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Troubleshooting PDF
Troubleshooting PDF
General Information
If any of these items (above items) is a source of the trouble, the device will be damaged even if it is replaced with a
new one. Be sure to check the above items and replace carefully.
Connection of the service tool Error code display
211358
2-1
TROUBLESHOOTING FOR CONTROL CIRCUITS
211359
Electronic parts cleaner SE000003
NOTE
The cleaner liquid is volatile. All you have to do is just
give a strong spray to wash off grime.
No need to wipe off the sprayed liquid.
NOTE
Do not spray too much liquid into the connector.
Cleaner liquid reacts differently with some resins
(plastic materials).
Do not completely fill connectors with Nyogel from
kit or you may push pins out of connectors.
Contact surface
*: Products contained in Terminal Maintenance Kit activator
(SE000003)
205047
2-2
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Let truck cool for 15 minutes.
Overheat indicator ON Overheat indicator OFF
If problem reoccurs
(6) Disconnect battery plug. Disengage brake
and parking brake, and check their drag.
No drag Drag
(14) Disconnect battery plug. Wait until traction motor (15) Disconnect battery plug.
temperature becomes close to room temperature.
2-3
TROUBLESHOOTING FOR CONTROL CIRCUITS
(16) Perform inverter discharging work. See page 1-45. (17) Troubleshoot display unit by referring Display
Communication Fault (60)-(4).
(18) Disconnect connector P15 of traction motor thermal
sensor. Measure resistance between P15(77) and (83)
at motor side.
581 at 20 C(68 F)
(Min. 555 , Max. 607 )
For resistance at temperature
other than 20 C(68 F), see table
on page 2-5. Out of range
Thermal
(19) Disconnect connector P1 of traction inverter. (20) Replace traction motor. See Chassis & Mast.
Check continuity between P1-1 and P15(83).
Check continuity between P1-2 and P15(77).
Continuity No continuity
Power supply
(21) Check continuity between P8-3 and P1-17(47).
Check continuity between P8-6 and P1-20(44).
Continuity No continuity
CAN
(22) Disconnect connector P3 of logic unit.
Check continuity between P3-5(92A) and P1-3(92).
Check continuity between P3-6(93A) and P1-4(93).
Check continuity between P1-14 and P1-15(18).
Continuity No continuity
(23) Connect connector P8, then turn on power again. (24) Repair or replace harness.
2-4
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1 Traction inverter
G 0 to 5V G
CAN 5 GW 92A 0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
5V * 1 L 1
Power supply card GND LB V IV
P8 2
12V R Flat
5 cable W IW
0 to 5V W
6
0 to 5V G
7
GND B
19
Traction motor
P14
82 B 4 Speed
G 3 sensor W TW
81
80 W 2 IM V TV
U TU
79
R 1 Thermal
77
LB 2 sensor
391 [-30 C(-22 F)] to
83
L 1 1407 [160 C(320 F)]
P15
*1: With connector disconnected
AMBIENT RESISTANCE
TEMPERATURE
( C) ( F) MIN. TYP. MAX.
-30 -22 362 391 419
-10 14 428 460 492
0 32 464 498 532
10 50 503 538 574
30 86 587 626 665
50 122 679 722 764
70 158 781 826 872
90 194 891 940 989
110 230 1007 1062 1117
130 266 1128 1194 1259
150 302 1256 1334 1412
211360
2-5
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Let truck cool for 15 minutes.
Overheat indicator ON Overheat indicator OFF
(12) Disconnect battery plug. Wait until pump motor (13) Disconnect battery plug.
temperature becomes close to room temperature.
(14) Perform inverter discharging work. See page 1-45. (15) Troubleshoot display unit by referring Display
Communication Fault (60)-(4).
(16) Disconnect connector P17 of pump motor thermal
sensor. Measure resistance between P17(78) and (89).
581 at 20 C(68 F)
(Min. 555 , Max. 607 )
For resistance at temperature
other than 20 C(68 F), see table
on page 2-8. Out of range
Thermal
(17) Disconnect connector P2 of pump motor inverter. (18) Replace pump motor. See Chassis & Mast.
Check continuity between P2-1 and P17(89).
Check continuity between P2-2 and P17(78).
Continuity No continuity
2-6
TROUBLESHOOTING FOR CONTROL CIRCUITS
Power supply
(19) Check continuity between P8-3(47) and P2-17(47A).
Check continuity between P8-6(44) and P2-20(44B).
Continuity No continuity
CAN
(20) Disconnect connector P3 of logic unit.
Check continuity between P3-5(92A) and P2-3(92).
