Professional Documents
Culture Documents
Chapter 1 CONTROLLER
1. Controller System
1.1 System Layout
The lift truck is controlled by the logic unit and the inverter. The logic unit, the inverter, and meter panel are linked
together by the Controller Area Network (CAN) to
The logic unit is the main part of the control system and
communicate with each other. The logic unit sends the
controls the travel, lifting and safety function systems. The
motor control command to the inverter and the inverter
logic unit is connected to the inverter, meter panel and
sends the sensing data to the logic unit.
other control switches.
The meter panel indicates the lift truck conditions and
The inverter controls the AC induction traction motor and
setting data.
the AC induction pump motor.
CAN bus
Lift cylinder
DSP card DSP card Tilt cylinder
Micro
switches
Steering
Hydraulic motor
Sensors Sensors control valve
assembly
M M Lift lock M
solenoid
3~ 3~ valve
Hydraulic
Traction motor Pump motor pump
Contactor Battery
Electric power
608585
1-1
CHAPTER 1 CONTROLLER
1.2 Controller Area Network (CAN)
Each controller is linked with the lift truck harness to form a If the terminal resistors are not properly connected, a
network as follows: communication failure may occur between the logic unit
and the inverters.
The terminal resistors are built into the traction inverter and
the pump inverter. For details, refer to Traction Inverter Fault (63) and Pump
Inverter Fault (65) in Troubleshooting for Control Circuits.
CAN L
608586
The data are expressed with electric potential difference in high- and low-level signals as follows:
They are transferred to each controller through the serial communication protocol.
VCAN-L
Kind of
potential
Logic
bit Vdiff
Vdiff
dominant 0 VCAN-H
500921
Main specifications
Item Specifications
Non-return to zero method
Communication protocol CAN bus 2.0B passive
Broadcast communication protocol
Communication line Dual 2-wire type serial communication
Communication speed 500 kbps
Data length 0 to 8 bytes
1-2
CHAPTER 1 CONTROLLER
1.3 Outline of Logic Unit
Logic unit
The logic unit consists of the logic card and the power The logic unit communicates with the meter panel through
supply card. the CAN bus. The lift truck speed and residual battery power
are monitored and shown on the meter panel. The seat belt
The logic card has the CPU chips and controls all the jobs for
and brake fluid level are also monitored and shown on the
the lift truck.
meter panel.
The logic unit calculates the traction motor control
The logic unit sets the model information and optional
command through the input of the direction lever or
default data into internal memory. The information is
accelerator pedal and sends the command to the traction
secured even if the power supply for the logic unit is turned
inverter. It also monitors malfunctions of the traveling
OFF. This information is set at the factory.
control system.
The following table shows the model information. The
The logic unit calculates the AC induction pump motor
system will not work properly if the actual controller system
control command through the input of the hydraulic levers
is different from the model information.
and sends the command to the pump inverter. It also
monitors malfunctions of the lifting control system.
Model information
1-3
CHAPTER 1 CONTROLLER
Logic unit
608587
Logic card
CN1
1)
2) 3) 4)
608588
1) Logic card side CN1 3) Main harness side E-03
2) Main harness side E-02 4) Main harness side E-04
1-4
CHAPTER 1 CONTROLLER
Power supply card
CN1
1) 2)
608589
1) Power supply card side CN1 2) Main Harness side E-01
1-5
CHAPTER 1 CONTROLLER
1.4 Outline of Inverter
The inverter is a motor drive controller that consists of Digital Signal Processor (DSP) card, Insulated Metal Substrate (IMS)
module and their drive boards.
It drives the AC induction motors according to the motor control command from the logic unit. It also monitors malfunctions
of motors and its own condition.
When a malfunction occurs, it stops the motors and informs the logic unit.
The DSP card has the DSP chips that enables high-speed calculation and controls the AC induction motors.
The IMS module has plural MOS-FET modules and converts the battery DC current into AC current for supplying to the traction
and pump motors. Also refer to 1-64 "AC Motor System Basics".
Traction and pump inverters
608590
1. DSP card
CN2
1) 2) 608591
1) Traction inverter card side CN2 2) Main harness side, Traction E-06
Pump inverter card side CN2 Main harness side, Pump E-05
1-6
CHAPTER 1 CONTROLLER
2. Traction Controller Feature
The line contactor closes in the following conditions when the key switch is turned ON. This enables the inverter to control the
traction motor.
All the following must be satisfied:
- The seat switch is turned ON.
- The lifting operation is not performed (the hydraulic lever input does not occur).
- The traveling operation is not performed: The direction lever is placed to NEUTRAL and the accelerator pedal is not
pressed.
- Warning related to the traveling and lifting operations does not occur.
2.1 Powering
Normal traveling
Travel speed is controlled by the accelerator pedal depression. The speed is also controlled by the accelerator pedal depression
when descending a grade and it is controlled only in the output torque range of the traction motor.
The controller supplies power to the traction motor according to the acceleration rate and the torque characteristic when the
accelerator pedal is pressed.
Torque
[%]
POWER (3)
100 STANDARD (2)
85
ECONOMY (1)
70
Brake limit *1 (50%)
Thermal, BDI [0] or Service indicator*2
(30%)
Speed
0 5 10 15 (km/h)
500939
*1 Brake limit: Torque value resulting from reduction in current when the service brake or parking brake is applied.
*2 Thermal, BDI Level [0] or Service indicator: Curve of limited torque under a condition of overheating or battery voltage low
or maintenance time over.
1-7
CHAPTER 1 CONTROLLER
Boost
When lift truck travel is blocked by a step, the boost function Fully depress the accelerator pedal for 2 seconds. The boost
prevents stalling of the lift truck. This function allows the lift function increases the motor maximum torque for 5
truck to bypass a step regardless of the value setting of the seconds. If the pressure on the accelerator pedal is reduced
motor maximum torque. or the direction lever is moved, the boost function will be
canceled immediately.
