Caterpillar ET4000

CONTROLLER
Controller System .................................................................................... 3 – 1

System Layout .......................................................................................... 3 – 1
Controller Area Network (CAN) ................................................................. 3 – 3
Outline of Controller .................................................................................. 3 – 4
Controller Features ................................................................................. 3 – 10 3
Traction Features ...................................................................................... 3 – 10
Lifting Features ......................................................................................... 3 – 12
Outline Features ....................................................................................... 3 – 13
Setup Option ............................................................................................ 3 – 16
Outline ...................................................................................................... 3 – 16
Operation Procedure ................................................................................ 3 – 16
Details of Setup Options ........................................................................... 3 – 18
Diagnostics ............................................................................................... 3 – 37
Outline ...................................................................................................... 3 – 37
Operation Procedure ................................................................................ 3 – 37
Self-Diagnostics ........................................................................................ 3 – 40
Power Steering Diagnostics ....................................................................... 3 – 41
Self-Diagnostics (Power steering system) ................................................. 3 – 42
Run Time Diagnostics ............................................................................... 3 – 43
Removal and Installation ....................................................................... 3 – 45
Inverter Discharging Procedure ................................................................ 3 – 45
Replacing Inverter ..................................................................................... 3 – 46
Replacing DSP (Digital Signal Processor) Card ........................................ 3 – 48
Replacing Logic Unit ................................................................................. 3 – 50
Replacing Logic Card ............................................................................... 3 – 51
Replacing Power Supply Card .................................................................. 3 – 52
Replacing Input Unit ................................................................................. 3 – 53
Replacing Output Unit ............................................................................... 3 – 54
Basic Check .............................................................................................. 3 – 55
Testing Tools ............................................................................................. 3 – 55
Measurement of Card Voltage .................................................................. 3 – 56
Checking Contactor Coil ........................................................................... 3 – 61
Checking Contactor Tips ........................................................................... 3 – 61
Checking Inverter ...................................................................................... 3 – 62
Regeneration Check ................................................................................. 3 – 63
AC Motor System Basics ....................................................................... 3 – 64
CONTROLLER
Controller System
The configuration of the controller system is classified
System Layout into two types according to the lifting system.
Four or six independent controllers are linked together The input unit is connected to the FC control lever.
by the Controller Area Network (CAN) to communicate The output unit is connected to the FC hydraulic control
with each other to control the truck. valve assembly.
The logic unit is the heart of the control system for the The inverters are connected to the each motor.
lift trucks. The logic unit is connected to the other devices.
System layout for FC type
Contactors
Switches Logic Unit
Display Logic card

Contactor control signal
Traveling control,
Lifting control,
Key Lift lock solenoid control signal
switch Safety function,
etc.
Power
B2
R
N
F
FC control lever
Direction lever
Motor control Input
command FC lever input unit
Accelerator Sensing
data
FC solenoid
CAN bus command
FC solenoid Lift cylinder,

Right Left Output control signal Tilt cylinder
traction inverter Pump inverter
traction inverter unit
DSP card DSP card DSP card
FC hydraulic
control valve
Sensors Sensors Sensors
assembly
U U U Lift lock
M solenoid valve
V M V V M
W W W
Left traction motor Pump motor Hydraulic

Right traction motor pump
Contactor Battery
Electric power
213089
3-1
CONTROLLER
System layout for MC type
Contactors
Switches Logic Unit
Display Logic card Contactor control signal

Traveling control,
Lifting control, Lift lock solenoid/unload solenoid control signal
Key
switch Safety function, Hydraulic lever input
etc.
Power
B2
R
N
F
Direction lever
Motor control
command
Accelerator Sensing
data
CAN bus
Right Left
traction inverter Pump inverter
traction inverter Lift cylinder,
Tilt cylinder
DSP card DSP card DSP card Micro switches
MC hydraulic
control valve
Sensors Sensors Sensors assembly
U U U
V M V M V M Lift lock
W W W solenoid valve
Hydraulic Unload
Right traction motor Left traction motor Pump motor pump solenoid valve
Contactor Battery
Electric power
213090
3-2
CONTROLLER
Controller Area Network (CAN)

Each controller is linked with the truck harness to form a
network as follows.
The input unit and output unit are used for FC models
only.
The terminal resistors are built into the right traction
inverter and the pump inverter.
If the terminal resistors are not properly connected, the
communication failure may occur between the logic unit
and the inverters.
For details, see the “Traction Inverter R.H. Fault (63)”,
“Traction Inverter L.H. Fault (64)” and “Pump Inverter
Fault (65)” in “Troubleshooting for Control Circuits.”
*1 *2
Right Left Logic Input Output Pump
traction traction unit unit unit inverter
inverter inverter
CAN H
CAN L
*1, * 2: Input unit and output unit are used

for FC model only.
211323
The data are expressed as electric potential difference

between high- and low-level signals as follows.
The signals are transferred to each controller through
the serial communication protocol.
Kind of VCAN-L
potential
bit Logic Vdiff Vdiff
dominant 0 VCAN-H
recessive 1 recessive dominant recessive

time
211176
Main specifications
Communication protocol CANbus 2.0B passive Non-Return to Zero method
Broadcast communication protocol
Communication line Dual 2-wire type serial communication
Communication speed 500 kbps
Data length 0 to 8 bytes
3-3
CONTROLLER
Outline of Controller
1. Logic unit
This controller includes the power card and logic card.
It controls all the jobs for the truck based on the
operator’s input.
The controller sends a motor control command to the
right and left traction inverters through the input of the
direction lever or the accelerator pedal. It also monitors
malfunctions of the traction system.
The lever input triggers to send the motor control
commands to the pump inverter. It also monitors
malfunctions in the hydraulic control system. In the FC
specifications, this controller sends a control command
to the solenoid valves from the output unit by the lever
input. A malfunction in the valve control system is also
monitored by this controller.
The truck speed and residual battery power are
monitored and shown on the display unit.
The logic unit sets its model information and optional
default data into internal memory. The information is
secured even if the power supply for the logic unit is
turned off. This information is set at the factory.
The following table shows the model information. The
system will not work properly if the actual controller
system is different from the model information.
Model information
Item Description SUO No.
Truck type Model set #40
Battery voltage 36 V, 48 V #41
Battery type Battery type #42
Hydraulic control selection FC type, MC type #43
Mast type Mast type #44
Valve section Number of valves #45
Battery voltage adjust Battery voltage adjustment #46
Foot direction Optional equipment #47
The current information is available to confirm and

modify.
Refer to Setup Option on page 3-16 for details and
setting procedure.
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.
3-4
CONTROLLER
Logic unit
211177
Logic card
CN1
Harness B side CN3 Harness B side CN2 Harness B side CN1

211178
Power supply card
CN1
211179
The Service Tool connector exists on harness B CN21.

3-5
CONTROLLER
2. Inverter When a malfunction occurs, it stops the motors and

informs the logic unit.
The inverter is a motor drive controller that consists of
a Digital Signal Processor (DSP) card, Insulated Metal The DSP card has the DSP chips that enables high-
Substrate (IMS) module and their drive boards. speed calculation and controls the AC induction
motors.
It drives the AC induction motors according to the
motor control command from the logic unit. It also The IMS module has multiple MOS-FET modules
monitors malfunctions of motors and its own condition. which convert battery DC current into AC current for
the traction and pump motors. See also the “AC Motor
System Basics” section on page 3-64.
Traction inverter (right and left)
DSP card
211180
Traction inverter
DSP card
(right and left)
CN2
Harness B side, Traction Right CN7

Inverter card side CN2 Harness B side, Traction Left CN6
211181
3-6
CONTROLLER
Pump inverter
DSP card
211182
Pump inverter
DSP card
CN2
Inverter card side CN2 Harness B side, Pump CN5

211183
3-7
CONTROLLER
3. Input unit
This input unit is connected to FC specification models.
It is the dedicated input unit for connecting equipment
such as the FC control lever and switches. It monitors
for malfunctions of connected equipment and its own
condition. When a malfunction occurs, it informs the
logic unit.
Input unit
Input unit card

CN1
Input unit card side CN1 FC-IN harness side CN2

211184
3-8
CONTROLLER
4. Output unit
This output unit is connected to FC specification according to the valve control command from the logic
models. It is the dedicated output unit for controlling unit. It monitors for malfunctions of the solenoid valves
the solenoid valves. It drives the solenoid valves and its own condition. When a malfunction occurs, it
informs the logic unit.
Current to
solenoid [%]
100
Current increases
drastically as lever
movement angle
increases.
0
100 Lever angle [%]
209550
Current characteristics of proportioning

solenoid valve
Output unit
Output unit card

CN3
Output unit card side CN3
Harness B side CN22 FC-OUT harness side CN9

211185
3-9
CONTROLLER
Controller Features
The following describes the features of the controller.
Traction Features
1. Modification of traction characteristics
Acceleration power, maximum output power and There are two types of auto regeneration and selectable.
battery consumption can be set. The following two Accelerator regeneration type: The regeneration starts
parameters can be set. when the accelerator
Acceleration rate: Sets acceleration power. pedal is released during
traction.
Traveling power: Selection of the maximum output
power changes the amount of Brake regeneration type: Releasing the accelerator
battery consumption. It also pedal during traction
influences the acceleration power causes dry run. The
during loading operation. regeneration starts when
the brake pedal is
Regeneration power and type of regeneration can be
pressed.
set. There are two types of regeneration and each has
availability of setting for regeneration power. The lever regeneration starts when the travel direction
and the direction lever are in opposite directions. The
Auto regeneration: Normal deceleration that occurs
amount is determined by the pressure on the accelerator
between the traveling and the
pedal.
direction lever when they are in the
same direction.
Lever regeneration:The deceleration that occurs
between the travel and the direction
lever when they are in the opposite
directions.
Setting feature for traction characteristics
Description SUO No.
Acceleration rate Acceleration of traction #8
Powering Traveling power Max. power, amount of battery
#9
consumption
Regen function Selection of auto regeneration #21
Regen adjustment for auto regen Rate of regeneration at normal
Regeneration #23
slowdown
Regen adjustment for lever regen Rate of regeneration when operating to
#22
the opposite direction
Refer to page 3-16 for details and setting procedure of controlled roll-back function prevents hazardous
the “Setup Option.” descending of the truck.
The application preset feature (#1) has the preset The descending speed changes with the steepness of
setting pattern registered. grade, the weight of load and value setting of the SUO
#23.
2. Controlled roll-back NOTICE: When the regeneration is selected by SUO

#21, the controlled roll-back does not work.
When the accelerator pedal is released on a grade, the
3-10
CONTROLLER
3. Boost
When truck traveling is blocked by a step, the boost Fully depress the accelerator pedal for 2 seconds. The
function prevents stalling of the truck. Usually the boost function increases the motor maximum torque for
motor maximum torque is set by SUO #9, but this 5 seconds. If the pressure to the accelerator pedal is
function allows the truck to bypass a step regardless of reduced or the direction lever is moved, the boost
the value setting of the motor maximum torque. function will be cancelled immediately.
Torque [%]
* Torque required to
climb over a step
* #9
100 HIGH POWER; Full acceleration
85 STANDARD; Full acceleration

70 ECONOMY; Full acceleration
0 Time [sec]
2 7
211324
NOTICE: When the motor overheats, the boost will not work.
If the stall time setting is small, the motor protection function will be applied during prolonged slow
speed traveling.
4. Limitation of maximum travel speed

The speed limitation is classified into two major types Conditional type: The limitation that is triggered from a
and available to set each maximum speed. specific switch input occurrence.
Normal type: The limitation that functions at all Selectable quadruple input signals.
times and is used to keep the speed Available to set a speed limit for each
within the limits. signal.
Feature of maximum speed limit
Description SUO No. Harness Pin No.