Check continuity between P3-6(93A) and P2-4(93).
Check continuity between P2-14 and P2-15(73).
Continuity No continuity
(21) Connect connector P8, then turn on power again. (22) Repair or replace harness.
(25) Replace power supply card of logic unit. See page 1-52.
With service tool
Without service tool
(26)Ensure all connectors are connected. Check Run
Time Diagnosis data. See page 1-43.
The latest data is "E2". Not "E2"
(29) Replace DSP card of pump motor inverter. See page 1-48.
2-7
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
GW GND 44B GW 20 card card
6 44 U IU
5V* 1 LB 1
Power supply card GND LB V IV
2 Flat
P8 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
AMBIENT RESISTANCE
TEMPERATURE
( C) ( F) MIN. TYP. MAX.
-30 -22 362 391 419
-10 14 428 460 492
0 32 464 498 532
10 50 503 538 574
30 86 587 626 665
50 122 679 722 764
70 158 781 826 872
90 194 891 940 989
110 230 1007 1062 1117
130 266 1128 1194 1259
150 302 1256 1334 1412
211361
2-8
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Let truck cool for 15 minutes.
Overheat indicator ON Overheat indicator OFF
If problem reoccurs
(6) Check if truck is operated to lift large cargo load.
Normal
(7) Perform inverter discharging work. See page 1-45.
(12) Disconnect battery plug. Wait until pump motor (13) Disconnect battery plug.
temperature becomes close to room temperature.
(14) Perform inverter discharging work. See page 1-45. (15) Troubleshoot display unit by referring Display
Communication Fault (60)-(4).
(16) Disconnect terminals T6 and T7 of pump motor.
Measure resistance of pump motor thermal switch.
0 at
165 C(329 F) to 175 C(347 F) Out of range
Thermal
(17) Disconnect connectors P4 and P8 of logic unit. (18) Replace pump motor. See Chassis & Mast.
Check continuity between P4-31 and T7(86).
Check continuity between P8-16 and T6(13C).
Continuity No continuity
2-9
TROUBLESHOOTING FOR CONTROL CIRCUITS
2-10
TROUBLESHOOTING FOR CONTROL CIRCUITS
Power
P8
B
16 13BC
Pump motor
B
Logic 13C T6
P4
W M
31 86 T7
Thermal
switch
T4 T5
211362
2-11
TROUBLESHOOTING FOR CONTROL CIRCUITS
2-12
TROUBLESHOOTING FOR CONTROL CIRCUITS
CAN
(18)Disconnect connector P3 of logic unit.
Check continuity between P3-5(92A) and P1-3(92).
Check continuity between P3-6(93A) and P1-4(93).
Check continuity between P1-14 and P1-15(18).
Continuity No continuity
(19)Connect connector P8, then turn on power again. (20) Repair or replace harness.
(23) Replace power supply card of logic unit. See page 1-52.
With service tool
Without service tool
(24) Ensure all connectors are connected. Check Run
Time Diagnosis data. See page 1-43.
The latest data is "E5". Not "E5"
If fault remains
(28) Disconnect battery plug, then perform inverter
discharging work. See page 1-45.
2-13
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1 Traction inverter
G 0 to 5V G
CAN 5 GW 92A 0 to 5V
92 3 Inside Inside Line contactor
6 93A
GW
93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
Power supply card V IV
P8 2
Flat Controller
5 cable thermistor W IW
6
Capacitor
7 thermistor
19
Traction motor
P14
DSP flat Speed
cable 82 4
sensor W TW
81 3
Inverter
2
IM V TV
80
case U TU
79 1 Thermal
sensor
DSP card 77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211363
2-14
TROUBLESHOOTING FOR CONTROL CIRCUITS
2-15
TROUBLESHOOTING FOR CONTROL CIRCUITS
CAN
(18) Disconnect connector P3 of logic unit.
Check continuity between P3-5(92A) and P2-3(92).
Check continuity between P3-6(93A) and P2-4(93).
Check continuity between P2-14 and P2-15(73).
Continuity No continuity
(19) Connect connector P8, then turn on power again. (20) Repair or replace harness.
(23) Replace power supply card of logic unit. See page 1-52.
With service tool
Without service tool
If fault remains
2-16
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
GW GND 44B GW 20 card card
6 44 U IU
1
Power supply card V IV
2 Flat Controller
P8
5 cable thermistor W IW
6
Capacitor
7 thermistor
19
P17
211364
2-17
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Check oil level in brake oil reservoir tank.
Normal Abnormal
(7) Disconnect battery plug, then perform inverter (8) Disconnect battery plug. Replace display unit.
discharging work. See page 1-45. See Chassis & Mast.