Torque [%]
*Torque required to climb over a step
* #9
100 POWER; Full acceleration
85 STANDARD; Full acceleration
70 ECONOMY; Full acceleration
0 Time [sec]
2 7
500931
Note: The lift truck is equipped with a stall timer. If the lift truck travel is blocked by an obstruction or is traveling on too steep
a grade and the accelerator is fully depressed, the stall timer will only allow the boost function to operate for a preset
duration of time to prevent overheating and damage to the traction motor. If the preset stall time is exceeded, diagnostic
code 16 will be present.
1-8
CHAPTER 1 CONTROLLER
2.2 Regeneration
0
1 2 3 4 5 6 7 8 9 10
Value of #23
505670
Lever regeneration
The lever regeneration starts when the direction lever is
shifted into the position opposite of the traveling direction Amount of lever regeneration
with the accelerator pedal depressed during travel.
[%]
100
0
1 2 3 4 5 6 7 8 9 10
Value of #22
505670
1-9
CHAPTER 1 CONTROLLER
Brake regeneration
Brake regeneration starts when the brake pedal is pressed.
Note: Brake regeneration also starts when the parking brake Amount of brake regeneration
is applied. [%]
100
0
1 2 3 4 5 6 7 8 9 10
Value of #21
505670
Controlled roll-back
Descends slowly when accelerator
This function prevents hazardous descending of the lift pedal is released on a grade.
truck on a grade.
The controlled roll-back is activated when the accelerator
pedal is released on a grade with the direction lever shifted
into the FORWARD or REVERSE position.
The descending speed changes with the steepness of grade
and the weight of load.
Note: This is not a function to stop the lift truck when the 608595
accelerator pedal is released on a grade. This function
is activated only in the output torque range of the
traction motor.
1-10
CHAPTER 1 CONTROLLER
3. Lifting Controller Feature
3.1 Setting and Limitation of Lift Work Speed
Each lift work speed can be set. The lift work speed can be limited or stopped when specific switch input occurs.
Triple input signals are selectable and available to set limit value to each signal.
Feature of lifting work speed setting
1-11
CHAPTER 1 CONTROLLER
5. Meter Panel
5.1 Configuration of Meter Panel
Meter panel
3 E00880
1. Warning LED 3. Front panel buttons
2. Screen
1. Warning LED
In addition to a text message on the screen, this red warning LED will illuminate in the case of a detected warning, which limits
lift truck operation.
2. Screen
For details, refer to 1-13 "Meter Panel Screen".
3. Front panel buttons
These directional buttons are used to make adjustments to items shown on the screen and to access the main menu where
further set-up options and diagnostics features are housed.
1-12
CHAPTER 1 CONTROLLER
5.2 Meter Panel Screen
4 6
3 7
2 8
1 9
10
12 11 E00881
1. Overheated warning icon 7. Service brake fluid warning icon
2. Parking brake warning icon 8. Service indicator
3. Seatbelt warning icon 9. Slow speed mode icon
4. Travel direction indicator 10. Advisory area
5. Travel speed/Message center 11. Battery discharge indicator
6. Mast interlock indicator icon 12. Battery warning icon
1-13
CHAPTER 1 CONTROLLER
1-14
CHAPTER 1 CONTROLLER
5.3 Meter Panel Screen Transition
The screen transition on the meter panel and the operation procedures are as follows:
Screen operation procedures
(1) Press r button with the speed data displayed.
When the warning is being displayed, first press M button to display the speed data, then press r button.
(2) Press M or m button to display "Adjustment Menu", then press r button.
(3) Press M or m button to choose from "Date", "Clock", "Speed", "Date format", "Clock format", "Brightness", "Truck mode",
"Software version", and "Exit for setup.
(4) Press M or m button to display "Exit", then press r button.
KEY-ON
1. KEY-Switch ON
1. CAN Connection Check
2. PASSWORD Check (Option)
2. Main Monitor 1
1. SPEED DATA
2. WARNING (s)
3. Main Menu 1
1. Adjustment Menu
2. EXIT
4. Adjustment Menu
1. Date
2. Clock
3. Speed
4. Date format
5. Clock format
6. Brightness
7. Truck mode
8. Software version
9. EXIT
608780
1-15
CHAPTER 1 CONTROLLER
5.4 Diagnostic Code
608781
Item Description
Diagnostic code Indicates the code assigned to the fault.
Warning R Glows (or blinks) while the fault is occurring.
1-16
CHAPTER 1 CONTROLLER
5.5 Password Entry
PASSWORD
0000
0 KM/H
608782
1-17
CHAPTER 1 CONTROLLER
5.6 User Setting Function
(1) Date
Adjust date. ADJUSTMENT
(2) Clock 1 *
1/1 / 2004
Adjust clock.
(3) Speed unit
Select MPH or KM/H. ADJUSTMENT
(4) Date format
2 *
0:0
Select US, EU or JPN.
ADJUSTMENT
6 BRIGHTNESS
3
ADJUSTMENT
7 TRUCK MODE
A
ADJUSTMENT
8 SOFTWARE
VERSION ****
608783
1-18
CHAPTER 1 CONTROLLER
6. Other Features
6.1 PDS (Presence Detection System) Feature
This controller is part of the "Presence Detection System" (PDS) of the lift truck. This system features an enhanced, integral
computer based feed back system which provides "certain product intelligence" to the operator. The table shows processes for
traction and lifting. Refer to 1-20 "PDS status transfer chart" for details.
PDS features
1-19
CHAPTER 1 CONTROLLER
Seat SW
Traction Control PDS Seat SW flag: ON
Seat SW off time Delay time
2 sec or 3 sec
Direction lever: N
Accelerator pedal: OFF
Seat SW flag: ON
Seat SW flag: OFF
1-20
CHAPTER 1 CONTROLLER
Prevention result
Operated item When operator is on seat again
When turning ON power
after leaving seat
Traveling, lifting, and steering stop. Traveling and lifting stop.