Normal Top travel speed limit Always effective #7 –
Auxiliary travel speed limit 1 Effective when aux. input 1 close/open #11, 12 CN2-30
Conditional
Auxiliary maximum travel speed Effective when aux. switch close/open #30, 31 CN2-31
3-11
CONTROLLER
5. Miscellaneous features for traction
Miscellaneous features for traction

Item Description SUO No. Harness Pin No.
Auxiliary power reduction 1 Effective when aux. input 1 close/open #11, 13 CN2-30
Auxiliary output power limit Effective when aux. switch close/open #30, 32 CN2-31
Speed alarm 1 Alarm 1 signal output if speed exceeds set value. #26 CN1-61
Speed alarm 2 Alarm 2 signal output if speed exceeds set value. #34 CN1-62
Tire size adjustment Correction value to compensate for a diameter change
#27 –
resulting from tire wear
Stall timer Stops traction motor to protect it, if lift truck does not
#20 –
move within set time.
Lifting Features
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
Description SUO No. Harness Pin No.

Start lift speed Start lift speed setting #2 –
Top lift speed Top lift speed setting #3 –
Lowering lift speed Lowering lift speed setting #35 –
Normal Tilt speed Tilt speed setting #4 –
Auxiliary 1 speed Attachment 1 #5 –
Auxiliary input for lift 1 Stops lift when aux. input 1 close/open #11 CN2-30
Conditional Auxiliary input for lift 2 Stops lift when aux. input 2 close/open #14 CN2-40
Auxiliary input for lift 3 Stops lift when aux. input 3 close/open #17 CN2-41
Refer to page 3-16 for details and setting procedure of

the “Setup Option.”
The application preset feature (#1) has the preset
setting pattern registered.
3-12
CONTROLLER
Outline Features
two additional modes: the mode related to truck failure
1. Diagnostics/Run/Setup (DRS) modes
and the mode for setting the truck parameter as shown
In addition to the normal operation mode for controlling in the table below.
the traveling and lifting operations, the controller has
DRS modes
Mode Description
Self diagnostics Performs failure diagnostics of each equipment.
Diagnostics Displays and deletes fault data that were detected and
Run time diagnostics
stored in normal operation mode.
Run – Normal operation mode
Default data set Sets default data of Group 1 & Group 2.
Group 1 data set Sets basic function (#1 to #10).
Setup
Group 2 data set Sets detailed function (#11 to #35).
Group 3 data set Sets model information (#40 to #47)
Refer to page 3-16 for details and setting procedure of
the “Setup Option.” Also, refer to page 3-37 for details
and setting procedure of the “Diagnostics.”
R
DRS switch
DRS switch is installed under floor

plate at right side of truck. 211186
2. PDS (Presence Detection System) features

This controller is part of the “Presence Detection which provides “certain product intelligence” to the
System” (PDS) of the truck. This system features an operator. The table shows processes for traction and
enhanced, integral computer based feed back system lifting. Refer to the Status Transfer Chart for details.
PDS features
Protect condition Result Release method
Seat Sit → Leave Slowdown Sit
Traction control and Direction lever: N
Direction lever F or R Stop Accelerator pedal: Release
Sit
MC
Hydraulic Control valve SW: All open
Seat Sit → Leave Stop
control Sit
FC
FC control lever: All neutral
3-13
CONTROLLER
Status transfer chart
Traction Control PDS Seat SW

Seat Sw flag: ON Seat SW off time Delay time
2 sec or 3 sec
Normal operation
Seat SW flag: OFF Seat Sw flag :
Seat SW: ON OFF
Direction lever: N (Chosen foot direction: no effect)
Seat SW flag: OFF

Motor: Regen brake Travel speed 0.5km/h
Display: Blinking "E"
Motor: Zero torque

Seat SW flag: OFF Seat SW flag: ON Display: Blinking "E"
Line Contactor OFF
Motor: Regen brake Seat SW flag: OFF Seat SW flag: ON

Display: "E"
Motor: Zero torque

Display: "E"
Direction lever: N
Travel speed 0.5km/h Line Contactor OFF
Accelerator pedal: OFF
Direction lever: N
Accelerator pedal: OFF
Seat SW
Seat Sw flag: ON Seat SW off time Delay time
2 sec or 3 sec
Hydraulic Control PDS
Seat Sw flag :
Seat SW: ON OFF
MC Specification FC Specification
Normal operation Normal operation

Seat SW flag: OFF Seat SW flag: OFF
Lift lock valve: LOCK FC solenoid: All off

Unload valve: UNLOAD Display: Blinking "L"
Display: Blinking "L"
Seat SW flag: ON Seat SW flag: ON
Seat SW flag: OFF Seat SW flag: OFF
Lift lock valve: LOCK FC solenoid: All off

Unload valve: UNLOAD Display: "H1 to H5"
Display: "H1 to H5"
Control valve SW: All off FC control lever: All neutral

(LIFT lever doesn't have SW to detect DOWN.) 211187
3-14
CONTROLLER
3. BDI display features

This feature shows with 11 levels (BDI 0 to BDI 10) of
remaining battery capacity of the current battery
voltage.
Set #41 or #42 depends on installed battery type and

voltage.
For further details, see OMM.
4. Warning buzzer features

The buzzer sounds when the key switch is turned off or
the operator leaves the operator’s seat with the parking
brake not applied.
5. Miscellaneous features
The table shows miscellaneous features.
Miscellaneous features
Item Description SUO No.

Service indicator Shows or warns maintenance time. #10
Speed, error code, hour-meter, BDI, etc. are shown depending on DRS
mode.
Display unit Diag. mode:Refer to Operation on page 3-37. –
Run mode: Normal operation mode.
Setup mode:Refer to Operation on page 3-16.
3-15
CONTROLLER
Setup Option off.

The model information and various features are set
Outline before factory shipment.
The logic unit is equipped with a memory module that The setup options are categorized from Group 1 to
retains recorded data even if the main power is turned Group 3 according to the feature levels.
Setup group
Group Description
Group 1 Basic function (#1 to #10)
Group 2 Detailed function (#11 to #35)
Group 3 Model information (#40 to #47)
The Group 1 and 2 are available to set the default value each setup mode.
in a one-step operation and can be customized in Summary list in each group is shown on page 3-33 to 3-
accordance with applications. Since the Group 3 is for 36.
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. Operation Procedure
When setting the setup option data for the first time Turning on the key switch allows you to enter one of
after the assembly is completed or the logic card is the modes in each setup group and shows as the figure.
replaced, be sure to set Group 3 data first, then the You can not transfer to another mode unless the source
default data of Group 1 and 2, with the “service tool” in power is turned off.
Entry to setup mode
DRS Direction Accel. Lift Tilt Attachment 1
Function Description Seat
switch lever pedal lever lever lever
Default data Sets default data of Not
S R ON OFF OFF OFF
set Group 1 & Group 2. seated
Checks and sets basic Not
Group 1 data S N OFF OFF OFF OFF
function (#1 to #10). seated
Checks and sets detailed Not Pull Pull
Group 2 data S N OFF OFF
function (#11 to #35). seated back back
Checks and sets model Not Pull
Group 3 data S N OFF OFF OFF
information (#40 to #47). seated back
First SUO # of each group

“01” for group 1
Current set value for SUO #11*

donE flashes for default data set. 209558 *The current value is displayed. For the meaning
of each number or symbol displayed, refer to the
First SUO # of Group 2 setup options (example) “Range” column of the relevant Setup Options
table and Notes below the table.
3-16
CONTROLLER
Selecting SUO # and changing set value

How to change set value
The set value change procedure consists of selecting the When changing setting of SUO #20 (stall timer) from
desired SUO # using the DRS switch, changing the set default 5 seconds to 3 seconds:
value by moving the direction lever, and registering the
new value. Step 1. Since SUO #20 belongs to Group 2 setup
options, the first SUO # “11” of the group
appears on the screen when using the operation
• Cycle the DRS switch S → R → S. The set value procedure on page 3-16.
displayed on the screen is registered. The SUO # on the
screen then advances to the next SUO #. Changing the
set value is now possible for the SUO #.
The first half of the DRS switch operation (S→R) is for Step 2. Move the DRS switch as follows to change the
overwriting the previous value with the value on the current setting for the SUO #20.
screen (registering). When the value is registered, a set R
S (1) Move the DRS switch S →R.
of three dotted lines appears on the screen as shown in The display changes as shown
Pull
the illustration on the right. The second half of the below. The set value (0) for
operation (R→S) is for advancing the SUO #. the SUO #11 is overwritten
simultaneously.
• Every time the DRS switch is cycled S → R → S, the
SUO # increments. When advancing the SUO # without
changing the set value, simply repeat by cycling the
switch as many times as necessary. When the last SUO
# is reached, “donE” appears in the set value display
area. R (2) Move the DRS switch R →S.
S
Pull The display shows the current
• Use the direction lever to change the set value. The setting for the next SUO #12.
value increases when the lever is cycled N→F→N; it
decreases when the lever is cycled N→R→N. In either
case, by increasing or decreasing direction, the value
returns to the first or last value in the available value
range.
(3) Cycle the DRS switch S→R→S 8 times to cause the
SUO #20 to appear on the screen.
Default value 5 for SUO #20
Step 3. Change the set value from 5 to 3 by moving the

direction lever N→R twice.
Value increases.
Direction
lever F
N
R
Value decreases.
Step 4. Register the new value by cycling the DRS
switch S → R → S. The current value is
overwritten with the new value. The screen
shows the next SUO #21. 213091
3-17
CONTROLLER
Details of Setup Options