If fault remains
2-18
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic Logic
P4 P3
38 23
0V/12V GND
17
WB B
84 17D
P33
Brake fluid
sensor
211365
2-19
TROUBLESHOOTING FOR CONTROL CIRCUITS
Problem: Pump Motor, Worn Brushes (Contactor Control Type Only) (br)
(1) Situation
Display: "br". "br" and truck speed alternately displayed during traveling (when no other fault codes are displayed).
Lifting (lift and attachment) operates for 1 second only. Normal traction motor and power steering operations.
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(5) Disconnect brush wear detector wires T4(87) and T5(88) from pump motor. Reconnect battery plug,
and close key switch. Confirm error code display.
Error code br No error code
(6) Disconnect battery plug, then perform inverter (10) Check brushes and replace, if necessary.
discharging work. See page 1-45.
(8) Replace logic card of logic unit. See page 1-51. (9) Correct or replace wiring.
2-20
TROUBLESHOOTING FOR CONTROL CIRCUITS
Pump motor
M
Logic
P4 T4 T5
40 87
G
B
41 88
211366
2-21
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(9) Connect connector P8 to logic unit, then turn on power (10)Repair or replace harness.
again.
(12) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(13)Replace DSP card of traction inverter. See page 1-48. (14) Replace power supply card of logic unit. See page 1-52.
If fault remains
2-22
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1 Traction inverter
G 0 to 5V G U current sensor
CAN 5 GW 92A 0 to 5V
92 3 Inside Inside Line contactor
6 93A 93
GW 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
Power supply card V IV
P8 2
Flat
5 cable W IW
6 V current sensor
7
19
Traction motor
P14
DSP flat Speed
cable 82 4
sensor W TW
81 3
Inverter
2
IM V TV
80
case U TU
79 1 Thermal
sensor
DSP card 77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211367
2-23
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(5) Check traction motor and terminal for burning and smell.
Normal Abnormal
(10) Confirm connection of traction motor speed sensor (11) Secure DSP flat cable if loose.
connector P14. Replace inverter if wire breaks. See page 1-46.
Normal Abnormal
Sensor
(12) Disconnect connectors P1 and P14. (13) Connect connector securely.
Check continuity between P1-5 and P14(79).
Check continuity between P1-6 and P14(80).
Check continuity between P1-7 and P14(81).
Check continuity between P1-19 and P14(82).
Continuity No continuity
8V power
supply
(14) Check continuity between P8-4 and P1-18(46).
Check continuity between P8-6 and P1-20(44).
Continuity No continuity
CAN
(15) Disconnect connector P3 of logic unit.
Check continuity between P3-5(92A) and P1-3(92).
Check continuity between P3-6(93A) and P1-4(93).
Check continuity between P1-14 and P1-15(18).
Continuity No continuity
(16) Connect connector P8 to logic unit, then turn on power (17) Repair or replace harness.
again.
2-24
TROUBLESHOOTING FOR CONTROL CIRCUITS
(20) Replace DSP card of traction inverter. (21) Replace power supply card of logic unit.
See page 1-48. See page 1-52.
If fault remains
If fault remains
(23) Perform inverter discharging work, then reinstall
traction inverter and replace traction motor.
2-25
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1 Traction inverter
G 0 to 5V G
CAN 5 GW 92A 0 to 5V
92 3 Inside Inside Line contactor
6 93A
GW
93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
Power supply card V IV
P8 2
12V R Flat
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
Traction motor
P14
DSP flat 82 B 4 Speed
cable G sensor W TW
81 3
Inverter W 2
IM V TV
80 U TU
case R
79 1 Thermal
sensor
DSP card 77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211368
2-26
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
No error, problem recurs Error code 14
(7) Check to see if truck is operated with heavy cargo load or (8) Change set time. See page 1-27.
on steps when motor stalls.
Normal steeps Heavy load Note: The more stall occurs, the more overheating
occurs. Operate truck under normal condition.
(15) Connect connector P8 to logic unit, then turn on power (16)Repair or replace harness.
again.
(18) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(19) Replace DSP card of traction inverter. See page 1-48. (20)Replace power supply card of logic unit. See page 1-52.
2-27
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1 Traction inverter
0 to 5V U current sensor
G G
CAN 5 GW 92A 0 to 5V
92 3 Inside Inside Line contactor
6 93A 93
GW 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
Power supply card V IV
P8 2
Flat
5 cable W IW
6 V current sensor
7
19
Traction motor
P14
82 4 Speed
sensor W TW
81 3
80 2
IM V TV
U TU
79 1 Thermal
sensor
77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211369
2-28
TROUBLESHOOTING FOR CONTROL CIRCUITS
Problem: Pump Motor Current Sensor Fault (Transistor Control Type Only) (34)
(1) Situation
Display: "34". All truck operations inhibited. This fault occurs only when turning on power.