Direction lever or accelerator pedal Travel direction N of meter panel
Diagnostic code E glows
glows
Traveling, lifting, and steering stop. Traveling and lifting stop.
Lift lever Mast interlock indicator of meter panel
Diagnostic code H1 glows
glows
Traveling, lifting, and steering stop. Traveling and lifting stop.
Tilt lever Mast interlock indicator of meter panel
Diagnostic code H2 glows
glows
Traveling, lifting, and steering stop. Traveling and lifting stop.
Attachment 1 lever Mast interlock indicator of meter panel
Diagnostic code H3 glows
glows
Traveling, lifting, and steering stop. Traveling and lifting stop.
Attachment 2 lever Mast interlock indicator of meter panel
Diagnostic code H4 glows
glows
1-21
CHAPTER 1 CONTROLLER
Warning buzzer
- Parking brake warning
The buzzer sounds when the key switch is turned OFF or the operator leaves the operator's seat with the parking brake not
applied.
- Seat belt warning
The buzzer sounds when the seat belt is not fastened with the operator on the operator's seat.
Traction Motor Stall Timer (Diagnostic code 16) warning occurs to prevent the traction motor from overheating when the lift
truck travel is blocked for several seconds and the accelerator pedal is fully depressed.
Password effective time can be changed within the preset time range. If the lapse time from key-OFF to key-ON is within the set
time, input of password can be omitted.
The BDI shows the remaining battery capacity of the current battery voltage with 11 levels from BDI 0 to BDI 10.
Set the BDI by SUO #41 and SUO #42 depending on the installed battery type and voltage.
If the previous indication is BDI 4 or less and the following indication is not BDI 7 or more when turning ON the key switch, the
BDI will show the previous indication.
When the battery voltage lowers, the following output power control is activated by the BDI function to protect the battery:
Control by BDI 1: Traveling is limited.
Control by BDI 0: Traveling and lifting are limited, and simultaneous operations of traveling and lifting are inhibited.
1-22
CHAPTER 1 CONTROLLER
6.5 Service Indicator
The service indicator starts blinking 20 hours before the set maintenance time, and remains lit when the lift truck hour meter
indication reaches the set time.
If the output power control is selected, the output power control will also be activated at the same time to limit the traveling
and lifting operations.
Tire diameter change resulting from tire wear can be compensated for.
This setting is used to adjust the travel speed indication when it differs from the actual speed by tire wear.
1-23
CHAPTER 1 CONTROLLER
7. Setup Option
7.1 Outline
The logic unit is equipped with a type of memory module to hold recorded data even if the main power is turned OFF.
The model information and various features are set during factory shipment.
The setup options are categorized from Group 1 to Group 3 according to the feature levels.
Setup group
Group Description
Group 1 Basic function (#1 to #10)
Group 2 Detailed function (#11 to #38)
Group 3 Model information (#40 to #47)
The Group 1 and 2 are available to set the default value in a one-step operation and can be customized in accordance with
applications. Since the Group 3 is for model information, it is required to be set to the same value as actual control system. It
will not work properly if the model information is different.
When setting the setup option data for the first time after the assembly is completed or the logic card is replaced, be sure to set
Group 3 data first, then the default data of Group 1 and 2 with service tool in each setup mode.
608778
1-24
CHAPTER 1 CONTROLLER
7.2 Details of Setup Options (Group-1)
SUO#
Mode A B C D E
Feature/ 1
Preset 1 Preset 2 Preset 3 Preset 4 Preset 5
Application
Lift Fast Fast Medium Fast Fast
Tilt Slow Slow Slow Slow Slow
Travel speed Medium Fast Slow Fast Medium
Characteristic
Acceleration Medium Fast Medium Medium Fast
Power Standard Powerful Economy Standard Powerful
Regeneration Medium Medium Medium Medium Medium
Start lift speed 1 1 1 1 1 2
Top lift speed 9 10 8 9 10 3
Tilt speed 1 1 1 1 1 4
Maximum travel
15 18 12 17 15 7
Default value speed
(Standard) Acceleration rate 3 5 2 3 5 8
Traveling power 2 3 1 2 3 9
Brake regeneration 7 7 7 7 7 21
Accelerator
7 7 7 7 7 23
regeneration
Start lift speed 1 1 1 1 1 2
Top lift speed 8 8 8 8 8 3
Tilt speed 1 1 1 1 1 4
Maximum travel
14 14 14 14 14 7
Default value speed
(EE) Acceleration rate 2 2 2 2 2 8
Traveling power 1 1 1 1 1 9
Brake regeneration 7 7 7 7 7 21
Accelerator
7 7 7 7 7 23
regeneration
1-25
CHAPTER 1 CONTROLLER
36V type mode setting
SUO#
Mode A B C D E 1
Feature/
Preset 1 Preset 2 Preset 3 Preset 4 Preset 5
Application
Lift Fast Fast Medium Fast Fast
Tilt Slow Slow Slow Slow Slow
Travel speed Medium Fast Slow Fast Medium
Characteristic
Acceleration Medium Fast Medium Medium Fast
Power Standard Powerful Economy Standard Powerful
Regeneration Medium Medium Medium Medium Medium
Start lift speed 1 1 1 1 1 2
Top lift speed 9 10 8 9 10 3
Tilt speed 1 1 1 1 1 4
Maximum travel
15 17 12 17 15 7
Default value speed
(Standard) Acceleration rate 3 5 2 3 5 8
Traveling power 2 3 1 2 3 9
Brake regeneration 7 7 7 7 7 21
Automatic
7 7 7 7 7 23
regeneration
Start lift speed 1 1 1 1 1 2
Top lift speed 8 8 8 8 8 3
Tilt speed 1 1 1 1 1 4
Maximum travel
12 12 12 12 12 7
Default value speed
(EE) Acceleration rate 2 2 2 2 2 8
Traveling power 1 1 1 1 1 9
Brake regeneration 7 7 7 7 7 21
Automatic
7 7 7 7 7 23
regeneration
1-26
CHAPTER 1 CONTROLLER
2
1
0
SW1 SW2 Lever operation
close close
608597
#4 Tilt speed
This setting affects pump speed when you pull the tilt lever.
