire of coil.


(2) Set the circuit tester to 200 ohm range.
(3) Measure coil resistance.
The resistance must be 44 ohm at -30C (-22F) to 65 ohm at 80C (176F).
- If the measured value deviates from the above range, replace the contactor assembly.
(4) With the lead wire of contactor coil connected, set the circuit tester to 200-VDC range.
(5) Connect the negative () terminal of the circuit tester to the negative-side coil terminal (small terminal) and the positive (+)
terminal of the circuit tester to the positive side coil terminal (large terminal).
(6) Connect the battery, and operate the control device that activates the contactor.
(7) The circuit tester should indicate about 24V after the contactor operates. If the contactor is found normal during the coil
resistance test and if the measured voltage is not 24V, replace the logic card.

10.4 Checking Contactor Tips

(1) Visually inspect the contactor tips for melting,


adhesion, heat seizure, and pitting corrosion.
(2) To check for interference, press the tips and release
them.
(3) Visually inspect the contactor assemblies. Make sure
there are no foreign materials in the assemblies to
interfere with contactor movement.
(4) Measure the gap at each contactor tips using a
thickness gauge.
Note:
- It must be 3 0.5 mm (0.12 0.02 in.)
608625
- If you find any trouble, replace or repair contactor.
(5) Check for free movement of contactor.

1-62
CHAPTER 1 CONTROLLER
10.5 Checking Inverter

R CAUTION
Disconnect the battery plug and discharge the inverter before working on electrical system.

(1) Disconnect all five power cables from F, N, U, V, and W


terminals.
(2) Check the resistance between terminals shown in the
following table.

- +

608626

Positive probe Negative probe Resistance (ohm)


U
N V
W
8 k to 11 K
U
V P
V

Note: Short-circuit/disconnection of the inverter MOSFET can be confirmed by this check.


Other faults cannot be determined.

Note: On diode scale you will read about .460 volts on all test.

10.6 Regeneration Check

The AC motor uses a common circuit for current flow in both loading and regeneration. This allows the following procedure to
confirm regeneration:

(1) Place the ammeter clamp onto the cable connected to


the inverters F terminal (use DC current range). This is
positive direction as current flows from the battery to
the inverter. N F
(2) Drive the lift truck FORWARD. With the direction lever
shifted in FORWARD position, release the accelerator W
pedal. Then perform a full-reverse operation.
(3) The ammeter clamp should show a negative value. This V F
Ammeter clamp
value becomes the regeneration current. setting direction
N

608627

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

1-63
CHAPTER 1 CONTROLLER
11. AC Motor System Basics
11.1 Feature of AC motor

The AC motor model lift trucks covered by this manual use AC motors (three-phase induction motors) as the traction motor
and pump motor. AC motors have the following advantages over DC motors:
(1) AC motors are simple in construction. As they have no such friction parts as brushes and commutators, daily maintenance
load is significantly reduced.
(2) AC motors are compatible with high-speed operation.
(3) An AC motor of a certain size produces higher power than a DC motor of the same size.

11.2 Speed Control of Induction Motors

Speed control of DC motors depends on regulation of the


field and armature current amounts, while that of AC motors U
basically depends on adjustment of the frequency of the
alternating current power supply. The speed of an AC motor V M
Inverter 3
is determined by the frequency of the power supply AC W
current and the load on the motor.
In addition, the voltage and current to the motor must be V V
controlled properly so that the motor operates in its U V W
optimum characteristic range. See Fig. 1. t t
The frequency and voltage can be controlled by a variety of Low-speed operation High-speed operation
(low frequency)
methods including the vector control method employed 608628
in the AC motor model lift trucks. This method provides
Fig. 1
highly responsive control according to ever changing lift
truck operating conditions through high speed calculation
on huge amount of data. The vector control calculation is
performed by the inverter. See Fig. 2.

Logic unit Inverter

Gate MOS-FET modules


driving
pulse
Speed Vector control
Accelerator order calculation
Calculation for M
F required output 3
N
R
Truck
speed
Current
Brake
Speed

608629
Fig. 2

1-64
CHAPTER 1 CONTROLLER
11.3 Inverter

The lift truck battery delivers DC current, so the current must


be converted into AC current to drive an AC motor. The
device that converts direct current into alternating current is Switch
generally called an inverter. The processes involved in
creating AC current from DC current are described below. VB Load
VL
(1) Changing DC voltage cyclically
If the switch in a circuit like the one shown in Fig. 3 is
turned ON for time T1 and then turned OFF for time T2 T1 T2 T1 T2
and this ON-OFF operation is repeated many times, the T1
VL x VB
average of the voltage applied to the load is T1+ T2
determined by the ratio between T1 and T2. Varying
the ratio, therefore, results in varying voltage. The ratio Average voltage VL
between T1 and T2 is called duty ratio. By changing
the duty ratio cyclically, it is possible to obtain cyclically
changing DC voltage shown in Fig. 3.
Small duty ratio Large duty ratio
ON ON ON

608630

(Fig. 3)

(2) Converting DC power into AC power


Driving a three-phase AC motor using battery delivered
power requires creating three phase outputs (U, V, W)
of an identical waveform that differ in phase by 120
using a circuit with six switches S1 to S6 that are
arranged as shown in Fig. 4. The outputs created forms S1 S3 S5
a three-phase alternating current. Fig. 5 shows ON-OFF U
condition of each switch (arm) and output voltage V
variation. W
Functioning as switches in the inverter of the AC motor S2 S4 S6
lift trucks are MOS-FET transistors. The MOS-FET
transistors can switch at very high speeds, thus creating
smooth waveforms of alternating current.
608631

(Fig. 4)

S1 ON

Switching for U phase


S3 ON
S2 ON

Switching for V phase


S5 ON S4 ON

Switching for W phase

S6 ON

608632
(Fig. 5)

12. AC Motor Troubleshooting


1-65
CHAPTER 1 CONTROLLER
12.1 Motor Noises

(1) Problem
Clunking on direction changes.
Check
To see if stator is loose in frame of motor.
(2) Problem
Motor/lift truck chatters or shutters with wheel off floor and accelerator pedal slightly pressed; the wheels move in one
direction, then the other. Check forward and backward.
Check
Forward and reverse.
Check sensor bearing.
Check sensor bearing connector and wiring.
(3) Problem
Motor makes squealing sound like a bearing noise.
Check
Check sensor bearings to see if signals are OK. Check motor connections and stator windings. In order to check and isolate
bearing sounds using a stethoscope. If the sound is a general area sound then use a piece of flexible tubing or hose to locate
the source of the sounds. Stators can make a squealing sound when windings are not correct or when windings are open
(broken wire) or shorted.
(4) Problem
Motor has lower power, but reaches full speed.
Check
Check connections at motor terminals both out of motor and at the inverter connections. Check stator windings. You will need
a meter that checks insulation or can measure in the million ohm range. From (-) to (-). Normal readings are shown in the chart
below.

Normal readings

Phase line
Remarks Part Number Description
resistance (m) Nominal
2 to 4 20C (68F) 97N20-00300 Traction AC Motor
Traction AC Motor (for seat
2 to 4 20C (68F) 97N20-00700
operated parking brake option)
2 to 4 20C (68F) 97N20-01600 Pump AC Motor (for EE)
2 to 4 20C (68F) 97N20-00400 Pump AC Motor
2 to 4 20C (68F) 97N20-01500 Pump AC Motor (for EE)

1-66