TROUBLESHOOTING MANUAL O5W-2201 Transer Fontan FBC20P,25P,30P-70 NIGHIYU RIPPON YUSOKI CO,LTD. KYOTO, JAPANCONTENTS 1, Adjustment of SICOS-AC f 1-1. Explanation of the MPU board... 1-1-1, Basic control board construction 1-1-2, Travel’ Hydraulic board 1-1-3. Display board 1-1-4. Rotary switch on the Travel/ Hydraulic board 1-1-5. Rotary switch on the Display board 1-1-6. Adjustment Standards List for FBC-70 series 1-1-7. Confirmation of other services 1-2. SIGOS-AC check and adjustment 1-2-1. Chassis insulation check 1-2-2. Battery voltage adjustment 1-2-3. Current detector check 4-2-4, Forklift model setting check and adjustment 14 1-2-5. Safety circuit for contral onD anrann a 3 (contactor tripping} check 16 1-2-6, Hour meter working check 7 1-2-7. Colling fan working check 7 1-2-8, Rear axle steering angle potentiometer adjustment 18 4-2-9. Adjusting the position of handle and knob 19 4-2-10. Auto suspension working check 19 adjustment and working check 48 2-3-25. Laser pointer (optional) working check 48 2-93-26, Accelerator potentiometer adjustment 49 2-3-27. Seat switch (optional) working check 50 2-3-28. Automated fork horizontal stop (optional) 51 2-3-29, Built-in charger (optional) working check 53 2. Troubleshooting 20 2-1. Self diagnosis function..............cce.0e 20 2-4-1. Display 20 2-1-2, Error messages and Display conditions 22 2-2. Error history MEMOPy..........-.ceeceeceeeceeee 25 2-2-1. Error history memory 1 25 2.2.2. Error history mamory 2 26 2-2-3. Clearing the error history memory {memory initialization) 28 2-3. VO Check. stint 29 2-3-1. /O check made display method 29 2-3-2. /O port table 3t 3. Adjustments of truck with proportional control valve Er) 3-1. Names and functions of the device ........ 39 3-1-1. Overall appearance 39 3-1-2. Optional setting 40 3-1-3. Lever potentiometer adjustment 42 3-1-4. Solenoid valve current adjustment 454. Wiring and main controller layo Ly 4-1. FBC-70 System Wiring..........seeeseee AT 4-1-1. FBC20P/25P/30P 47 4-1-2. AOS, FT 48 4-1-3. Automated fork horizontal stop 49 4-2. FBC-70 Body Wiring oo... eessseeeseeeee 50 4-2-1. FBC20P/25P/30P 50 4-2-2. Automated fork horizontal stop 51 4-2-3. FT 52 4-3. FBC-70 Body harness. 4-3-1. FBC20P/25P/30P 4-4, FBC-70 Controller wiring ... 4-5.FBC-70 Controller harness 4-6. FBC-70 Main controller... 4-7. FBC-70 PS controller.........-.--cseseeeeseees 57 4-8. -BC-70 Charger harness .........-..:-++ 58 4-8-1. Charger harness(1) 58 4-8-2. Charger harness(2) 59 4-9. FBC-70 Wiring, chime. 4-9-1. Forward/backward directional interlock 60 4-9-2. Forward directional interlock 61 4-9-3. Backward chime 62 4-9-4. Forward directional interlock (with changeover switch) 63 4-10.FBC-70 Harness, switch... 64 4-10-1. FT 64ER Adjustment of SICOS-AC Explanation of the MPU board 1-1-1. [Basic control board construction _| As shown in the figure below, the SICOS-AC uses the display board as the central point for connecting all other boards for the exchange of data. In addition, all control boards use a one-chip CPU (with flash ROM) as their main CPUs, so their ROM can not be removed. Travel/ Hydraulic board (MPU board) Display unit || | Switch board Travel circuit {+ t _ control CPU Gate board) Motor i Hydraulic circuit ee pce | rene +(wo=() PS >| control board mt Mier ) ¥v Microcomputer chargerAdjustment of SICOS-AC 1-1-2. [Travel/ Hydraulic board (MPU board) [RS1] Truck model selection @ This board controls the traction motor and the hydraulic motor. Proportional ive agjustment z Connector fr writing software personal computer @ This board controls both the data exchanged between the other boards and the display. (Wiener ealy Buzzor (CPU) CPU drive: 1AS1] : Rotary switch for monitor selection Connector for a Connector for made select switch flourscent monitor ce | ‘Connectar for E coer ~ personal computer : ANKLE BONA Backup battery mom Tous | on pl % Body harness: wee © Normal condition while turning on the key switch. LED Travel/Hydraulic board Display board PI5 lighting P6 lighting HYD