Pump motor
Speed when tilt switch is turned ON. output [%]
2
1
0 SW Close
608596
1-27
CHAPTER 1 CONTROLLER
#5 Auxiliary 1 speed
This setting affects pump speed when you operate the attachment 1 lever.
Speed when attachment 1 switch is turned ON
Attachment 1 speed will become faster if the value setting is increased. The range setting is 1 to 10 for all models.
#6 Auxiliary 2 speed
This setting affects pump speed when you operate the attachment 2 lever.
Speed when attachment 2 switch is turned ON
Attachment 2 speed will become faster if the value setting is increased. The range setting is 1 to 10 for all models.
#8 Acceleration rate
This setting affects response time to calculate speed order from accelerator pedal position.
Acceleration of lift trucks becomes faster if the value setting is increased.
The range setting is 1 (slowest) to 5(fastest).
(When #40 is set for EE type: 1 to 2.)
1-28
CHAPTER 1 CONTROLLER
Torque
[%]
POWER (3)
100 STANDARD (2)
85 ECONOMY (1)
70
Brake limit *1 (50%)
Thermal, BDI [0] or Service indicator*2
(30%)
Speed
0 5 10 15 (km/h)
500939
*1 Brake limit: Torque value resulting from *2 Thermal, BDI [0], or BDI [0] or Service indicator: Curve
reduction in current when the Service indicator: of limited torque under a condition
brake is applied. of overheating or battery voltage
low or maintenance time over.
6 min In increments
Maintenance time [hour] - 100 150 950 1000
(test) of 50
Invalid 0
Set data on
Only warning 0.1 100 150 ----- 950 1000
meter panel
Torque limit =0.1 =100 =150 ----- =950 =1000
1-29
CHAPTER 1 CONTROLLER
7.3 Details of Setup Options (Group-2)
*1 Place the lever in NEUTRAL. Lift starts moving by operating the lever again.
1-30
CHAPTER 1 CONTROLLER
0
1 2 3 4 5 6 7 8 9 10
Value of #22
505670
1-31
CHAPTER 1 CONTROLLER
0
1 2 3 4 5 6 7 8 9 10
Value of #23
505670
#30 Auxiliary input for travel speed (Harness pin No. 31)
When the speed limit signal is ON, travel speed or power is limited to set value. The amount of maximum speed is defined at
#31. The amount of power reduction is defined at #32.
The setting range is 0 or 1. (0: Disable, 1: Enable)
#31 Auxiliary maximum travel speed setting (Harness pin No. 31)
This setting defines the truck speed limit set up by #30.
The setting range is 5 to 18 [km/h].
1-32
CHAPTER 1 CONTROLLER
7.4 Details of Setup Options (Group-3)
Display Model
1 EC22N2
2 EC22N2EE
3 EC25N2
4 EC25N2EE
5 EC25EN2
6 EC25N2EE
7 EC25LN2
8 EC25LN2EE
9 EC30N2
10 EC30N2EE
11 EC30LN2
12 EC30LN2EE
R CAUTION
If the lift truck model setting is incorrect, the lift truck may show unexpected movement.
1-33
CHAPTER 1 CONTROLLER
Gel BDI
BDI# 36V 48V
0 - 32.9 - 43.8
1 33.0 - 33.5 43.9 - 44.7
2 33.6 - 34.0 44.8 - 45.4
3 34.1 - 34.5 45.5 - 46.1
4 34.6 - 35.0 46.2 - 46.7
5 35.1 - 35.5 46.8 - 47.3
6 35.6 - 35.9 47.4 - 47.8
7 36.0 - 36.2 47.9 48.3
8 36.3 - 36.5 48.4 - 48.7
9 36.6 - 36.7 48.8 - 48.9
10 36.8 - 49.0 -
1-34
CHAPTER 1 CONTROLLER
- +
1
49.6V
V
- +
3
4
505685
1. Battery 3. Tester or multi-meter
2. Line contactor (POSITIVE) 4. Traction inverter (NEGATIVE)
1-35
CHAPTER 1 CONTROLLER
7.5 Setup Options (Group 1)
Option Default
Title Description Range
# Value
The value setting of the following 8 items are 1: A
registered beforehand: 2: B
Application presets
Start lift speed, top lift speed, tilt speed, maximum 3: C
#1 (Lift truck operation 1 (3)
travel speed, acceleration rate, traveling power, 4: D
mode)
brake regeneration, and accelerator regeneration. 5: E
Refer to the explanation for details See note (1)
Beginning lift speed
#2 Start lift speed 1 (Slow) to 10 (Fast) 1
Start lift speed cannot exceed top lift speed.