1. Setup Options (Group-1)
#1 Application Pre-Sets (Truck Operation Mode)

Truck mode can be selected from A to E, each with
preset values for maximum vehicle speed, acceleration
rate, power, automatic regeneration power, start lift
speed, top lift speed and tilt speed.
These 7 settings are automatically set by changing the
value of this setting.
Preset values for each setting are as follows (#40 EE
type : C only) .
• 48V type mode setting
SUO#
Mode A b C d E 1
Feature/ HIGH LONG SHORT
STANDARD ECONOMY
Application POWER DISTANCE SHUTTLE
Lift Medium Fast Slow Medium Medium
Tilt Medium Medium Medium Medium Medium
Vehicle speed Medium Fast Slow Fast Medium
Characteristic
Acceleration Medium Fast Medium Medium Fast
Power Standard Powerful Economy Powerful Standard
Regeneration Medium High Low Medium High
Start Lift Speed 1 1 1 1 1 2
Top Lift Speed 6 10 3 6 6 3
Tilt Speed 5 7 5 7 7 4
Max Vehicle Speed 15 17 12 17 15 7
Default value
Acceleration Rate 3 5 2 3 5 8
Traveling Power 2 3 1 3 2 9
Automatic
5 9 3 7 9 23
Regeneration
You can modify these 7 settings afterwards

individually. When settings are changed, the indication
(A to E) flashes to indicate that the settings are
modified.
3-18
CONTROLLER
• 36V type mode setting
SUO#
Mode A b C d E 1
Feature/ HIGH LONG SHORT
STANDARD ECONOMY
Application POWER DISTANCE SHUTTLE
Lift Medium Fast Slow Medium Medium
Tilt Medium Medium Medium Medium Medium
Vehicle speed Medium Fast Slow Fast Medium
Characteristic
Acceleration Medium Medium Medium Medium Medium
Power Standard Powerful Economy Powerful Standard
Regeneration Medium High Low Medium High
Start Lift Speed 1 1 1 1 1 2
Top Lift Speed 6 10 3 6 6 3
Tilt Speed 5 7 5 7 7 4
Max Vehicle Speed 15 17 12 17 13 7
Default value
Acceleration Rate 3 3 2 3 3 8
Traveling Power 2 3 1 3 2 9
Automatic
5 9 3 7 9 23
Regeneration
#2 Start Lift Speed

This setting affects pump speed when you start lifting
operation.
FC spec: speed when the lift lever is slightly pulled
MC spec: speed when lift switch 1 is turned on
Lift speed in the rise direction will become faster if the
setting value is increased.
The setting range is 1 to 10 (#40 EE type : 1 to 8).
3-19
CONTROLLER
#3 Top Lift Speed

This setting affects pump speed and FC solenoid MC spec: speed when lift switch 2 is turned on
current when you pull the lift lever. If you set a smaller Lifting speed will become faster if the value setting is
value than #2, then the #2 setting will be ignored. increased.
FC spec: speed when the lift lever is pulled The setting range is 1 to 10 (#40 EE type : 1 to 8).
FC MC
Pump motor Pump motor
output [%] SUO #3 output [%]
(top lift speed)
SUO #3
100 10 100
9 10
8 9
8
SUO #2 SUO #2
(start lift speed)
0 0
100 Lever angle [%] SW1 SW2 Lever operation
Close Close
209551 209553
Pump motor output characteristics Pump motor output characteristics

(FC type, lift-up operation) (MC type, lift-up operation)
#4 Tilt Speed
This setting affects pump speed and FC solenoid Tilt speed has priority over lifting speed, when the two
current when you operate the tilt lever or tilt switch. levers are operated simultaneously.
Tilt speed will be faster if the value setting is increased.
The setting range is 2 to 10 (#40 EE type : 1 to 7).
FC MC
Pump motor
Pump motor output [%]
output [%] SUO #4 (Tilt)
SUO #4
10 100 10
100
1 to 9 2
1
0 SW Close Lever operation

0
100 Lever angle [%]
209554
211189
Pump motor output characteristics
Pump motor output characteristics
(MC type, tilt operation)
(FC type, tilt operation)
3-20
CONTROLLER
FC
Solenoid
current [%]
SUO #4
100 10
9
0 100 Lever
operation
211287
Solenoid current characteristics

(FC type, tilt operation)
3-21
CONTROLLER
#5 Auxiliary 1 Speed #6 Auxiliary 2 Speed

This setting affects pump speed and FC solenoid This setting affects pump speed and FC solenoid
current when you operate the attachment 1 lever or current when you operate the attachment 2 lever or
attachment 1 switch. attachment 2 switch.
Attachment 1 speed will become faster if the value Characteristic is almost the same as auxiliary 1.
setting is increased. The setting range is 1 to 10. Attachment 2 speed will become faster if the value
setting is increased. The setting range is 1 to 10.
FC MC
Pump motor
output [%] Pump motor
output [%]
SUO #5, #6, #33
SUO #5, #6, #33
100 10
100 10
6
1 to 5 2
1
0 SW Close
0 Lever operation
100 Lever angle [%]
211325 209554
Pump motor output characteristics Pump motor output characteristics

(FC type, attachment 1, 2 and 3 operations) (MC type, attachment 1, 2 and 3 operations)
Solenoid
current [%]
SUO #5, #6, #33

100 5 to 10
4
0
100 Lever operation
211326
Solenoid current characteristics

(FC type, attachment 1, 2 and 3 operations)
3-22
CONTROLLER
#7 Top Travel Speed Limit

This setting affects maximum truck speed without load.
Truck speed with load will be less than this setting.
This setting affects top speed, and does not affect
gradeability or acceleration.
The setting range is 5 to 17 [km/h] (#40 EE type : 5 to
13)
#8 Acceleration Rate
This setting affects response time to calculate torque
order from accelerator pedal position.
Acceleration of trucks becomes faster if the value
setting is increased. The setting range is 1 to 5 (#40 EE
type : 1 to 3)
#9 Traveling Power
This setting affects torque order which is calculated The figure is a torque characteristic at the time of
from accelerator pedal position. Powering.
The values are selected from three types : ECONOMY,
STANDARD and HIGH POWER (#40 EE type :
ECONOMY only).
Torque
[%] HIGH POWER(3)
100 STANDARD(2)
85
ECONOMY(1)
70
Brake limit*1 (48V: 40%, 36V: 52%)
Thermal, BDI [0] or Service indicator*2
(48V: 32%, 36V: 42%)
Speed
0 5 13 15 17
(km/h)
211190
*1
Brake limit : Torque value resulting from reduction in *2
Thermal, BDI [0] or Service indicator :
current when the service brake or Curve of limited torque under a condition of
parking brake is applied. overheating or battery voltage low or
maintenance time over.
3-23
CONTROLLER
#10 Service Indicator

This setting sets the maintenance time. The time set You can reduce the truck power when the LED flashes
here is added to the truck’s hour meter and that value is by setting the service indicator selection. You can also
stored in memory as the “maintenance time.” set the demo-mode, which shows the Service Indicator
When the truck’s hour meter reaches maintenance time, function in a short period of time.
the service reminder LED turns on. The setting value is as follows.
It will flash 20 hours before the time.
6 min In increments
Maintenance time [hour] – 100 150 950 1000
(test) of 50
Invalid 0
Set data on display Only warning 0.1 100 150 ····· 950 1000
Torque limit =0.1 =100 =150 ····· =950 =1000
The present hour meter time will be registered if the

DRS switch is operated after the display of #10.
3-24
CONTROLLER
#11 Auxiliary Input for Lift and Drive Speed 1

(Harness pin No. CN2-30)
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 Stop lift *1 (switch closed) –
2 – Speed limit (switch closed)
3 – Power reduction (switch closed)
4 Stop lift (switch opened) –
5 – Speed limit (switch opened)
6 – Power reduction (switch closed)
*1
Lever is returned to neutral. Lift moves with
operating lever again.
#12 Auxiliary Travel Speed Limit 1 (Harness pin No. #16 Auxiliary Power Reduction 2 (Harness pin No.
CN2-30) CN2-40)
This setting defines maximum speed when the This setting defines traction power reduction when the
“Auxiliary 1” switch is closed or opened. “Auxiliary 2” switch is closed or opened.
The setting range is 5 to 17 [km/h]. Effective when the The setting range is 0 to 100 [%]. Effective when the
data of #11 is 2 or 5. data of #14 is 3 or 6.
#13 Auxiliary Power Reduction 1 (Harness pin No.

CN2-30)
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.

The setting value is the same as that of #11.
#15 Auxiliary Travel Speed Limit 2 (Harness pin No.

CN2-40)
This setting defines maximum speed when the
The setting range is 5 to 17 [km/h]. Effective when the
3-25
CONTROLLER

The setting value is the same as that of #11.
#18 Auxiliary Travel Speed Limit 3 (Harness pin No.

CN2-41)
This setting defines maximum speed when the
The setting range is 5 to 17 [km/h]. Effective when the
#19 Auxiliary Power Reduction 3 (Harness pin No.