Line contactor OPEN and steering contactor HOLD.
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(9) Connect connector P8 to logic unit, then turn on power (10) Repair or replace harness.
again.
(12) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(13) Replace DSP card of pump inverter. See page 1-48. (14) Replace power supply card of logic unit. See page 1-52.
If fault remains
(15) Perform inverter discharging work, then replace pump
inverter. (DSP card is normal.) See page 1-46.
2-29
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P2 Pump inverter
G 0 to 5V G U current sensor
CAN 5 GW 92A
0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
GW GND 44B GW 20 card card
6 44 U IU
1
Power supply card V IV
2 Flat
P8
5 cable W IW
6
7 V current sensor
19
P17
211370
2-30
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(5) Check pump motor and terminal for burning and smell.
Normal Abnormal
(10) Confirm connection of pump motor speed sensor (11) Secure DSP flat cable if loose.
connector P16. Replace pump inverter if wire breaks. See page 1-46.
Normal Abnormal
Sensor
(12) Disconnect connectors P2 and P16.
(13) Connect connector securely.
Check continuity between P2-5 and P16(85).
Check continuity between P2-6 and P16(86).
Check continuity between P2-7 and P16(87).
Check continuity between P2-19 and P16(88).
Continuity No continuity
8V power
supply
(14) Check continuity between P8-4(46) and P2-18(46A).
Check continuity between P8-6(44) and P2-20(44B).
Continuity No continuity
CAN
(15)Disconnect connector P3 of logic unit.
Check continuity between P3-5(92A) and P2-3(92).
Check continuity between P3-6(93A) and P2-4(93).
Check continuity between P2-14 and P2-15(73).
Continuity No continuity
(16) Connect connector P8 to logic unit, then turn on power (17) Repair or replace harness.
again.
2-31
TROUBLESHOOTING FOR CONTROL CIRCUITS
(19) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(20) Replace DSP card of pump inverter. See page 1-48. (21) Replace power supply card of logic unit. See page 1-52.
If fault remains
If fault remains
2-32
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P2 Pump inverter
G 0 to 5V G U current sensor
CAN 5 GW 92A
0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
GW GND 44B GW 20 card card
6 44 U IU
1
Power supply card V IV
2 Flat
P8 12V R
5 cable W IW
0 to 5V W
6
0 to 5V G
7 V current sensor
GND B
19
P17
211371
2-33
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
Error code 40 Error code 63 or 65
(5) Block wheels, then confirm line contactor operation in (6) See troubleshooting for code "63" or "65".
self-diagnosis mode [14]. See page 1-41 or 1-42. See page 2-61 or 2-64.
Not operated Operated
Without service tool
With service tool
(7) Check DC voltage of pump and traction inverters (8) Disconnect battery plug, then perform
with monitor. These values should be same as inverter discharging work. See page 1-45.
battery voltage.
Traction inverter value Pump inverter value
abnormal abnormal
(11) Replace traction inverter.
(9) Disconnect battery (10) Disconnect battery See page 1-46.
plug, then perform plug, then perform
inverter discharging inverter discharging If fault remains
work. See page 1-45. work. See page 1-45.
(14) Disconnect battery plug, then perform
(12) Replace traction (13)Replace pump inverter. inverter discharging work. See page 1-45.
inverter. See page 1-46. See page 1-46.
(21) Perform inverter discharging work, then replace logic (22) Repair or replace harness.
card of logic unit. See page 1-51.
2-34
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1
G 0 to 5V G Traction inverter
5 92A 92 3
CAN GW 93A 0 to 5V GW
6 93 4 F
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
Fuse
-
R J4-3
Pump
contactor
60 32 RW GY +
7 J7
LB LR
54 50 12 J12
- Fuse
R J4-1
Steering
contactor
61 31 RW GR +
6 J6
L
55 48 11 LW J11
211372
2-35
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1
G 0 to 5V G Traction inverter
5 92A 92 3
CAN GW 93A 0 to 5V GW
6 93 4 F
P2
Power supply card
P8 G 3
92 Pump inverter
Y 10A GW
14 F
93 4
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
- Fuse
R J4-1
Steering
contactor
61 RW GR +
31 6 J6
L
55 48 11 LW J11
211373
2-36
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Block wheels, then confirm steering contactor operation
in self-diagnosis mode [16]. See page 1-41 or 1-42.