#3 Top lift speed Lift speed when operating the lever at maximum 1 (Slow) to 10 (Fast) 9 (3)
#4 Tilt speed Speed setting for tilt 1 (Slow) to 10 (Fast) 1
#5 Auxiliary 1 speed Speed setting for attachment 1 1 (Slow) to 10 (Fast) 3
#6 Auxiliary 2 speed Speed setting for attachment 2 1 (Slow) to 10 (Fast) 3
5 to 18 [km/h] or
Maximum travel speed
#7 Maximum travel speed 5 to 17 [km/h] 15 (3)
limit
See note (2), (3)
1 to 5 See note (3)
#8 Acceleration rate Choice of acceleration rate (1: Slowest, 2: Slow, 3: 3 (3)
Middle, 4: Fast, 5: Fastest)
1, 2, 3 See note (3)
#9 Traveling power Choice of powering characteristic (1: ECONOMY, 2: 2 (3)
STANDARD, 3: POWER)
This function notifies service personnel that
maintenance time is approaching or has passed. 0, 0.1,
100, 150, ...950, 1000,
It means the lapsed time when setting up. =0.1 (6 min.),
#10 Service indicator Service indicator icon on meter =100, =150, =950, =1000 0
Approached: (In increments of 50 [hour])
panel blink (20 hour)
=: power reduction
The icon glows and power 0: no action
Passed :
reduction (selected)
Note:
(1) Before changing, when parameter data are different from the values of the selected mode, the lift truck operation mode
indicator (A to E) blinks. When the lift truck operation mode is changed, all parameter data is replaced by the set values of
the selected mode.
(2) When #41 is set for 36 volts, the setting range is 5 to 17 [km/h].
For setting other than above, the setting range is 5 to 18 [km/h].
(3) When #40 is set for EE type, the setting range and default value of each Setup Option data are as follows:
1-36
CHAPTER 1 CONTROLLER
7.6 Setup Options (Group 2)
1-37
CHAPTER 1 CONTROLLER
1-38
CHAPTER 1 CONTROLLER
7.7 Setup Options (Group 3)
Option Default
Title Description Range
# Value
This option is used to set the size 12 patterns (Refer to 1-33 "Details of
#40 Truck model and type of the lift truck. Setup Options (Group-3)" for model
Refer to the explanation for details. names.
This option is used to set the voltage
#41 Battery voltage 36, 48 [V]
of the battery.
This option is used to set the type of
the battery. 0: Normal BDI
#42 Battery type The electric discharge characteristic 1: Tubular BDI
of a battery changes with battery 2: Gel BDI
type.
0: 2FF (2-stage full-free / Duplex mast)
This option is used to set the type of 1: 3FF (3-stage full-free / Triplex mast)
#44 Mast type
the mast. 2: 2SP (2-stage panorama / Simplex
mast)
This option is used to set the 1: 3V (Lift, tilt, and attachment1)
#45 Valve section
number of valve section 2: 4V (Lift, tilt, and attachment1,2)
This setting corrects the gap of the
battery voltage which the controller
recognizes, and actual battery
Battery voltage voltage.
#46 5.0 to 120.0 [V]
adjustment Measure actual battery voltage and
use service tool in order to adjust the
value which is shown on the service
tool actual battery voltage.
This option is used to enable the 1: Standard direction lever
#47 Foot direction
function for foot direction option. 2: Foot Directional Control (FoDiCo)
Note:
(1) The data of group 3 have no default value, but it needs to set data by the actual lift truck model. If the value and the lift
truck model are not in agreement, the lift truck does not operate normally.
(2) When you set up for the first time, set up group 3 first, and then set default data of group 1 and 2.
(3) This value was adjusted at the time of LOGIC CARD inspection. Adjust the value if the value shown on the service tool is
different from actual battery voltage.
(4) Use this option to achieve the lift lockout at the designed battery voltage.
(5) Setting volts lower than battery volts will activate lift lock out at a higher voltage.
(6) Setting higher than battery voltage will discharge the battery to a deeper level.
1-39
CHAPTER 1 CONTROLLER
8. Diagnostics
8.1 Outline
The controller monitors status of various input/output equipment to allow diagnostics of lift trucks malfunction.
There is a diagnostics called Self Diagnostics, which performs an equipment check during maintenance.
Diagnostics
Mode Description
Diagnostics Self diagnostics Checks function of electrical systems.
Self diagnostics that exclusively checks the power steering system is also available.
Turn ON the key switch and enter the diagnostics mode using the service tool.
Perform diagnostics by following the procedure below.
Preparatory operations (excluding steering) (4) Discharge all inverters. Refer to 1-48 "Inverter
Discharging Procedure".
(1) Place the parking brake lever in the locked position. (5) Place the direction lever in the NEUTRAL position.
(2) Turn OFF the key switch. (6) Remove the fuses (500 A) on traction and pump
(3) Disconnect the battery plug/connector. inverters and steering fuse (60 A).
(7) Connect the battery plug/connector.
Diagnostics procedure
Perform the procedure using the Self-Diagnostics table (refer to 1-41 "Self-Diagnostics") in accordance with the following
guide.
(1) Start diagnostics with the Step 0 in the table. Without sitting in the seat, turn ON the key switch according to the
instruction in the Action column on the Step 0 line. If the item passes the check without any problem, the next Step 01
appears on the meter panel.
If the item involves any problem and fails in the check, dd is shown on the meter panel. The meter panel also shows dd
when diagnostics is started without removing the fuse. In this case, diagnostics is prohibited from going even to the first
step.
(2) When the Step 0 has passed the check, diagnostics may
advance the Step 1 (seat switch). Cycle the seat
switch OFF 6 ON 6 OFF according to the instruction in 1
the Action column on the Step 1 line. If the item
passes the check, the next step number 02 appears on
the meter panel.
Do likewise for the succeeding items, following the
instructions in the Action column boxes. If the step
fails in the check, diagnostics does not advance
automatically. In this case, diagnostics can be forcibly
advanced to the next step by pressing the next button
on the service tool.
Note: Diagnostic items can be skipped by pressing the Skip 500946
button on the service tool.
1. Diagnostics result indication
(3) When all the steps have been checked through, turn OFF the key switch. Be sure to install the 500 A fuses and 60 A steering
fuse.
- Turn OFF the key switch to exit from the diagnostics mode.
- Repair all faults found immediately after diagnostics.
Follow the instructions in the diagnostics procedure guide above as well as Self-Diagnostics table in the applicable Action
column.