blinking TRV blinking P7 lighting CPU blinkingAdjustment of SICOS-AC: AACAUTION In case of changing the settings for the rotary switches, be sure to turn off the key switch before changing them. 1-1-4. Rotary switch on the Travel/ Hydraulic board The rotary switch (RS1) on the travel/hydraulic board is used to select forklift models. When replacing the travel/hydraulic board, be sure to refer to the table below to match it with the forklift. ® RS1 Setting forklift models. RSi Applicable model types 0° FBC20P 7 FBC25P 2 FBC3OP 3 4 5 6 7 8 9 A B ¢c D E { F @ DS1(DIP Switch) DS1 is not used. Volume No. Function Remarks LiFT Lift proportional control valve Tuming the volume clockwise increases the (VA1) | current adjustment current. TILT —_| Tit proportional control valve _| Tuming the volume clockwise increases the (VR2) | current adjustment current. ATT1 | Attachment 2 proportional control | Turning the volume clockwise increases the (VR3) valve current adjustment current. ATT2 __| (Attachment 3 proportional control | Turning the volume clockwise increases the (vR4) | valve current adjustment) current. REACH | Attachment 1 proportional control | Turing the volume clockwise increases the (vR5) _| valve current adjustment current. Note: The standard board is not equipped with volumes. Only fingertip control or AOS model is equipped. 3Adjustment of SICOS-AC [1-1-5. [Rotary switch on the Display board The rotary switch (RS1) on the display board is used for selecting the displays and adjustments shown in the table below. @ AS1 setting functions RSI Functions Remarks MONITORING OK ‘After tuming on the Key switch, this message is displayed. Normal monitor Neer (Bele ciectege. cece em Error Hour meter check Total, travel, and hydraulic hour meters appear. Reserve charge screen ‘Specify when charging begins. | Date and time setting Set the date and time. i Set the maximum speed under the slow speed a Slow speed setting mode. (4, 8, 6, 8 10, 12, 15km/h) Travel mode setting Select ECONOMY, NORMAL, or POWER. Select the hour meter or odometer VIEW (contrast) « BRIGHTNESS (0-7 intensity of back light) Adjustment of regensrative Power | select NON, LOW, MID, or HIGH Meter mode setting Display mode setting when accelerator Is teleased 1 Monitor symbol setting STEER, BATT, OIL, LOAD, BRAKE 2 Forklift modal check Displays the settings for the travel/hydraulic board 3 Plugging strength setting 0-32 | Brake strength setting 0-32 Maximum lift speed 1 (- 32 (Fast) : For travel speeds of 0- 5 Kavh Maximum litt speed 2 0 - 32 (Fast) : For travel speeds of 5 - 10 Knvh Maximum lift speed 3 (0 - 82 (Fast) : For travel speeds of over 10 Kmv/h Lift speed 1 = 32 (Fast) : 1st microswitch 4 Lift speed 2 = 82 (Fast) : and microswitch Tilt speed 0-82 (Fast) Attachment 1 speed 0- 82 (Fast) ‘Attachment 2 speed 0- 32 (Fast) Attachment 3 speed 0 - 32 (Fast) s Display language selection ‘Six languages 6 Option setting Set the options. 7 Voltage, current, and temperature check 8 RAM and /0 memory data check é Error history memory 1 Displays the details of the 10 latest cases Error history memory 2 Records all past errors A Battery voltage setting Voltage settings for capacity standards B ‘Turning speed reduction 0-16 c AOS setting 1 Ses the lifVilt end and others D ‘AOS satting 2 Checks the lever switch E Memory initial Clears the error history F Normal screen 2 No errors are displayed on the screenSi on display board > votage | peas | “ra” 4 as 4 4 =F M boat |sPo-LisPo-NisPo-H! HyD | HyD | Hyo [tte] tte | AYP br uscpraccy Travel speed] Lit speed |Pugjegbres| | ber | rr) uFr |uiF lieve) rier YAC|AUACIAUTACY ug [tag [RAE) HYD STEER} BATT | Ol 101 re Ce) _| (mmsec) | estncsin) | | recor | o [oa ||| o|alalololol#ls|ol|olo [eal vases | eoouso | 00-22] | rv [race |x; [#[*|*]*]*#]/+/*#|/t+i#*]#]+]/*]41¢ | # [tases | eoouso [0-22] | racop | 2 |#|*ti|*|*|/t|t+|+|+/*+/*/t]*]+/¢ # | [ross [esto | eo-e7 | |S 3 4 toi Q z 5 [6 a [a i) [3 a 2 a A c : c c Q z cs Le = im TT a a ; Puppia botedatires —————T Memory Initial (display ASt=E) Option setting (Display board RS1=6) ‘Flat, unladen, and fui oO ‘Slow speed (turtle speed): Sisn/h ‘UFTLOCK {Lift Interrupt) ‘Specific gravity of electrolyte : more than 1.25 at 20. ! Traval ede NORMAL ‘SPEED LIMIT [Speed tit at hich iting helgh) ‘¢Ful ecealeration ~ BaIGHTTNESS 3 SEAT SWITCH iWin seat ste) ) Nawal rogenarative power : MD FINGERTIP [WE finger fp) ‘eLanguage soloetion (Olsplay board RS1=5) a Motor rage Hour mater fos twin ads] Gheescueea g ror stony lar Fone NODE FPover mote} Meee 2 S87 OK @ CHARGER (Charger) — ‘When Japmess [s not selected for display, ‘CHARGER’ FRENCH > CONTROLEUR OK ose Bees, ema er emaeee & FA METER (hour molar cou) sli 5 HOUR METEF retin ta ‘SPEED SWITCH [Stow speod meda snitch} DUTCH > MONTOAING OK 2: Actual operation time (malor oparalin tia) [Bg vso0is 10 weunsnipyAdjustment of SICOS-AC [ 1-1-7. |Confirmation of other services Display After pressing "@®)" button for more than 3 seconds, it is displayed as follows. ® Model confirmation Io F gy Ohh © 1s 20 1g (AUNEO RABE BERR BDERE | fe F gm Chu & 1 ea 2 [AURRAOAREH ARBRE BREE SOFTWARE ©| lea E Esaiaa) | cb Leeeaay | je FUNCTION The model set by rotary switch ‘on the MPU board is displayed. The software program numbers :T (travel), H (hydraulic), E (PS), D (display) are displayed. Ee BUZZER OFF? ei a] ROTARY SW OFF o| fe (continues on next page) Buzzer mode setting is highlighted. © Set buzzer mode by pressing "<<" or ">" button (OFF/ ON) ON: (Normal) OFF: (turns off all the buzzer except blinkers)(continued from previous page) @| je Ghvh § 1G 1B 2a HEQRHOERAE AARERRE Adjustment of SICOS-A\ ‘The setting number of rotary switch is cispleyed. ® Rotary switch mode setting is flashed. © Set rotary SW mode by pressing "" or "@* button (OFF/ ON) ON: normal OFF:The rotary SW is disabled and the setting number of rotary SW is able to change by mode select button. @ When the connection is failure between display board and MPU board, PS controller, software numbers are not displayed. © If buzzer mode is set to OFF, al) buzzer sounds are turned off except blinker sound. @ If rotary SW mode is set to OFF, the rotary ‘SW is disabled on the display board. You can change the rotary SW setting by “keeping pressing down (}> button for more than 3 seconds while pressing ©) button" or "keeping pressing down <<] button for more than 3 seconds while pressing @) button.Adjustment of SICOS-AC In checking and adjusting procedure without mention of the content, refer to FB-75 troubleshooting manual (03W-2204), SICOS-AC check and adjustment AcamToi| © Even if the key is turned off, battery voltage is still supplied to the display board. Disconnect the ‘battery plug and discharge the capacitors in the control unit before performing this work. @ After finishing the setting, be sure to return rotary switch RS1 to "0". © Before measuring current, change the mode depending on the objects. ‘Traction motor current Hydraulic motor current Battery current PS motor current Demade AC mode (1-241. [Chassis insulation check . Disconnect the battery plug. 2. Discharge the capacitors in the control unit. (For the discharge procedure, see "10a-3-1. Capacitor - discharging procedure" in "FBC-70 WORKSHOP MANUAL". Remove the connector on the battery electrolyte level detection line (green/black) in the control unit. [Only models of electrolyte level detector is equipped] 2 - Use a tester to measure the insulation resistance between positive (+) terminal of the chassis battery plug and chassis, between negative (-) terminal of the chassis battery plug and chassis, and auxiliary terminal (red) of the chassis battery plug and chassis. Standard value 1MQor greater @ Display board $07 SPs S = Saree ° eM Feetum AS1 to "0".Adjustment of SICOS-AC 1-2-2, |Battery voltage adjustment [Power supply voltage from battery:48V] ® Open the battery cover and measure the voltage between the terminal connected the additional line (positive) and the terminal connected the lead wire (negative). Specific gravity of the battery electrolyte : over 1.25 at 20 Use a digital tester that can measure 1/100V. ‘Use Direct current (DC) mode. = Display board 1. Set rotary switch RS1 on the display board to "A". 