CN2-41)
This setting defines traction power reduction when the
The setting range is 0 to 100 [%]. Effective when the
#20 Stall Timer

This setting shuts down the truck when the traction
motor torque is high and it continues for preset time.
This function is used to detect pulse sensor faults and to
prevent the controller from overheating.
The setting range is 2 to 10 [second].
#21 Regen Function

This setting defines which regeneration function is
activated.
One is “Brake regen.” “Brake regen” will be applied
while “the brake pedal is pressed” and “the accelerator
pedal is released.”
The other is “Accelerator regen.” “Accelerator regen”
will be applied while “the accelerator pedal is
released.”
In any case, deceleration torque is constant and defined
by #23.
These two regeneration functions are collectively
termed “Auto regen.”
3-26
CONTROLLER
#22 Regen Adjustment for Lever Regen

This setting defines the “Lever regen” characteristic.
When the direction lever is shifted into the position
opposite to the truck’s traveling direction, the “Lever
regen” function is activated. The “Lever regen”
characteristic is shown in this diagram. The setting
range is 1 to 10.
(%)
100 10
Amount of lever Value of #22

regeneration
60 1
100
Level of throttle pedal [%]
213092
Amount of deceleration relative to setting “1” is about

60% of maximum (Setting “10”).
“Lever regen” function is available regardless of the
#21 setting.
Amount of deceleration when the accelerator pedal is
released is determined by #23.
3-27
CONTROLLER
#23 Regen Adjustment for Auto Regen Amount of auto regeneration

[%]
This setting defines amount of deceleration when 100 Accelerator regen
“Auto regen” is activated. Amount of deceleration
relative to setting “1” is about 40% of maximum
(Setting “10”). The setting range is 1 to 10 (#40 EE
type : 1 to 7).
0
1 2 3 4 5 6 7 8 9 10
Value of #23 211400
Brake regen Truck

speed [m/s] Accelerator regen
#23
10 9 1
Truck
0 Time [s]
speed [km/h]
211192 213093
#26 Speed Alarm 1 (Harness Pin No. CN1-61)

This setting defines speed of turning on “Speed alarm
1” light.
The setting range is 5 to 17 [km/h].
#27 Tire Size Adjustment

This setting is used to adjust the truck speed indicator.
1 digit equals 1 mm (0.04 in.) of wear in the diameter.
Default setting is 20.
When the tire diameter becomes 8 mm (0.31 in.)
smaller than original, set 12 into this setting.
The range setting is 0 to 40. This allows fitting a bigger
diameter wheel.
3-28
CONTROLLER
#30 Auxiliary Input for Travel Speed (Harness Pin

No. CN2-31)
This setting defines the function of “Speed Limit”
switch.
According to the combination of #30, #31 and #32, you
can reduce travel speed or traction power (torque).
Value Traction power Travel speed

0 – –
1 – Speed limit (switch closed)
2 Power reduction (switch closed) –
3 – Speed limit (switch opened)
4 Power reduction (switch opened) –
#31 Auxiliary Maximum Travel Speed Setting #35 Lowering Speed Adjust
(Harness Pin No. CN2-31) This setting is for adjustment of the maximum lowering
This setting defines the maximum travel speed when speed.
the speed limit function is activated by #30. The range In case the lowering speed is higher than the
setting is 5 to 17 [km/h]. specification as mentioned in the service manual, it can
#32 Auxiliary Output Power Limit (Harness Pin No. be adjusted. When lowering the setting, the current to
CN2-31) the solenoid will be reduced, but this does not mean it
affects the lowering speed immediately due to tolerance
This setting defines the maximum traction power
in oil flow and oil characteristics. Further lowering of
(torque) when speed limit function is activated by #30.
the setting may be required.
This value means a proportion of output torque to
This setting is applicable to the FC models only.
normal condition.
The setting range is 0 to 100 [%].
#33 Auxiliary 3 Speed

This setting affects pump speed when you operate the
attachment 3 lever or attachment 3 switch.
Characteristic is almost the same as tilt.
Attachment 3 speed will become faster if the setting
value is increased. The range setting is 1 to 10.
#34 Speed Alarm 2 (Harness Pin No. CN1-62)

This setting defines speed of turning on “Speed alarm
2” light. The setting range is 5 to 17 [km/h].
3-29
CONTROLLER
#40 Truck Type

This setting defines the type of truck.
The setting value is as follows.
Display value Model
II II II II II No setting
P16:3 ET3000
P16:3.E ET3000EE
P18:3 ET3500
P18:3.E ET3500EE
P20:3 ET4000
P20:3.E ET4000EE
! CAUTION
If the truck type setting is incorrect, the truck may
show unexpected movement.
#41 Battery Voltage

This setting defines the voltage of battery carried in the truck.
The setting value is 36 or 48 [v].
No setting shows “II II II II II.”
3-30
CONTROLLER
#42 Battery Type

This setting defines the type of battery carried in the
truck.
The setting value is 0, 1 or 2.
0: Normal 1: Tubular 2: Reserve
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 –
Reserve BDI
BDI# 36V 48V

0 – –
1 – –
2 – –
3 – –
4 – –
5 – –
6 – –
7 – –
8 – –
9 – –
10 – –
3-31
CONTROLLER
#43 Hydraulic Control Selection #46 Battery Voltage Adjust

This setting defines the type of hydraulic control. This setting corrects the gap of the battery voltage
0: FC system 1: MC system which the controller recognizes, and actual battery
voltage. The display shows battery voltage which the
#44 Mast Type controller recognizes.
This setting defines the type of the mast. Measure actual battery voltage using a tester (or a
2-FF: 2-stage full-free 3-FF: 3-stage full-free multi-meter) and operate the direction lever to adjust
the value.
2-SP: 2-stage panorama
Refer to the “Measurement of battery voltage” below.
#45 Valve Section
This setting defines the number of valve sections.
1: 3ways (lift, tilt, attachment 1)
2: 4ways (lift, tilt, attachment 1, 2)
3: 5ways (lift, tilt, attachment 1 to 3)
Direction lever Accelerator pedal Value change [V]

N→F – +0.1
N→R – –0.1
F Release → depress +10
R Release → depress –10
Line contactor
Pump contactor
Contactor
- +
Battery
49.6V
V
- + Set 49.6 on display.
Tester or Multi-meter
Right traction
inverter
211327
Measurement of battery voltage

#47 Foot Direction
This setting defines the foot direction option.
1: Standard direction lever
2: Foot Directional Control (FoDiCo)
3-32
CONTROLLER
Setup Options (Group 1)
Option Default
Title of Option Description Range
# Value
The value setting of the following 7 items
are registered beforehand.
Application Pre-Sets Top travel speed, Acceleration rate, A, b, C, d, E
#1 A
(Truck Operation Mode) Traveling power, Regen adjustment, Start (1)
lift speed, Top lift speed, Tilt speed.
Refer to the explanation for details.
Beginning lift speed
Start lift speed cannot exceed top lift
#2 Start Lift Speed 1 to 10 1
speed.
(1: SLOW → 10: FAST)
Lift speed when operating the lever at
#3 Top Lift Speed 1 to 10 6
maximum
#4 Tilt Speed Speed setting for tilt 1 to 10 5
#5 Auxiliary 1 Speed Speed setting for attachment 1 1 to 10 3
#6 Auxiliary 2 Speed Speed setting for attachment 2 1 to 10 1
#7 Top Travel Speed Limit Maximum travel speed 5 to 17 [km/h] 15
Choice of acceleration rate
#8 Acceleration Rate 1 to 5 3
(1: SLOW → 5: FAST)
Choice of power characteristic
#9 Traveling Power (1: ECONOMY, 2: STANDARD, 1, 2, 3 2
3: HIGH POWER)
This function notifies service personnel 0, 0.1,
that maintenance time is approaching or 100, 150, ...950, 1000,
has passed.
=0.1 (6 min.),
It means the lapsed time when setting up.
=100, =150, ..=950, =1000
#10 Service Indicator Approached : !LED flashes (20 hour) 0
(In increments of 50 [hour])
Passed : !LED turn on
and power reduction (selected)
“=”: power reduction
(2)
0: no action
Refer to the explanation for details.
NOTICE: (1) Before changing, when parameter data are different from the values of the selected mode, the truck
mode indicator (A to E) flashes.
When the truck mode is changed, all parameter data is replaced by the set values of the selected
mode.
(2) The data from the truck hour meter at set time is saved apart from the selected value. If the key switch
is turned off without setting the DRS switch to R, the data at set time is maintained.
When the DRS switch is set to R, the data at set time is replaced by the current truck hour meter data.
3-33
CONTROLLER
Option Default Harness

# Value Pin No.
0: Disable
When the auxiliary input 1 signal is on, 1: Disable lift (switch closed)
travel speed or lift speed is limited to 2: Speed limit (switch closed)
Auxiliary Input for set value. 3: Power reduction
#11 Lift and Drive The amount of maximum speed is (switch closed) 0 CN2-30
Speed 1 defined at #12. 4: Disable lift (switch opened)
The amount of power reduction is 5: Speed limit (switch opened)
defined at #13. 6: Power reduction
(switch opened)
Auxiliary Travel
#12 Travel speed limit for #11 5 to 17 [km/h] 12 CN2-30
Speed Limit 1
Auxiliary Power
#13 Traction power reduction ratio for #11 0 to 100 [%] 70 CN2-30
Reduction 1
When the auxiliary input 2 signal is on,

travel speed or lift speed is limited to
Auxiliary Input for set value.
#14 Lift and Drive The amount of maximum speed is Same as #11 0 CN2-40
Speed 2 defined at #15.
The amount of power reduction is
defined at #16.
Auxiliary Travel
Speed Limit 2
Auxiliary Power
#16 Traction power reduction ratio for #14 0 to 100 [%] 70 CN2-40
Reduction 2
When the auxiliary input 3 signal is on,

travel speed or lift speed is limited to
Auxiliary Input for set value.
#17 Lift and Drive The amount of maximum speed is Same as #11 0 CN2-41
Speed 3 defined at #18.
The amount of power reduction is
defined at #19.
Auxiliary Travel
Speed Limit 3
Auxiliary Power
#19 Power reduction ratio for #17 0 to 100 [%] 70 CN2-41
Reduction 3
This option allows to shut down truck

#20 Stall Timer when the traction motor torque is too 2 to 10 [sec] 5 –
high.
3-34
CONTROLLER
Option Default Harness

# Value Pin No.
1: Brake regen
This option enables one of two Regen (accel must be off)
#21 Regen Function 2 –
Modes. 2: Accelerator regen
(also called “auto regen”)
Regen Adjustment
#22 10 steps for regen power on lever regen 1 to 10 7 –
for Lever Regen
Regen Adjustment 10 steps for regen power on
#23 1 to 10 5 –
for Auto Regen brake/accelerator regen
CN1-61,
#26 Speed Alarm 1 Sets speed for turning on alarm 1 light. 5 to 17 [km/h] 12
max.1A
Tire Size Adjusts the amount of tire wear. It