Not operated Operated
(5) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(6) Check to see if steering contactor tip moves smoothly. (7) Repair or replace harness.
Check steering contactor tip for melting.
Normal Abnormal
2-37
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1
G 0 to 5V G Traction inverter
5 92A 92 3
CAN GW 93A 0 to 5V GW
6 93 4 F
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
Fuse
-
R J4-3
Pump
contactor
60 32 RW GY +
7 J7
LB LR
54 50 12 J12
- Fuse
R J4-1
Steering
contactor
61 31 RW GR +
6 J6
L
55 48 11 LW J11
211372
2-38
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1
G 0 to 5V G Traction inverter
5 92A 92 3
CAN GW 93A 0 to 5V GW
6 93 4 F
P2
Power supply card
P8 G 3
92 Pump inverter
Y 10A GW
14 F
93 4
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
- Fuse
R J4-1
Steering
contactor
61 RW GR +
31 6 J6
L
55 48 11 LW J11
211373
2-39
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Block wheels, then confirm pump contactor operation in
self-diagnosis mode[15]. See page 1-42.
Not operated Operated
(5) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(6) Check to see if pump contactor tip moves smoothly. (7) Repair or replace harness.
Check pump contactor tip for melting.
Normal Abnormal
(9) Disconnect connectors P5, P8 and P19. (10)Replace pump contactor. See Chassis & Mast.
Check continuity between P8-14(10A) and P19-4(10B).
Check continuity between P19-4(10B) and J4-3.
Check continuity between P5-60(32) and P19-7(32).
Check continuity between P19-7(32) and J7.
Check continuity between P5-54(50) and P19-12(50).
Check continuity between P19-12(50) and J12.
Continuity No continuity
2-40
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1
G 0 to 5V G Traction inverter
5 92A 92 3
CAN GW 93A 0 to 5V GW
6 93 4 F
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
Fuse
-
R J4-3
Pump
contactor
60 32 RW GY +
7 J7
LB LR
54 50 12 J12
- Fuse
R J4-1
Steering
contactor
61 31 RW GR +
6 J6
L
55 48 11 LW J11
211372
2-41
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(6) Disconnect traction motor cables from inverter. (7) Secure cable if loose.
Measure resistance of motor cables (U, V and W phases).
Less than 1 1 or more
(8) Check connector P1 of traction inverter for looseness. (9) Measure resistance between terminals of both cable
Normal Abnormal ends (between U and U, V and V, and W and W).
Less than 1 1 or more
(17) Connect connector P8 to logic unit, then turn on power (18) Repair or replace harness.
again.
2-42
TROUBLESHOOTING FOR CONTROL CIRCUITS
(20) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(21) Replace DSP card of traction inverter. See page 1-48. (22) Replace power supply card of logic unit.
See page 1-52.
If fault remains
2-43
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1 Traction inverter
G 0 to 5V G
CAN 5 GW 92A 0 to 5V
92 3 Inside Inside Line contactor
6 93A
GW
93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
Power supply card V IV
P8 2
Flat
5 cable W IW
6
7
19
Traction motor
P14
DSP flat 82 4 Speed
cable sensor W TW
81 3
Inverter 80 2
IM V TV
case U TU
79 1 Thermal
sensor
DSP card 77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211374
2-44
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(5) Check pump inverter and motor for cable looseness and
improper contact.
Normal Abnormal
(6) Disconnect pump motor cables from inverter. (7) Secure cable if loose.
Measure resistance of motor cables (U, V and W phases).
Less than 1 1 or more
(8) Check connector P2 of pump inverter for looseness. (9) Measure resistance between terminals of both cable
Normal Abnormal ends (between U and U, V and V, and W and W).
Less than 1 1 or more
(17) Connect connector P8 to logic unit, then turn on (18) Repair or replace harness.
power again.
2-45
TROUBLESHOOTING FOR CONTROL CIRCUITS
(20) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(21) Replace DSP card of pump inverter. See page 1-48. (22) Replace power supply card of logic unit.
See page 1-52.
If fault remains
2-46
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
GW GND 44B GW 20 card card
6 44 U IU
1
Power supply card V IV
2 Flat
P8
5 cable W IW
6
7
19
P17
211375
2-47
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Raise front wheels until they clear floor.
Without service tool With service tool
(5) Disconnect battery plug. (6) Check accelerator sensor voltage with input/output
monitor and confirm value is in range of 0.2V to 4.8V.
Check relation between sensor voltage and accelerator
switch operation.