2. Turn on the key switch and the following screen appears, Set RS1 to "A". © Battery voltage a screen aa) mh 1 20 = * iii HANIA AGEL [VOLTAGE (BATTERY ) tanta ana a v Battery Voltage Parameter (lashing) 3. Set the parameter for battery voltage the same as the measured value for the tester, (the toterance is within + 0.1 V. ) ©Press (3 button to increase the parameter. Press S) button to decrease the parameter.FEB agjustment of sicos-ac Current detector check Traction motor current check IU: traction motor U phase electric current (V phase or W phase is also possible.) Specific gravity of the battery electrolyte : over 1.25 at 20 °C Alternating current (AC) mode ! = t Board comp., —= Ou mpu | BM ' ‘ pone ——= 6 u2 | Harness, M (3) t mae ul Hig > \ fens]ena] [ona] end ‘Analog lomp aremeter_~ | ‘Traction motor U phase Lee ae i et ee | Control! unit ACAUTION When measuring AC motor current, use the ACAUTION recommended ammeter below: Recommended ammeter : Hioki 3109-01 (Analog) Hioki 3209 AC/DC high tester (Digital) When measuring locked travel/hydraulic motor 10 current using Hioki 3209 AC/DC (Digital), you need to: 1, Use AC + DC mode 2. Use H mode (do not use AUTO range) 3. Use SLOW responseAdjustment of SICOS: 1. Set rotary switch RS1 on the display board to "7". Display board Lie 2. Turn on the key switch and the following screen sae appears. 8 ‘Set RS1 to "7". GeaNOTE ILTRV is not flashing, press J button to make *] lash. Voltage, current, and ees sueaie screen, F yim, Ohh & * [Ga BEG ANBAR YHYO/EPS/OSP BATT- sav MOTOR 100A Flashing Flashing Tatton motor Curent Display = 7 [iti miuniuui ~ THRU HORE HNO REDE E HYDFEPS/OSP Flashing 3. Not depressing the accelerator pedal,check if the traction motor current (MOTOR) shows 000A. 4. Jack up the drive wheel and depress the accelerator pedal fully. 5. At this condition, check if the traction motor current (MOTOR) shows a traction motor current (IU) meter value within :20A, 1BEIT Acjustment of sicos-ac Hydraulic motor current check JU: hydraulic motor U phase electric current (V phase or W phase is also possible.) Specific gravity of the battery electrolyte : over 1.25 at 20 °C Alternating current (AC) mode Eee Board comp., MPU Harness, M (4) Analog clamp ammeter Ee ena [ena] [ove[ eng AXCAUTION When measuring AC motor current, use the recommended ammeter below: Recommended ammeter : Hioki 3109-01 (Analog) Hioki 3209 AC/DC high tester (Digital) AACAUTION When measuring locked travel/hydraulic motor 12 current using Hioki 3209 AC/DC (Digital), you need to: 1. Use AC + DC mode 2. Use H mode (do not use AUTO range) 3. Use SLOW responseAdjustment of SICOS-AC 1. Set rotary switch RS1 on the display board to "7". Display board 2. Turn on the key switch and the following screen appears. 3. Press either (> or G] button to make HYD flash. SBS) 8-7 © Voliage, current, and temperature checking screen. F yim Ch & 1D IE 20 a * {AEE BEQR RROW NBR ie 18° 8) #18: 88 5o¥ Flashing Hydraulic motor Curront Display Flashing ~ Not operating the lift lever, check if the hydraulic motor current (MOTOR) shows 000A. a Pull the lift lever (lift up) fully until lift relief position (lift stroke end). 2 . At this lift relief current, check if the hydraulic motor current (MOTOR) shows a hydraulic motor current (IU) meter value within 120A. 13EE Adjustment of Sicos-ac [ 1-2-4, [Forklift model setting check and adjustment Display board 4. Set rotary switch RS1 on the display board to "2". — 2. Turn on the key switch and the following screen lle, appears. Saye 3. Confirm the madel type is set correctly. AT ‘Set AS1 to "2". 1. Keep pressing ® button for 3 seconds. 2. The following screen appears. 3. Confirm the model type is set correctly. © Forklift model type checking screen (|f rotary switch RS1 on the travel/hydraulic board is set STiavele yore oon oa oy to"2") gue Saye of t ie Asie 14