#27 0 to 40 20 –
Adjustment changes truck’s speed recognition.
0: Disabled
When the auxiliary input signal is on, 1: Travel speed limit
travel speed or traction power is (switch closed)
limited at value of set. 2: Power reduction
Auxiliary Input for
#30 The amount of maximum speed is (switch closed) 0 CN2-31
Travel Speed
defined at #31. 3: Travel speed limit
The amount of power reduction is (switch opened)
defined at #32. 4: Power reduction
(switch opened)
Auxiliary
This option determines the maximum
#31 Maximum Travel 5 to 17 [km/h] 12 CN2-31
travel speed limit of #30.
Speed Setting
Auxiliary Output This option determines the output

#32 0 to 100 [%] 70 CN2-31
Power Limit traction power limit in % of #30.
#33 Auxiliary 3 Speed Speed setting for attachment 3 1 to 10 3 –

CN2-62,
#34 Speed Alarm 2 Sets speed for turning on alarm 2 light. 5 to 17 [km/h] 12
max.1A
Lowering Speed In this option, the display shows value

#35 0 to 15 15 –
Adjust *1 for lowering speed adjustment.
*1: This setting is applicable to the FC models only.
3-35
CONTROLLER
Option Default
# Value
This option is used to set the size and type P16:3 (ET3000) to
#40 Truck Type of the truck. P20:3.E (ET4000ET) 6 –
Refer to the explanation for details. pattern
This option is used to set the voltage of
#41 Battery Voltage 36, 48 [V] –
the battery.
This option is used to set the type of the 0: Normal BDI
battery.
#42 Battery Type 1: Tubular BDI –
The electric discharge characteristic of a
battery changes with battery type. 2: Reserve BDI
Hydraulic Control This option is used to set the type of the 0: FC specification
#43 –
Selection hydraulic control. 1: MC specification
2FF: 2-stage full-free
This option is used to set the type of the
#44 Mast Type 3FF: 3-stage full-free –
mast.
2SP: 2-stage panorama
1: 3ways
(lift, tilt, attachment 1)
This option is used to set the number of 2: 4ways
#45 Valve Section –
valve sections. (lift, tilt, attachment 1,2)
3: 5ways
(lift, tilt, attachment 1-3)
This setting corrects the gap of the battery
voltage which the controller recognizes,
and actual battery voltage.
Measure actual battery voltage and
operate the direction lever in order to
#46 Battery Voltage Adjust adjust the value which is shown on the 5.0 to 120.0 [V] –
display to actual battery voltage.
N→F: +0.1 F, Accel off→on: +10
N→R:–0.1 R, Accel off→on: –10
Refer to the explanation for operation. (4)
1: Standard direction lever
This option is used to enable the function
#47 Foot Direction 2: Foot Directional Control –
for foot direction option.
(FoDiCo)
NOTICE: (1) The data of group 3 has no default value, but it needs to set data by the actual truck type. If the
value and the truck model aren’t in agreement, the 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) If SUO data is not set, “| |” is displayed.
(4) This value was adjusted at the time of LOGIC CARD inspection. Adjust the value, when the value
shown on the display is different from actual battery voltage.
3-36
CONTROLLER
Diagnostics
Outline
The controller monitors status of various input/output
equipment to allow diagnostics of lift truck's
malfunctions. There are two types of diagnostics: Run
Time Diagnostics, diagnostics during normal operation,
and Self Diagnostics, performing equipment check
during maintenance.
Diagnostics
Mode Description
Self diagnostics Checks function of electrical systems.
Diagnostics
Run time diagnostics Diagnostics during normal operation.
The logic unit is equipped with a memory module that

retains recorded data even if the main power is turned
off. The errors occurring during lift truck use are
compared with Run Time Diagnostics and recorded to
be displayed.
Self diagnostics that exclusively checks the power
steering system is also available.
Operation Procedure
Turning on the key switch allows entry into each
diagnostics mode. You can not transfer to another
mode unless the source power is turned off.
Entry to diagnostics mode
Function DRS switch Seat Lift lever Tilt lever Note
When run time diagnostics can not

Self diagnostics D – – –
be performed
Run time diagnostics D Not seated ON ON
3-37
CONTROLLER
Perform diagnostics using the following procedure.
1. Preparatory operations
(1) Place the parking brake lever in the locked position.
(2) Turn OFF the key switch.
(3) Disconnect the battery plug.
(4) Discharge all inverters. See page 3-45.
(5) Place the direction lever in the N position.
(6) Set the DRS switch to the D (diagnostics) position.
R
(7) Remove the line fuse and pump fuse (500 A). S D
(8) Connect the battery plug.
Pull
2. Diagnostics procedure
Perform the procedure using the Self-Diagnostics table
in accordance with the following guide.
(1) Start diagnostics with the Step 0 in the table. Turn 211195
ON the key switch according to the instruction in
the “Do this” box on the Step 0 line. If the item
passes the check without any problem, the next step
number “01” appears on the display. If the item Diagnostics result indication
involves any problem and fails in the check,“dd” is
shown on the display. The display 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 to the Step 1 item (seat switch). 209561
Cycle the seat switch OFF→ON→OFF according
to the instruction in the “Do this” box on the Step
1 line. If the item passes the check, the next step
number “02” appears on the display. Do likewise
for the succeeding items, following the instructions
in the “Do this” 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 cycling the
DRS switch D→R→D.
3-38
CONTROLLER
(3) When all the steps have been checked through, turn
OFF the key switch and place the DRS switch in the R R
position. Do not forget to reinstall the 500 A line fuse S D
and pump fuse.
Pull
• Turn OFF the key switch to exit from the diagnostics
mode.
• Repair all faults found immediately after diagnostics.
Diagnostics procedure requires moving the DRS switch to 211196
the D or R position. Follow the instructions in the
diagnostics procedure guide above as well as those in the
applicable boxes in the “Do this” column.
3. Fault Data Record of Run Time Diagnostics

When the fault is detected by the Run Time Diagnostics,
Battery discharge indicator
the fault data will be stored in the memory of the logic at the time of fault
card. The fault data includes the error code, the battery
discharge indicator at the time of fault and the vehicle
hourmeter reading at the time of fault. The stored data is
maintained even if the key switch is turned off.
E F
The maximum number of faults that can be stored in the
memory is 32. When faults exceeding 32 occur, the oldest
data will be erased to accommodate new data.
The data on the latest fault will appear on the display unit.
After all the fault data are reviewed or when there are no Vehicle hourmeter reading Error code
data items stored for the fault, “donE” will appear. at the time of fault
211412
Perform the following procedures to review the stored fault
data.
• To review the data of the next older fault
Move the DRS switch from the D position to the R
position and then back to the D position.
• To review the data of the latest fault again E F
With “donE” appeared on the display after all the fault

data are reviewed, move the DRS switch from the D
position to the R position and then back to the D
position.
• To delete all the stored fault data After all the fault data are reviewed or when
there are no data items stored for the fault,
With “donE” appeared on the display after all the fault "donE" will appear.
data are reviewed, move the DRS switch from the D When all the stored data have been deleted,
position to the R position and then to the S position. "donE" flashes.
When all the stored data have been deleted, “donE” 211413
flashes. Never turn off the key switch until “donE”
flashes.
NOTICE: If the key switch is turned off before data
deletion is completed, erroneous data will be
displayed when reviewing the fault data. In
this case, be sure to delete all the stored fault
data by using the proper procedure again.
3-39
CONTROLLER
Self-Diagnostics
Step Checking Do this Controller check this Result Display Motion
Line contactor
Power line Close line contactor and Pass 01
closes and opens.
0 voltage Turn on key switch. check power line
Line contactor closes
(Fuse check) voltage. Fail dd
and doesn’t open.
Release & press & release Input Pass 02
1 Seat switch
seat SW. OFF → ON → OFF Fail 01
Direction Cycle direction lever. Input changes as Pass 03
2
switch N→R→N→F→N N→R→N→F→N Fail 02
Release & apply & release Input Pass 04
3 Parking brake
parking brake. OFF → ON → OFF Fail 03
Depress and release Input Pass 05
4 Service brake
service brake. OFF → ON → OFF Fail 04
Number 0 to 15 flashes as
Depress accelerator and Pass
accelerator is pressed.
5 Accelerator release.
Fail -
DIAG → RUN - 06
Number r7-r1, 0, L1-L7
Present steering wheel Pass
Steering flashes as steering is rotated.
6 SW information is shown.
sensor Fail -
RUN → DIAG → RUN - 07
Battery Check battery voltage: Pass 08
7 Automatic
voltage (34V-51V) Fail 07
Input Pass 09
8 Lift switch Pull and release lift lever.
OFF → ON → OFF Fail 08
Input Pass 10
9 Tilt switch Pull and release tilt lever.
OFF → ON → OFF Fail 09
Auxiliary 1 Pull and release Aux. 1 Input Pass 11
10
switch lever. OFF → ON → OFF Fail 10
11
12
Pull any lever and see Pass Flashing pump speed value
Hydraulic
13 display. Fail Other than above
speed check
RUN → DIAG → RUN - 14
Pass 14 Contactor closes
RUN → DIAG See line contactor close.
Fail 14 No operation
14 Line contactor
Pass 15 Contactor closes
DIAG → RUN See line contactor open.
Fail 15 No operation
See pump contactor Pass 15 Contactor closes
RUN → DIAG
Pump close. Fail 15 No operation
15
contactor See pump contactor Pass 98 Contactor closes
DIAG → RUN
open. Fail 98 No operation
Controller
See software version
98 software RUN → DIAG → RUN - donE
No. in hourmeter.
version
3-40
CONTROLLER
Power Steering Diagnostics