1-40
CHAPTER 1 CONTROLLER
8.3 Self-Diagnostics
Skip button - 07
Input Pass 10
9 Tilt lever SW Pull and release tilt lever. Release - Pull -
Release Fail 09
Input Pass 11
Attachment Pull and release Attachment1
10 Release - Pull -
lever 1 switch lever. Fail 10
Release
Input Pass 13
Attachment Pull and release Attachment 2
11 Release - Pull -
lever 2 switch lever. Fail 11
Release
1-41
CHAPTER 1 CONTROLLER
Note:
(4) Input (ON/OFF) to the accelerator switch and travel of the accelerator pedal (0 to100%) appears.
(5) Setting of hydraulic speed (0 to 10) appears when any lever is pulled.
(1) dd indicates the fuse needs to be removed.
1-42
CHAPTER 1 CONTROLLER
8.4 Run Time Diagnostics
Availability of operation:
z: Yes, 9: No, *: Applicable
Meter panel
Steering operation
Icon
Memory
Return
Driving interlock
Mast interlock
Parking brake
Over temp.
Code Fault How to detect
Battery low
Result to
Brake fluid
Code
Warning
normal
1-43
CHAPTER 1 CONTROLLER
Meter panel
Steering operation
Icon
Memory
Return
Driving interlock
Mast interlock
Parking brake
Over temp.
Battery low
Code Fault How to detect Result to
Brake fluid
Code
Warning
normal
Line contactor
Pump motor, OFF Turn OFF
47 Pump motor open * 47 z *
Open Steering key
contactor Hold
Line contactor
Steering motor, Steering motors warning OFF Turn OFF
49 * 49 9 *
Fault signal is open (high) Steering key
contactor OFF
- Accel sensor voltage 1 is
out of range from 0.15 to
4.2 V.
- Accel sensor 2 input value
Line contactor
when multiplied by two is
Accelerator OFF Turn OFF
51 out of range from 0.15 to * 51 z *
sensor, Fault Steering key
4.2 V.
contactor Hold
- Difference in input
between accelerator
sensors 1 and 2 (multiplied
by two) is 0.4 or more.
Line contactor
Traction motor, Out of normal range OFF Turn OFF
52 * 52 z *
Pulse input fault (5800 min-1) Steering key
contactor Hold
- Out of normal range Line contactor
Pump motor, (-200 min-1) OFF Turn OFF
57 * 57 z *
Pulse input fault - Out of normal range Steering key
(5800 min-1) contactor Hold
Line contactor
FNR lever/accel is not Seat
OFF
NEUTRAL at power-ON and E 9 switch ON
Direction lever Steering
seat SW ON Direction
E or accelerator, contactor OFF
lever is in
Faulty setting Slow down and NEUTRAL
Seat SW is turned ON after
* - z Line contactor accel OFF
lever/accel is operated
OFF
Line contactor
OFF Seat
Seat SW is OFF at power-ON - 9 switch ON
Seat switch, Steering
contactor OFF Direction
(E) Faulty setting
lever is in
for traction Slow down and NEUTRAL
Seat SW is OFF * - z Line contactor accel OFF
OFF
1-44
CHAPTER 1 CONTROLLER
Meter panel
Steering operation
Icon
Memory
Return
Driving interlock
Mast interlock
Parking brake
Over temp.
Battery low
Code Fault How to detect Result to
Brake fluid
Code
Warning
normal
Line contactor
OFF Seat
Seat switch, Seat SW is OFF at power-ON - 9
Steering switch ON
(L) Faulty setting contactor OFF Lever is in
for hydraulic
Disables lever NEUTRAL
Seat SW is OFF - z
operation
Line contactor
Lever is not NEUTRAL at OFF Seat
H1 9
Lift lever, Faulty power-ON and seat SW ON Steering switch ON
H1 contactor OFF
setting Lever is in
Seat SW is turned ON after Disables lever NEUTRAL
* - z
lever is operated operation
Line contactor
Lever is not NEUTRAL at OFF Seat
H2 9
Tilt lever, Faulty power-ON and seat SW ON Steering switch ON
H2 contactor OFF
setting Lever is in
Seat SW is turned ON after Disables lever NEUTRAL
* - z
lever is operated operation
Line contactor
Lever is not NEUTRAL at OFF Seat
Attachment 1 H3 9
power-ON and seat SW ON Steering switch ON
H3 lever, Faulty contactor OFF Lever is in
setting
Seat SW is turned ON after Disables lever NEUTRAL
* - z
lever is operated operation
Line contactor
Lever is not NEUTRAL at OFF Seat
Attachment 2 H4 9
power-ON and seat SW ON Steering switch ON
H4 lever, Faulty contactor OFF Lever is in
setting
Seat SW is turned ON after Disables lever NEUTRAL
* - z
lever is operated operation
Meter panel, When serial
Comn fault is Turn OFF
60 Communication communication is not * - - *
displayed key
fault going on
Line contactor
- SUO Group #3 and default
Logic card, OFF Turn OFF
61 setting are not set * 61 9 *
Initialize failure Steering key
- Inverter setting warning
contactor OFF
- Sum check of ROM Line contactor
- Memory check of RAM OFF Turn OFF
62 Logic unit, Fault * 62 9 *
- Sum check of SUO data Steering key
(EEPROM) contactor OFF
1-45
CHAPTER 1 CONTROLLER
Meter panel
Steering operation
Icon
Memory
Return
Driving interlock
Mast interlock
Parking brake
Over temp.
Battery low
Code Fault How to detect Result to
Brake fluid
Code
Warning
normal
1-46
CHAPTER 1 CONTROLLER
Meter panel
Steering operation
Icon
Memory
Return
Driving interlock
Mast interlock
Parking brake
Over temp.
Battery low
Code Fault How to detect Result to
Brake fluid
Code
Warning
normal
Note:
- E0, E2, E5, and E7 do not appear on the meter panel, but are stored in the memory.