(7) Check link length of accelerator pedal. 0.3V or less: OFF
Normal Abnormal 1.41V or more: ON
Abnormal signal Interrupted
(8) Adjust accelerator pedal (9) Disconnect battery plug. (10) Adjust accelerator
linkage. pedal linkage.
2-48
TROUBLESHOOTING FOR CONTROL CIRCUITS
(17) Replace accelerator pedal. (18)Connect connectors P4 and P3. Turn on power and
check voltage between P9-4(56) and P9-1(28).
If fault remains 5V Not 5 V
2-49
TROUBLESHOOTING FOR CONTROL CIRCUITS
P9
1 2 3 4
Logic 28 15 29 56
P4
YB 12V/0V
SW 42 15
Accelerator
P9
2
B 56
5V
24 4
AN 20 W 29
0.30 to 1.40V
3
CLEAR GND
25 28 1
Logic
P3
211376
2-50
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(6) Check to see if connector P1 of traction inverter is (7) Connect cables properly.
fastened securely.
Normal Abnormal
(14) Connect connector P8 to logic unit, then turn on power (15) Repair or replace harness.
again.
2-51
TROUBLESHOOTING FOR CONTROL CIRCUITS
(17) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(18) Replace DSP card of traction inverter. See page 1-48. (19) Replace power supply card of logic unit. See page 1-52.
If fault remains
2-52
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1 Traction inverter
G 0 to 5V G
CAN 5 GW 92A 0 to 5V
92 3 Inside Inside Line contactor
6 93A
GW
93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
Power supply card V IV
P8 2
12V R Flat
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
Traction motor
P14
82 B 4 Speed
G sensor W TW
81 3
80 W 2
IM V TV
U TU
79
R 1 Thermal
sensor
77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211377
2-53
TROUBLESHOOTING FOR CONTROL CIRCUITS
Problem: Pump Motor Pulse Input Fault (Transistor Control Type Only) (57)
(1) Situation
Display: "57". All truck operations inhibited. Line contactor OPEN and steering contactor HOLD.
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(6) Check to see if connector P2 of pump inverter is fastened (7) Connect cables properly.
securely.
Normal Abnormal
(8) Check to see if connector P16 of pump motor speed (9) Fasten connector securely.
sensor is fastened securely.
Normal Abnormal
Sensor
(10) Disconnect connectors P2 and P16.
(11) Fasten connector securely.
Check continuity between P2-5 and P16(85).
Check continuity between P2-6 and P16(86).
Check continuity between P2-7 and P16(87).
Check continuity between P2-19 and P16(88).
Continuity No continuity
Power
supply
(12) Check continuity between P8-3(47) and P2-17(47A).
Check continuity between P8-6(44) and P2-20(44B).
Continuity No continuity
CAN
(13) Disconnect connector P3 of logic unit.
Check continuity between P3-5(92A) and P2-3(92).
Check continuity between P3-6(93A) and P2-4(93).
Check continuity between P2-14 and P2-15(73).
Continuity No continuity
(14) Connect connector P8 to logic unit, then turn on (15) Repair or replace harness.
power again.
2-54
TROUBLESHOOTING FOR CONTROL CIRCUITS
(17) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(18) Replace DSP card of pump inverter. See page 1-48. (19) Replace power supply card of logic unit. See page 1-52.
If fault remains
2-55
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
GW GND 44B GW 20 card card
6 44 U IU
1
Power supply card V IV
2 Flat
P8 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
P17
211378
2-56
TROUBLESHOOTING FOR CONTROL CIRCUITS
(6) Check to see if these are shorted to other signal cables. (7) Repair or replace harness.
Not shorted Shorted
If fault remains
2-57
TROUBLESHOOTING FOR CONTROL CIRCUITS
Y
14 10A Battery +
P19 P20
RW
1 11 4
1
12
W
Fuse holder
P6
Logic P6
P3 Battery voltage Y
10E 2 17 95
G 95
0 to 12V 10E 96
TXD 14 4
Display
W 0 to 12V
RXD 16 96 3
GND 23 B 17
GND
1
211379
2-58
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Turn off power, then turn on power in Setup Option Group 3 setting. See page 1-19.
(5) Set Setup Option Group 3 data. See page 1-31 to 1-33.
If fault remains
If fault remains
2-59
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Turn off power, then turn on power in Setup Option Group 3 setting. See page 1-19.
2-60
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(10)
Transistor control Contactor control
2-61
TROUBLESHOOTING FOR CONTROL CIRCUITS
Mode
(17) Check P1-8 and P1-9 that pin is not inserted in.
Normal Abnormal
(18) Connect connector P8 to logic unit, then turn on (19) Repair or replace harness.
power again.