Perform power steering diagnostics using the following
procedure.
1. Preparatory operations
(1) Place the parking brake lever in the locked position.
(2) Turn OFF the key switch.
(3) Disconnect the battery plug.
(4) Discharge all inverters. See page 3-45.
(5) Place the direction lever in the N position.
(6) Set the DRS switch to the D (diagnostics) position.
R
(7) Remove the pump fuse (500 A).
S D
(8) Connect the battery plug.
Pull
2. Diagnostics procedure
Perform the procedure using the Self-Diagnostics
(Power steering system) table in accordance with the
following guide.
211195
(1) Start diagnostics with the Step 0 in the table. Turn
ON the key switch according to the instruction in
the “Do this” box on the Step 0 line. If the item
passes the check without any problem, the next step Diagnostics result indication
number “20” appears on the display. If the item
involves any problem and fails in the check, “dd” is
shown on the display. The display 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 213094
may advance to the Step 20 item (steering sensor).
Check the steering sensor according to the
instruction in the “Do this” box on the Step 20 line.
(3) When all the steps have been checked through, turn
OFF the key switch and place the DRS switch in R
the R position. Do not forget to reinstall the pump S D
fuse.
Pull
• Turn OFF the key switch to exit from the
diagnostics mode.
• Repair all faults found immediately after
diagnostics.
Diagnostics procedure requires moving the DRS 211196
switch to the D or R position. Follow the instructions
in the diagnostics procedure guide above as well as
those in the applicable boxes in the “Do this”
column.
3-41
CONTROLLER
Self-Diagnostics (Power steering system)

Step Checking Do this Controller check this Result Display Motion
Line contactor
Power line Close line contactor and Pass 20
closes and opens.
0 voltage Turn on key switch. check power line
Line contactor closes
(Fuse check) voltage. Fail dd
and doesn’t open.
Number r7-rl, 0, L1-L7
Present steering wheel SW Pass
Steering flashes as steering is rotated.
20 information is shown.
sensor Fail -
RUN → DIAG → RUN -
3-42
CONTROLLER
Run Time Diagnostics

Display
Steering operation
LED
Service Indicator
To return
Parking Brake
Fault How to detect Result
Battery Low
Over Temp.
Code
to normal
Brake Oil
Seat Belt
Error
Traction Motor R.H., Overheating Thermistor (145°C, -25°C) * E0 Power reduction Cool
Traction Motor L.H., Overheating Thermistor (145°C, -25°C) * E1 Power reduction Cool
Pump Motor, Overheating Thermistor (135°C, -25°C) * E2 Power reduction Cool
Traction Inverter R.H., Overheating Thermistor * E5 Power reduction Cool

(IMS 100°C, -25°C, Capacitor 110°C, -25°C)
Traction Inverter L.H., Overheating Thermistor * E6 Power reduction Cool
Pump Inverter, Overheating Thermistor * E7 Power reduction Cool
Brake Oil, Low Level Level sensor (Contact) * Turn key off
Traction Motor Current Sensor R.H. Out of normal range * 14 Line contactor off(*) Turn key off
Fault Pump contactor hold
Traction Motor R.H., Over-current More than 492 Amps (1.6 ms), 557 Amps (1 ms) * 15 Line contactor off
Pump contactor hold Turn key off
Line contactor off
Traction Motor R.H., Stall Timer Measure time (set by SUO #20) while stalling * 16 Pump contactor hold Turn key off
Traction Motor Current Sensor L.H. Out of normal range * 24 Line contactor off(*) Turn key off
Fault Pump contactor hold
Line contactor off
Traction Motor L.H., Over-current More than 492 Amps (1.6 ms), 557 Amps (1 ms) * 25 Pump contactor hold Turn key off
Line contactor off
Traction Motor L.H., Stall Timer Measure time (set by SUO #20) while stalling * 26 Pump contactor hold Turn key off
Line contactor off(*)
Pump Motor Current Sensor Fault Out of normal range * 34 X Pump contactor off(*) Turn key off
Pump Motor Over-current More than 985 Amps (1.6 ms), * 35 X Line contactor off Turn key off
1115 Amps (1.0 ms) Pump contactor off
Line Contactor Fault Check voltage of power circuit * 40 X Pump contactor off(*) Turn key off
Pump Contactor Fault Check voltage of power circuit * 42 X Pump contactor off(*) Turn key off
Line contactor off
Traction Motor R.H. Open Traction R.H. Motor Open * 45 Pump contactor hold
Turn key off
Line contactor off
Traction Motor L.H. Open Traction L.H. Motor Open * 46 Pump contactor hold Turn key off
Line contactor off
Pump Motor Open Pump Motor Open * 47 X Pump contactor off Turn key off
Steering Sensor Fault Sensor output is 0 or intermittent * 50 Line contactor off(*) Turn key off
(More than 10V) Pump contactor hold
Accel SW ON: Below 0.3V
Accelerator Sensor Fault Accel SW OFF: More than 1.41V/Below 0.2V, * 51 Line contactor off
Pump contactor hold Turn key off
More than 4.8V
Traction Motor R.H. Pulse Out of normal range (5800 rpm) * 52 Line contactor off Turn key off
Input Fault Pump contactor hold
Traction Motor L.H. Pulse Out of normal range (5800 rpm) * 53 Line contactor off
Turn key off
Input Fault Pump contactor hold
FC Lever Fault Below 0.25V, More than 4.75V * 54 Disable lever op. Turn key off
FC Solenoid Fault Below 0.16A, More than 1.9A * 55 Disable solenoid Turn key off
Line contactor off
FC Solenoid Current Leak More than 0.18A * 56 X Pump contactor off Turn key off
Pump Motor Pulse Input Fault Out of normal range (4000 rpm) * 57 X Line contactor off Turn key off
With no rotation input during output Pump contactor off
Display Communication Fault When serial communication is not going on * 60 Indicate if it possible Turn key off
Line contactor off
Logic Card Initialize Failure SUO Gr. #3 and default setting are not set * 61 X Pump contactor off Turn key off
Logics Fault Parity check of SUO data * 62 X Line contactor off Turn key off
Sum check of ROM and RAM Pump contactor off
When CAN communication is not going on
Traction Inverter R.H. Fault Sum check of ROM & RAM * 63 X Line contactor off
Pump contactor off Turn key off
Initial mode SW setting Fault
Traction Inverter L.H. Fault Sum check of ROM & RAM * 64 X Line contactor off
3-43
CONTROLLER
Display
Steering operation
LED
Service Indicator
To return
Parking Brake
Fault How to detect Result
Battery Low
Over Temp.
Code
to normal
Brake Oil
Seat Belt
Error
Pump Inverter Fault Sum check of ROM & RAM * 65 X Line contactor off
Input Unit Fault When CAN communication is not going on * 67 X Line contactor off Turn key off
Sum check of ROM & RAM Pump contactor off
Output Unit Fault When CAN communication is not going on * 68 X Line contactor off Turn key off
Sum check of ROM & RAM Pump contactor off
Line contactor off
Contactor Coil Fault Contactor coil current sensor * 72 X Pump contactor off Turn key off
Hydraulic Lock Solenoid Fault Check current of unload valve * 74 Disable all lever op. Turn key off
Check current of lift lock valve
Line contactor off
Battery Voltage Too Low Voltage class is not correct * 78 X Pump contactor off Turn key off
Line contactor off
Battery Voltage Too High Voltage class is not correct * 79 X Pump contactor off Turn key off
Lever/accel is not neutral at power-on and seat Line contactor off FNR Neutral
Direction Lever or Accelerator, Faulty switch closed Disable traction Accel Open
Setting E X Seat SW
Seat switch is turned on after lever/accel is Slow down and Line
operated contactor off Close
Line contactor off FNR Neutral
Switch is off at power-on Disable traction Accel Open
Seat Switch, Faulty Setting For Traction (E) X Seat SW
Slow down and Line
Seat switch is off during operation contactor off Close
Line contactor off Lever
Seat Switch, Faulty Setting For
Switch is off at power-on X Pump contactor off Off/Neutral
Hydraulic
(L) Seat SW
Seat switch is off Disable all lever op. Close
Line contactor off
Lever is not neutral at power-on and seat switch X Pump contactor off Lever
on Disable pump and Off/Neutral
Lift Lever, Faulty Setting H1 steering op. Seat SW
Close
Seat switch is turned on after lever is pulled Disable all lever op.
Line contactor off
Tilt Lever, Faulty Setting H2 steering op. Seat SW
Close
Line contactor off
Attachment 1 Lever, Faulty Setting H3 steering op. Seat SW
Close
Line contactor off
Close
Line contactor off
Lever is not neutral at power-on and seat switch on X Pump contactor off
Disable pump and
Lever
Off/Neutral
Close
Battery Consumption Too Much Too much consumption with small capacity * (Lo) Line contactor off(*) Turn key off
battery Pump contactor off(*)
Charge
Battery Consumption Much Much consumption with small capacity battery (*) Power reduction battery
NOTICE: (1) E0-E7 don’t appear on the display, but are stored in the history folder.
(2) E, (E), (L), H1-H5, and Lo appear on the display, but are not stored in the history folder. (E) means
flashing.
(3) “Line contactor off(*)” means that the contactor will open immediately when a fault is detected.
“Line contactor off” means that the contactor will open when a current gets to 0.
(4) Contactor “hold” means “no change.” When error occurs while the contactor is turned on, it stays
on.
3-44
CONTROLLER
Removal and Installation
Inverter Discharging Procedure

Discharge the inverters by using the following procedure.
1. Turn off the key switch.
2. Disconnect the battery plug.
3. Lift up the seat.
! CAUTION
Be careful not to place yourself between the head
guard and seat.
211197
4. Place a 150 Ω/25 W resistor between P and N

terminals in the right traction inverter to discharge the
inverter.
5. After touching the resistor to the P and N terminals for
approx. five seconds, measure the voltage between the
terminals with a multimeter and confirm a reading of 5
V or less.
6. Perform the same procedure for the left traction
inverter and pump inverter in order to discharge all
inverters.
Check whether the resistance between + and - of the battery

211198
plug on the truck side is 1 kΩ or more when connecting the
battery plug for the first time after maintenance.
(Discharge all inverters completely before measuring.
Longer measurement time reduces resistance value.)
3-45
CONTROLLER
Replacing Inverter
Removal
1. Raise the front wheels.
2. Perform step 1 to 5 in Inverter Discharging Procedure.
! CAUTION
Be sure to discharge all inverters.
3. Disconnect all five power cables from P, N, U, V and

W terminals. For the pump inverter, leave P terminal
connected, and disconnect F terminal.
4. Disconnect the connector.
! 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 211199
breakage.
5. Remove the M10 bolts (four places) mounting the

inverter, then remove the inverter.
Installation
1. Wipe off the dirt and thermal paste from the inverter
mounting surface first, and then remove the dirt from
the inverter mounting surface and aluminum base plate.
2. Apply thermal paste approx. 1 mm (0.04 in.) thick to
the area where the aluminum base plate of the inverter
comes into contact with the truck body.
! CAUTION
Apply a thin and even coat of thermal paste
because it releases generated heat from the
inverter to the lift truck body.
3. Mount the inverter with M10 bolts.