- Line contactor OFF (*)/Steering contactor OFF (*) means that the contactor will open immediately when a fault is
detected.
Line contactor OFF means that the contactor will open when current goes to 0.
- Contactor hold means no change. When a warning occurs while the contactor is turned ON, it stays ON.
1-47
CHAPTER 1 CONTROLLER
9. Removal and Installation
9.1 Inverter Discharging Procedure
1 608606
1. Rear cover
608607
1-48
CHAPTER 1 CONTROLLER
9.2 Replacing Inverter
Removal
(1) Raise the front wheels.
(2) Perform Steps (1) through (6) in Inverter Discharging Procedure.
R CAUTION
Be sure to discharge electric charges from all inverters before working on the electrical system.
V F
608608
R CAUTION
When disconnecting the connector, hold the connector housing and plug, and unlock the connector.
Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage.
(5) Remove M8 nuts (five places) fixing the inverter, then remove the inverter.
1-49
CHAPTER 1 CONTROLLER
9.3 Insuring Proper Thermal Transfer
The presence of contaminants or air voids created by surface inconsistencies in either the lift truck or the heat sink will degrade
the inverters capacity for heat transfer. The inverters performance is de-rated proportionally as its own thermal sensors reduce
its operation to protect it from damage due to excessive heating.
Contained within the software of the controls are several diagnostic status codes related to controller thermal performance.
Failure to follow these mounting recommendations increases the likelihood of encountering these status codes.
Careful surface preparation, including adequate application of thermal compound, as detailed in the following paragraphs,
must be completed during the installation of the controls. There are many techniques for applying thermal compound. One
approach is outlined below that has shown to apply a consistent thickness of material.
Necessary tools
Recommended use of the following components, or equivalent substitutions, during the control installation process:
(1) Thermal compound, (5P9837), maintained per the manufacturers recommendations and free of contaminants
(2) 3/32" notched trowel, such as an adhesive spreader, P/N SE000049
(3) Calibrated torque wrench (0 15 ft-lbs)
The inverters
During the manufacture of the control, the surface flatness is maintained at 0.005" per linear inch (not to exceed 0.025" per 10.0
inches). The surface finish of the control has a Ra (average roughness) of 64 (micro inches), or better. This finish is consistent
with cold rolled or extruded aluminum. Care should always be taken in the handling and storage of controllers. The base of the
control should be free from nicks, bumps, protrusions, or any other foreign object that would prevent the control from sitting
flush with the lift truck mounting surface. Examine the base of the control to verify that it is in good condition and free from
damage or contamination.
R CAUTION
Apply thin and even heat sink grease since it works to release generated heat from the inverter to the lift truck body.
1-50
CHAPTER 1 CONTROLLER
1-51
CHAPTER 1 CONTROLLER
Installation
(1) Wipe off the dirt and heat sink grease from the inverter mounting surface and remove dirt from the mounting surface and
the aluminum base paste of the inverter.
(2) Apply heat sink grease approx. 1 mm (0.04 in) thick to the area where the aluminum base plate of the inverter comes into
contact with the lift truck body.
R CAUTION
Apply thin and even heat sink grease since it works to release generated heat from the inverter to the lift truck body.
R CAUTION
Use the correct power cables and terminate marked cable ends to the correct terminals marked on the motor.
Cables terminated at the wrong terminals on the motor may cause the motor to rotate in the opposite direction when
activated.
R CAUTION
You need to hold the DSP card connector when installing the harness connector to prevent any damages to the DSP card.
Ensure the connector is seated and the latch is locked.
Forcibly pressing the connector may cause damage to the DSP card. Hold the connector housing and press the connector, it
may not be easy to lock.
Note:
- It is recommended to check or replace the inverters every 10,000 hours of service operation.
- It is recommended to torque the U, V, W, P, N, and F terminals after 30 days service and at 1000 hour intervals.
1-52
CHAPTER 1 CONTROLLER
9.4 Replacing DSP (Digital Signal Processor) Card
Removal
(1) Perform Steps 1 through 6 in Inverter Discharging Procedure.
R CAUTION
Make sure to discharge inverters before working on the electrical system.
(2) Push and lift up at the four corners of the card cover to
remove the cover.
(3) Disconnect the connector.
608613
R CAUTION
When disconnecting the connector, hold the connector housing and plug, and unlock the connector.
Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage.
608614
R CAUTION
Be careful not to damage mounted parts with the pliers since the card has a number of fragile parts.
1-53
CHAPTER 1 CONTROLLER
Installation
(1) Align the four mounting holes of the new DSP card with the plastic spacer positions and press it into place.
R CAUTION
Press at the card edges.
Make sure that the spacer lock works completely and the card cannot be removed.
608615
R CAUTION
Do not forcibly bend the flat cable. Insert its conductive surface in the direction shown in the illustration.
Also, confirm that the cable is not tilted.
R CAUTION
Do not push the flat cable by the inside of the inverter cover. Do not forcibly bend the flat cable.
Make sure that the cable will not be pinched underneath the cover. Confirm that the cover is completely locked.
(5) Install the cover while pushing the flat cable toward the
card side slightly.
608616
R CAUTION
Forcibly pressing the connector may cause damage to the DSP card. Hold the connector housing and press the connector, it
may not be easy to lock. Insert connectors surely until they are locked.
1-54
CHAPTER 1 CONTROLLER
9.5 Replacing Logic Unit
Removal
(1) Turn OFF the key switch.
(2) Disconnect the battery plug.
505635
1. Meter panel 3. GSE connector cap
2. Cup holder
(3) Disconnect the connector (CN1, CN2, CN3) from the logic card and the connector (CN4) from the power supply card.
4) 1
2
1) 2) 3)
505636
1. Logic unit 1) CN 1
2. MC main harness 2) CN 2
3) CN 3
4) CN 4
R CAUTION
When disconnecting the connector, hold the connector housing and plug, and unlock the connector.
Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage.
1-55
CHAPTER 1 CONTROLLER
1 608618
1. Bolt, Washer (2 pcs)
Installation
Follow the removal sequence in reverse.
1-56
CHAPTER 1 CONTROLLER
9.6 Replacing Logic Card
Installation 2
Follow the removal sequence in reverse. 1
608620
1. Heat sink 2. Logic card
1
608621
1. Grommet 2. Logic card
R CAUTION
When installing the logic card onto the logic unit case, carefully tighten the logic card and heat sink fixing screws to the
specified torque to avoid excessive stresses. Repair the heat sink first.
Note: Apply LOCTITE No.242 to M3 screws (five places) on the side of the logic unit when installing.
1-57
CHAPTER 1 CONTROLLER
9.7 Replacing Power Supply Card
Installation
1 2
Follow the removal sequence in reverse.
608622
1. Heat sink 2. Power supply card
608623
1. Grommet 2. Power supply card
R CAUTION
When installing the power supply card onto the logic unit case, carefully tighten the power supply card and heat sink fixing
screws to the specified torque to avoid excessive stresses. Apply a small amount of heat sink compound before installing.
Note: Apply LOCTITE No.242 to M3 screws (five places) on the side of the logic unit when installing.
1-58
CHAPTER 1 CONTROLLER
10. Basic Check
Always follow basic troubleshooting steps.
- Talk to the operator.
- Confirm his description of the problem with an operational check.
- Visually inspect cables, connectors, contactor tips, etc.
- Perform basic battery cables to frame resistance test. (at least 20 k ohm)
- Check battery condition.
Always check each option and write down the reading.
608624
1. Circuit tester 3. IC clip
2. Clamp meter
R WARNING
Disconnect the battery plug before inspecting or adjusting the controller.
R WARNING
To prevent accidental movement of the lift truck, place wood blocks under the lift truck to lift the front wheels off the ground.
Do not place wood blocks close to the front wheels.
(1) Tilt the mast fully BACKWARD. Place blocks under the mast, and tilt the mast FORWARD.
(2) Turn the key switch OFF.
(3) Disconnect the battery plug. Remove the cover.
(4) Reconnect the battery plug.
(5) Turn the key switch ON. Connect the negative terminal of the circuit tester to the V GND terminal of the card.
(6) Set the circuit tester to the 100-VDC range.
(7) Connect the positive terminal of the circuit tester to each pin of connectors.
Note: Be careful not to short-circuit pins. For normal voltage1-60 "Logic card voltage chart".
1-59
CHAPTER 1 CONTROLLER
Logic card voltage chart
Card side connector No.: CN1, Main harness side connector No.: E-02, E-03, and E-04
1-60
CHAPTER 1 CONTROLLER
Power supply card voltage chart
Card side connector No.: CN1, Main harness side connector No.: E-01
1-61
CHAPTER 1 CONTROLLER
10.3 Checking Contactor Coil
R CAUTION
Disconnect the battery plug and discharge the inverter before working on electrical system.
1-62
CHAPTER 1 CONTROLLER
10.5 Checking Inverter
R CAUTION
Disconnect the battery plug and discharge the inverter before working on electrical system.
- +
608626
Note: On diode scale you will read about .460 volts on all test.
The AC motor uses a common circuit for current flow in both loading and regeneration. This allows the following procedure to
confirm regeneration:
608627
Energy is generated when a motor is rotated with external force. The regeneration power is produced when this energy is
larger than the one that is consumed by the controller and motor. This means that the regeneration current is not measured if
the speed or load changes gradually.
1-63
CHAPTER 1 CONTROLLER
11. AC Motor System Basics
11.1 Feature of AC motor
The AC motor model lift trucks covered by this manual use AC motors (three-phase induction motors) as the traction motor
and pump motor. AC motors have the following advantages over DC motors:
(1) AC motors are simple in construction. As they have no such friction parts as brushes and commutators, daily maintenance
load is significantly reduced.
(2) AC motors are compatible with high-speed operation.
(3) An AC motor of a certain size produces higher power than a DC motor of the same size.
608629
Fig. 2
1-64
CHAPTER 1 CONTROLLER
11.3 Inverter
608630
(Fig. 3)
(Fig. 4)
S1 ON
S6 ON
608632
(Fig. 5)
(1) Problem
Clunking on direction changes.
Check
To see if stator is loose in frame of motor.
(2) Problem
Motor/lift truck chatters or shutters with wheel off floor and accelerator pedal slightly pressed; the wheels move in one
direction, then the other. Check forward and backward.
Check
Forward and reverse.
Check sensor bearing.
Check sensor bearing connector and wiring.
(3) Problem
Motor makes squealing sound like a bearing noise.
Check
Check sensor bearings to see if signals are OK. Check motor connections and stator windings. In order to check and isolate
bearing sounds using a stethoscope. If the sound is a general area sound then use a piece of flexible tubing or hose to locate
the source of the sounds. Stators can make a squealing sound when windings are not correct or when windings are open
(broken wire) or shorted.
(4) Problem
Motor has lower power, but reaches full speed.
Check
Check connections at motor terminals both out of motor and at the inverter connections. Check stator windings. You will need
a meter that checks insulation or can measure in the million ohm range. From (-) to (-). Normal readings are shown in the chart
below.
Normal readings
Phase line
Remarks Part Number Description
resistance (m) Nominal
2 to 4 20C (68F) 97N20-00300 Traction AC Motor
Traction AC Motor (for seat
2 to 4 20C (68F) 97N20-00700
operated parking brake option)
2 to 4 20C (68F) 97N20-01600 Pump AC Motor (for EE)
2 to 4 20C (68F) 97N20-00400 Pump AC Motor
2 to 4 20C (68F) 97N20-01500 Pump AC Motor (for EE)
1-66