(21) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(22) Replace DSP card of traction inverter. (23) Replace power supply card of logic unit.
See page 1-48. See page 1-52.
2-62
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1 Traction inverter
G 0 to 5V G
CAN 5 GW 92A 0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 17
47
WL 8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U
8
Power supply card V
P8 9
Flat
cable W
DSP flat
cable
Inverter
case
DSP card
211380
2-63
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
2-64
TROUBLESHOOTING FOR CONTROL CIRCUITS
Mode
(15) Check continuity between P8-6(44) and P2-9(44A).
Continuity No continuity
(17) Connect connector P8 to logic unit, then turn on power (18) Repair or replace harness.
again.
(20) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(21) Replace DSP card of pump inverter. See page 1-48. (22) Replace power supply card of logic unit. See page 1-52.
2-65
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
GW GND 44B GW 20 card card
6 44 U
mode 1 8
Power supply card mode 2 GW V
9 Flat
P8
cable W
44A
DSP flat
cable
Inverter GND
case
DSP card
211381
2-66
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Without service tool With service tool
(8) Remove coil side terminals of (14) Remove coil side terminals of (20) Remove coil side terminals of
line contactor. steering contactor. pump contactor.
(9) Check short circuit between coil (15) Check short circuit between coil (21) Check short circuit between
terminal plus(+)(J4-2) and minus(-) terminal plus(+)(J4-1) and minus(-) coil terminal plus(+)(J4-3) and
(J5) of harness. (J6) of harness. minus(-)(J7) of harness.
Not shorted Shorted Not shorted Shorted Shorted Not shorted
(10) Repair or replace main harness. (16) Repair or replace main harness.
(11) Measure coil resistance. (17) Measure coil resistance. (22) Measure coil resistance.
[44 at -30 C(-22 F) to [44 at -30 C(-22 F) to [44 at -30 C(-22 F) to
66 at 80 C(176 F)] 66 at 80 C(176 F)] 66 at 80 C(176 F)]
Abnormal Normal Abnormal Normal Normal Abnormal
(12) Replace logic card of logic unit. (18) Replace logic card of logic unit.
See page 1-51. See page 1-51.
(13) Replace line contactor. (19) Replace steering contactor. (23) Replace pump contactor.
2-67
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1
G 0 to 5V G Traction inverter
5 92A 92 3
CAN GW 93A 0 to 5V GW
6 93 4 F
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
Fuse
-
R J4-3
Pump
contactor
60 32 RW GY +
7 J7
LB LR
54 50 12 J12
- Fuse
R J4-1
Steering
contactor
61 31 RW GR +
6 J6
L
55 48 11 LW J11
211372
2-68
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P3 P1
G 0 to 5V G Traction inverter
5 92A 92 3
CAN GW 93A 0 to 5V GW
6 93 4 F
P2
Power supply card
P8 G 3
92 Pump inverter
Y 10A GW
14 F
93 4
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
- Fuse
R J4-1
Steering
contactor
61 RW GR +
31 6 J6
L
55 48 11 LW J11
211373
2-69
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(5) Disconnect connector P5 of logic unit. Disconnect connector P11 of lift lock valve.
(9) Replace logic card of logic unit. (10) Replace lift lock valve.
See page 1-51.
2-70
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic P11
P5
1 Lift
57 BL 25
Y lock
58 26
2 valve
P11
1 2
25 26
211382
2-71
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(5) Disconnect connector P5 of logic unit. Disconnect connector P24 of electromagnetic brake.
(9) Replace electromagnetic brake. (10) Replace logic card of logic unit. See page 1-51.
2-72
TROUBLESHOOTING FOR CONTROL CIRCUITS
10G 5
1 2
211383
2-73
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug. Measure battery voltage with tester.
34 V to 55 V Abnormal
If fault remains
2-74
TROUBLESHOOTING FOR CONTROL CIRCUITS
Line contactor
P20 P19
4 RW
11 1 NEG
Fuse W RW J1
1 12 2
POS
+
Logic
P3 Battery
W
19 12B
211384
2-75
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug. Measure battery voltage with tester.
34V to 55 V Abnormal
If fault remains
(11) Perform inverter discharging work, then replace logic (12) Repair or replace main harness.
card of logic unit. See page 1-51.
2-76
TROUBLESHOOTING FOR CONTROL CIRCUITS
Line contactor
P20 P19
4 RW
11 1 NEG
Fuse W RW J1
1 12 2
POS
+
Logic
P3 Battery
W
19 12B
211384
2-77
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Move direction lever to neutral, and release accelerator pedal.