4. Connect the power cables to P, N, U, V and W
terminals. For the pump inverter, include F terminal.
3-46
CONTROLLER
! 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.
16 ± 1.0 N·m
U, V and W terminals [1.63 ± 0.10 kgf·m]
[11.80 ± 0.74 lbf·ft]
M8 nut
10 ± 1.0 N·m
P, N and F terminals (1.02 ± 0.10 kgf·m)
[7.38 ± 0.74 lbf·ft]
! CAUTION
Forcibly pressing the connector may cause damage
to the DSP card. Hold the connector housing and
press the connector, if required.
3-47
CONTROLLER
Replacing DSP (Digital Signal Processor)

Card
Removal
1. Perform step 1 to 5 in Inverter Discharging Procedure.
! CAUTION
Be sure to discharge inverters before working on
the electrical system.
2. Disconnect the connector.
! CAUTION
connector.
card, while holding the cable may cause wire
breakage.
3. Push and lift up at the four corners of the card cover to

remove the cover.
211200
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 connector 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.
! CAUTION
211201
Be careful not to damage mounted parts with the
pliers since the card has a number of fragile parts.
3-48
CONTROLLER
Installation
1. Align the four mounting holes of the new DSP card
with the plastic spacer positions and press it into place.
! CAUTION
Press at the card edges.
Make sure that the spacer lock works completely
and the card is secure.
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.
! CAUTION
Do not forcibly bend the flat cable. Insert its
conductive surface in the direction shown in the
illustration.
Confirm that the cable is inserted squarely into the
connector.
4. Install the cover while pushing the flat cable toward the
211202
card side slightly.
! CAUTION
Do not force the flat cable into 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. Connect the main harness connector to the inverter.
! CAUTION
Forcibly pressing the connector may cause damage
to the DSP card. Hold the connector housing and 211357
press the connector, if required (for the card with

vertical type connector).
3-49
CONTROLLER
Replacing Logic Unit

Removal
3. Remove the right side step.
211203
Logic unit
211204
4. Disconnect the connector (CN1, 2 and 3 complex) from

the logic card and the connector (CN4) from the power
supply card.
! CAUTION
connector.
breakage.
5. Remove M10 bolts (two places) and remove the logic

unit.
Installation
211205
Follow the removal sequence in reverse.
3-50
CONTROLLER
Replacing Logic Card

Cover
Removal
1. Perform step 1 to 5 in Replacing Logic Unit.
2. Remove M3 flat head screws (two places) from the
bottom of the logic unit to remove the cover.
3. Remove M3 screws (four places) mounting the logic
card plate to the logic unit case. Remove the logic card
and logic card plate as an assembly.
Logic unit
case
211206
Logic card
Heat sink
Installation
Follow the removal sequence in reverse. Logic card
plate
211207
! CAUTION
When installing the logic card onto the logic card Logic card
plate, carefully tighten the logic card and heat sink
mounting screws to the specified torque to avoid
excessive stresses. Mount the heat sink first.
Logic card
Tightening torque plate
0.98 ± 0.20 N·m

M3 screw (0.10 ± 0.02 kgf·m)
[0.72 ± 0.15 lbf·ft] Logic card assembly 211328
3-51
CONTROLLER
Replacing Power Supply Card

Removal
1. Perform step 1 to 5 in Replacing Logic Unit. Cover
2. Remove M3 screws (two places) from the bottom of

the logic unit to remove the cover.
3. Remove M3 screws (four places) from the logic unit
case. Remove the logic card and logic card plate as an
assembly.
Logic unit
case
211208
Power supply
card
Heat
sink
Installation
! CAUTION
When installing the power supply card onto the logic
Power supply card assembly 211209
unit case, carefully tighten the power supply card
and heat sink mounting screws to the specified
torque to avoid excessive stresses. Mount the heat
sink first.
Tightening torque
0.98 ± 0.20 N·m

M3 screw (0.10 ± 0.02 kgf·m)
[0.72 ± 0.15 lbf·ft]
3-52
CONTROLLER
FC MODEL ONLY
Replacing Input Unit
Removal
3. Disconnect the input unit connector (CN2 of FC-IN
harness).
! CAUTION
connector.
card, while holding the cable may cause wire 211329
breakage.
4. Remove M6 screws (two places) to remove the input

unit.
Installation
Tightening torque
2.90 ± 0.58 N·m

M6 screw (0.30 ± 0.06 kgf·m)
[2.14 ± 0.43 lbf·ft]
3-53
CONTROLLER
FC MODEL ONLY
Replacing Output Unit
Removal
3. Disconnect the output unit connector (CN9 of FC-OUT
harness).
! CAUTION
connector.
breakage.
211330
4. Remove M6 bolts (four places) to remove the output

unit.
Installation
Tightening torque
6.90 ± 1.38 N·m

M6 bolt (0.70 ± 0.14 kgf·m)
[5.09 ± 1.02 lbf·ft]
3-54
CONTROLLER
Basic Check
Always follow basic troubleshooting steps.

• Talk to the operator.
• Confirm the operator’s 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.
Testing Tools
(a) Multimeter
(b) Clamp meter S T
(c) IC clip
S T
NOTE
S T
The illustrations show digital multimeters. In these
multimeters, the positive (+) terminal is applied with
positive charge, and the negative (–) terminal with
negative charge. It should be noted that the terminals
must be connected inversely when using an analog
meter. 208282
! WARNING
Disconnect the battery plug before inspecting or
adjusting the controller.
3-55
CONTROLLER
Measurement of Card Voltage

! WARNING
To prevent accidental movement of the truck, place
wood blocks under the truck to lift the front wheels
off the ground. Do not position the wood blocks too
close to the front wheels.
1. Tilt the mast all the way back. 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 multimeter to the V GND terminal of the card.
6. Set the multimeter to the 100 VDC range.
7. Connect the positive terminal of the multimeter to each
pin of connectors detailed on the following pages.
NOTE
Be careful not to short-circuit pins. For the normal
voltage value, refer to the card voltage chart on the
following pages.
3-56
CONTROLLER
Logic card voltage chart

CN1
No. Name Stand-by voltage Active voltage Note
1 GND-L 0V 0V
2 +15V-L 13.0V to 16.0V 13.0V to 16.0V
3 GND-L 0V 0V
4 +5V-L 5V 5V
5 CANH 0 to 5V 0 to 5V
Do not measure the voltage between CAN and Logic GND terminal.
6 CANL 0 to 5V 0 to 5V
7 BOOT 11.5V 0V
8 FWE 11.5V 0V
9 GND 0V 0V
10 -
11 -
12 -
13 -
14 DISPLAY1-TxD 0 to 12V 0 to 12V
15 -
16 DISPLAY1-RxD 0 to 12V 0 to 12V
17 GSE-TxD - -
18 GSE-RxD - -
19 POS VOLTAGE Vbatt Vbatt Battery connector attached : Vbatt
20 ACCEL ANGLE 0V 0 to 4.7V
21 -
22 -
23 GND 0V 0V
24 +5V 5V 5V
25 GND 0V 0V
26 +5V 5V 5V
27 -
28 -
29 -
30 LIFT LIMIT SW1 11.5V 0V
31 SPEED LIMIT SW 11.5V 0V
32 SEAT BELT SW 11.5V 0V
33 SEAT SW 11.5V 0V
34 PARK BRAKE SW 11.5V 0V
35 SERVICE BRAKE SW 11.5V 0V
36 REVERSE SW 11.5V 0V
37 FORWARD SW 11.5V 0V
38 BRAKE FLUID SW 11.5V 0V
39 STEERING PRESSURE SW 11.5V 0V
42 ACCEL IDLE SW 11.5V 0V
43 GND 0V 0V
44 PDS BUZZER 0V 0 to Vbatt
45 DIAG SW 11.5V 0V
46 SET SW 11.5V 0V
47 ATTACH3 SW 11.5V 0V
50 TILT SW 11.5V 0V
51 LIFT2 SW 11.5V 0V
52 LIFT1 SW 11.5V 0V
53 STEERING-1 11.5V 0V
57 LIFT LOCK + 0V 0 to Vbatt
58 LIFT LOCK - 0V 0V
59 LINE CONTACTOR CON 0V 0 to Vbatt
60 HYDRAULIC CONTACTOR CON 0V 0 to Vbatt
61 ALARM1 0V 0 to Vbatt
62 ALARM2 0V 0 to Vbatt
63 CON VE Vbatt Vbatt
64 UNLOAD SOL 0V 0 to Vbatt
Vbatt: Battery voltage
3-57
CONTROLLER
Power supply card voltage chart

CN1
No. Name Voltage Note
1 +12V 12V Fan
2 GND 0V Fan
3 +15V-L 13.0V to 16.0V DSP
4 +5V 8V DSP
5 +15V-G 12V DSP
6 GND 0V DSP
7 +VE-L Vbatt
8 +VE-L Vbatt
9 +15V-L 13.0V to 16.0V Logic
10 +5V 5V Logic
11 GND 0V Logic
12 GND 0V Logic
13 V POW Vbatt Input
14 V POW Vbatt Input
15 V GND 0V Input
16 V GND 0V Input
DSP card voltage chart

CN2
1 MOTOR THERMAL + 0 to 5V 0 to 5V
2 MOTOR THERMAL - 0 to 5V 0 to 5V
3 CANH 0 to 5V 0 to 5V Do not measure the voltage between
4 CANL 0 to 5V 0 to 5V CAN and Logic GND terminal.
5 ROTARY SENSOR +15V 12V 12V
6 ROTARY SENSOR A+ 0 to 5V 0 to 5V
7 ROTARY SENSOR B+ 0 to 5V 0 to 5V
8 MODE1 11.5V 0V
9 MODE2 11.5V 0V
10 BOOT 11.5V 0V
11 GND 0V 0V
12 TxD(GSE) - -
13 RxD(GSE) - -
14 CANR+ - -
15 CANR- - -
16 +15V-G 12V 12V
17 +15V-L 13.0V to 16.0V 13.0V to 16.0V
18 +5V 8V 8V
19 GND 0V 0V
20 GND 0V 0V
3-58
CONTROLLER
Input unit card voltage chart
CN1
1 GND 0V 0V
2 12V IN 13.0V to 16.0V 13.0V to 16.0V
3 -
4 RS-232 Tx 0 to 12V 0 to 12V
5 RS-232 Rx 0 to 12V 0 to 12V
6 RS-232 GND 0V 0V
7 CAN H 0 to 5V 0 to 5V
8 CAN L 0 to 5V 0 to 5V
9 CAN R+ - -
10 CAN R- - -
11 BOOT MODE - -
12 -
13 -
14 GND 0V 0V
15 LIFT REDUCTION SW 13.0V to 16.0V 0V
16 -
17 4/5 VALVE CHANGE SW 13.0V to 16.0V 0V
18 -
19 -
20 -
21 -
22 -
23 +5V 5V 5V
24 GND 0V 0V
25 LIFT JOYSTICK1 2.3 to 2.7V 0.1 to 4.9V
26 LIFT JOYSTICK2 2.3 to 2.7V 0.1 to 4.9V
27 TILT JOYSTICK1 2.3 to 2.7V 0.1 to 4.9V
28 TILT JOYSTICK2 2.3 to 2.7V 0.1 to 4.9V
29 ATTACH1 JOYSTICK1 2.3 to 2.7V 0.1 to 4.9V
3-59
CONTROLLER
Output unit card voltage chart
CN3
1 GND 0V 0V
2 GND 0V 0V
3 SOL V IN Vbatt Vbatt
4 SOL V IN Vbatt Vbatt
5 NODE 0 - -
6 NODE 1 - -
7 GND 0V 0V
8 GND 0V 0V
9 GND 0V 0V
10 RS-232 Tx 0 to 12V 0 to 12V
11 RS-232 Rx 0 to 12V 0 to 12V
12 RS-232 GND 0V 0V
13 CAN H 0 to 5V 0 to 5V
14 CAN L 0 to 5V 0 to 5V
15 CAN R+ - -
16 CAN R- - -
17 BOOT MODE - -
18 -
19 GND 0V 0V
20 +15V 13.0V to 16.0V 13.0V to 16.0V
21 LIFT VALVE A 0V 0 to Vbatt
22 LIFT VALVE B 0V 0 to Vbatt
23 LIFT VALVE - 0V 0 to 0.5V
24 TILT VALVE A 0V 0 to Vbatt
25 TILT VALVE B 0V 0 to Vbatt
26 TILT VALVE - 0V 0 to 0.5V
27 ATTACH1 VALVE A 0V 0 to Vbatt
28 ATTACH1 VALVE B 0V 0 to Vbatt
29 ATTACH1 VALVE - 0V 0 to 0.5V
36 -
3-60
CONTROLLER
Checking Contactor Coil
! CAUTION
Disconnect the battery plug and discharge the
inverters before working on electrical system.
1. Disconnect coil lead wire.

2. Set the multimeter to the 200 ohm range.
3. Measure coil resistance.
The resistance must be between 44 ohm at -30°C
(-22°F) and 65 ohm at 80°C (176°F).
• If the measured value deviates from the above range,
replace the contactor assembly.
4. With the lead wire of contactor coil connected, set the
multimeter to the 200 VDC range.
5. Connect the negative (–) terminal of the multimeter to
the negative-side coil terminal (small terminal) and the
positive (+) terminal of the multimeter to the positive-
side coil terminal (large terminal).
6. Connect the battery, and operate the control device that
activates the contactor.
7. The multimeter should indicate about 24V after the
contactor operates. When the contactor is found to be
normal for the coil resistance test, but measured
voltage is not 24 V, replace the logic card.
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 assembly. Make sure
there is no foreign material that could interfere with
contactor movement.
4. Measure the gap at the contactor tips using a thickness
gauge. 208284
[It must be 3 ± 0.5 mm (0.12 ± 0.02 in.)]
• If you find any trouble, replace or repair the
contactor.
3-61
CONTROLLER
Checking Inverter
! CAUTION
Disconnect the battery plug and discharge the
inverters before working on electrical system.
1. Disconnect all five power cables from P, N, U, V and

W terminals. For the pump inverter, leave P terminal
connected, and disconnect F terminal.
2. Check the resistance between the terminal as shown in
the following table.
Positive probe Negative probe Resistance (ohm)
U
N V
W - +
8k to 11k
U
V P Multimeter
W 211212
NOTICE: Short- or open-circuits of the inverter MOSFET

can be confirmed with this check. Other
internal faults cannot be determined with this
check.
3-62
CONTROLLER
Regeneration Check
The AC motor uses a common circuit for current flow in
both loading and regeneration. The following procedure
will confirm the regeneration operation.
1. Place the clamp ammeter onto the cable connected to Clamp ammeter
the inverter’s P terminal (use DC current range). This setting direction
is positive direction as current flows from the battery to
the inverter.
2. Move the lift truck forward. With the direction lever
shifted in F position, release the accelerator pedal.
Then perform a full-reverse operation.
3. The clamp ammeter should show a negative value. This
value becomes the regeneration current.
Energy is generated when a motor is rotated by an 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 211213
current is not measured if the speed or load changes
gradually.
3-63
CONTROLLER
AC Motor System Basics
1. Feature of AC motor
The AC motor model trucks covered by this manual use The frequency and voltage can be controlled in a
AC motors (three-phase induction motors) as the variety of methods including the “vector control
traction motor and pump motor. AC motors have the method” employed in the AC motor model trucks. This
following advantages over DC motors: method provides highly responsive control according to
(1) AC motors are simple in construction. Since they ever changing truck-operating conditions through high-
do not have friction parts like brushes and speed calculation on huge amount of data. The vector
commutators, daily maintenance is significantly control calculation is performed by the inverter. (Fig. 2)
reduced.
(2) AC motors are compatible with high-speed
operation. U
(3) An AC motor of a certain size produces higher

Inverter V IM
power than a DC motor of the same size.
2. Speed control of induction motors W
Speed control of DC motors depends on regulation of

the field and armature current amounts, while that of
AC motors basically depends on adjustment of the V V
U V W
frequency of the alternating current power supply. The
speed of an AC motor is determined by the frequency
t t
of the power supply AC current and the load on the
motor. In addition, the voltage and current to the motor
Low-speed operation High-speed operation
must be controlled properly so that the motor operates (low frequency)
in its optimum characteristic range. (Fig. 1) 209542
Fig. 1
Logic unit Inverter
Gate
driving MOS-FET modules
pulse
Torque
Calculation for order
Accelerator Vector control
required output
F
calculation IM
N
R
Truck
speed
Current
Brake Speed
211214
Fig. 2
3-64
CONTROLLER
3. Inverter Switch
The truck battery delivers DC current, so the current must
be converted into AC current to drive an AC motor. The VB VL Load
device that converts direct current into alternating current is
generally called an “inverter.” The processes involved in T1 T2 T1 T2 T1
creating AC current from DC current are described below. VL = x VB
T1 + T2
ON OFF ON
(1) Changing DC voltage cyclically
Average voltage VL
If the switch in a circuit like a one shown in Fig. 3 is
turned on for time T1 and then turned off for time T2
and this on-off operation is repeated many times, the Small duty ratio Large duty ratio
ON ON ON
average of the voltage applied to the load is determined
by the ratio between T1 and T2. Varying the ratio,
therefore, results in varying voltage. The ratio between
OFF OFF
T1 and T2 is called “duty ratio.” By changing the duty 209544
ratio cyclically, it is possible to obtain cyclically
Fig. 3
changing DC voltage shown in 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 S1 S3 S5
are arranged as shown in Fig. 4. The outputs thus U
V
created forms a three-phase alternating current. Fig. 5 W
S2 S4 S6
shows on-off condition of each switch (arm) and output
voltage variation.
Functioning as switches in the inverter of the AC motor
trucks are MOS-FET transistors. The MOS-FET
209545
transistors can switch at very high speeds, thus creating
smooth waveforms of alternating current. 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
209546
V l b i
Fig. 5
3-65

Caterpillar ET4000

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CONTROLLER

Controller System .................................................................................... 3 – 1

System layout for FC type

Display Logic card

FC solenoid Lift cylinder,

Left traction motor Pump motor Hydraulic

System layout for MC type

Display Logic card Contactor control signal

Controller Area Network (CAN)

*1, * 2: Input unit and output unit are used

The data are expressed as electric potential difference

bit Logic Vdiff Vdiff

recessive 1 recessive dominant recessive

The current information is available to confirm and

Harness B side CN3 Harness B side CN2 Harness B side CN1

Power supply card

The Service Tool connector exists on harness B CN21.

2. Inverter When a malfunction occurs, it stops the motors and

Traction inverter (right and left)

Harness B side, Traction Right CN7

Inverter card side CN2 Harness B side, Pump CN5

Input unit card

Input unit card side CN1 FC-IN harness side CN2

Current characteristics of proportioning

Output unit card

Output unit card side CN3

Harness B side CN22 FC-OUT harness side CN9

The following describes the features of the controller.

2. Controlled roll-back NOTICE: When the regeneration is selected by SUO

85 STANDARD; Full acceleration

4. Limitation of maximum travel speed

Feature of maximum speed limit

Description SUO No. Harness Pin No.

5. Miscellaneous features for traction

Miscellaneous features for traction

Feature of lifting work speed setting

Description SUO No. Harness Pin No.

Refer to page 3-16 for details and setting procedure of

DRS switch is installed under floor

2. PDS (Presence Detection System) features

Status transfer chart

Traction Control PDS Seat SW

Direction lever: N (Chosen foot direction: no effect)

Seat SW flag: OFF

Motor: Zero torque

Motor: Regen brake Seat SW flag: OFF Seat SW flag: ON

Motor: Zero torque

Normal operation Normal operation

Lift lock valve: LOCK FC solenoid: All off

Seat SW flag: ON Seat SW flag: ON

Seat SW flag: OFF Seat SW flag: OFF

Lift lock valve: LOCK FC solenoid: All off

Control valve SW: All off FC control lever: All neutral

3. BDI display features

Set #41 or #42 depends on installed battery type and

For further details, see OMM.

4. Warning buzzer features

Item Description SUO No.

Setup Option off.

First SUO # of each group

Current set value for SUO #11*

Selecting SUO # and changing set value

Default value 5 for SUO #20

1, 2: Input unit and output unit are used