If fault remains
(11) Replace direction lever. (12) Disconnect connectors P4 and P3 of logic unit.
2-78
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P4
P7
G 0/12V
Forward 37 6 F
GW 0/12V Direction
Reverse 36 8 R lever
GND
17H
B
B2
Accel YB
42 15
P7
switch
8 6
17H
Main harness
0/12V
Logic Accelerator
P3 P9
GND 23 B 17 2
+ 5V 24 B 56
5V
4
AN 20 W 29
0 to 5V
3
CLEAR GND
GND 25 28 1
P9
1 2 3 4
28 15 29 56
Main harness
211385
2-79
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
If this fault occurred If this fault occurred when
during running turning on power
Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again.
If fault remains
(11) Disconnect battery plug, then perform inverter (12) Replace seat switch.
discharging work. See page 1-45.
(14) Replace logic card of logic unit. See page 1-51. (15) Repair or replace main harness.
2-80
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P4
0/12V BR
19 32 Seat belt switch
0/12V R
7 33 Seat switch
Seat belt switch
P62 Logic
1 19
P3
3 7
GND B
2 17A 17 23 GND
Seat switch
P62
7 17A 19
211386
2-81
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
If this fault occurred during If this fault occurred when
pump motor operation turning on power
Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again.
If fault remains
(11) Disconnect battery plug, then perform inverter (12) Replace seat switch.
discharging work. See page 1-45.
(14) Replace logic card of logic unit. See page 1-51. (15) Repair or replace main harness.
2-82
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P4
0/12V BR
19 32 Seat belt switch
0/12V R
7 33 Seat switch
Seat belt switch
P62 Logic
1 19
P3
3 7
GND B
2 17A 17 23 GND
Seat switch
P62
7 17A 19
211386
2-83
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
If this fault occurred during If this fault occurred when
pump motor operation turning on power
Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again
without lift operation.
If fault remains
(9) Disconnect battery plug, then perform inverter (10) Replace lift switch 1 or 2.
discharging work. See page 1-45.
2-84
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P13 P5
0/12V YB
5 53 52 Lift 1
Lift 1
6
0/12V
54 YR 51 Lift 2
Lift 2 1 B 17C
GND
P13 Logic
P3
1 17C 54 6 B 23
17
2 51 53 5
3 52 52A 4
Logic
P12 P5
YB
1 4 48 Lift down
Lift down
2 B 17G
P12
1 2
4 17G
211387
2-85
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
If this fault occurred during If this fault occurred when
pump motor operation turning on power
Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again
without tilt operation.
If fault remains
(9) Disconnect battery plug, then perform inverter (10) Replace tilt switch.
discharging work. See page 1-45.
2-86
TROUBLESHOOTING FOR CONTROL CIRCUITS
Logic
P13 P5
2
0/12V YG
51 50
Tilt
1 B 17C
GND
P13 Logic
P3
1 17C 54 6 B
17 23
2 51 53 5
3 52 52A 4
211388
2-87
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
If this fault occurred during If this fault occurred when
pump motor operation turning on power
Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again
without attachment 1 or 2 operation.
If fault remains
(9) Disconnect battery plug, then perform inverter (10) Replace attachment 1 or 2 switch.
discharging work. See page 1-45.
2-88
TROUBLESHOOTING FOR CONTROL CIRCUITS
P13 Logic
YL 52A P5
4
3 YL 0/12V YL
Aux 2 52 52 49
Aux 1
1 B
GND
17C
Logic
P13 P3
B
1 17C 54 6 17 23
2 51 53 5
3 52 52A 4
211389
2-89
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug.
(6) Set #46 of Setup Option Group 3. See page 1-33. (7) Charge battery or replace with new battery.
If fault remains
(10) Replace logic card of logic unit. See page 1-51. (11) Repair or replace main harness.
2-90
TROUBLESHOOTING FOR CONTROL CIRCUITS
Line contactor
P20 P19
4 RW
11 1 NEG
Fuse W RW J1
1 12 2
POS
+
Logic
P3 Battery
W
19 12B
211384
2-91
TROUBLESHOOTING FOR CONTROL CIRCUITS
(4) Checks
Disconnect battery plug.
(6) Set #46 of Setup Option Group 3. See page 1-33. (7) Charge battery or replace with new battery.
If fault remains
(10) Replace logic card of logic unit. See page 1-51. (11) Repair or replace main harness.
2-92
TROUBLESHOOTING FOR CONTROL CIRCUITS
Line contactor
P20 P19
4 RW
11 1 NEG
Fuse W RW J1
1 12 2
POS
+
Logic
P3 Battery
W
19 12B
211384
2-93