Fb10 30p Dc70 Series Trs

02W-2201

FB-DC70

FB

SERIES

10P/15P/18P 20P/25P/30P

Contents 1. How to adjust SICOS 60 (Major point only)

.........................1

1-1 The name and function of mode select switch

.......................1

q Slow speed speed mode button button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 w Mode select button button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 e Up button button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 r Down button (2 functions) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1-2 How to set the each mode

...........................................2

q Speed setting mode mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 w Po Power wer setting mode mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 e Acceleratio Acceleration n feeling mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 r Option setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 t Language selection selection on LCD LCD display display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 y Safety monitor monitor symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1-3 Adjustment of starting current and current limitation

..................6

q Zero(0) adjusting adjusting for installed installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 w Adjustment of starting current current and current limitation limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Adjustment for other functions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

q Aut Auto-to o-torque rque up up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 w Safety circuit circuit for out of control control (contactor tripping) tripping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 e Po Power wer settin setting g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 r Hydraulic setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 t Switch back braking distance (Plugging/ Regenerative braking) . . . . . . . . . . . . . . . . . . . . 12 y Regenera Regenerative tive braking braking force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 u Adjustment of brightness brightness of the back back light on monitor monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 14 i Checking of speed sensor sensor output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 o Hour meter meter workin working g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 !0 Confirming the working of auto-power cut off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 !1 Adju Adjusting sting of battery battery voltag voltage e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3. Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 q Confirming Over loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 w Confirming the travel travel inhibit inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 e Confirming the lift locking locking working at over discharge discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 r Confirming the seat switch switch working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4. Outline of New EPS system for FB–DC70

. . . . . . . . . . . . . . . . . . . . . 18

4-1 Outline of New EPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4-3 Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 q Protection of overheat overheat for for motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 w Self diagnosis diagnosis function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-4 Checking and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 q Neutral adjustment adjustment of torque sensor sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 w Checking by voltage voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5. Self diagnosis history memory and I/O check

. . . . . . . . . . . . . . . . 22

5-1 Self diagnosis history memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5-2 I/O check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6. Practical trouble shooting (How to find the cause of problem) . . . . . . . . 31 6-1 Before starting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

q Location of negative negative circuit circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 w Layout of the connectors on MPU board and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6-2 Attention for troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

q Visual checking checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 w Fault Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 e Error message message and and possibl possible e def defecti ective ve parts parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6-3 Troubleshooting Procedure P rocedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6-4 Analysis of malfunction causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 q No indications indications are made on the the LCD display display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 w Indication of the LCD LCD display display is normal, but the truck truck abnormally travels travels . . . . . . . . . . . 38 e On the LCD display display,, error meassages meassages appear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6-5 Flowchart for troubleshooting

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7. Wiring and layout of control unit Reference

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1. How to adjust SICOS60 (Major point only) 1-1 The name name and and func functi tion on of of mode select switch q Slow speed mode button. Change to traveling mode. When the slow speed mode button is turned on, the speed is regulated to the preset speed. (5km/h–12km/h). (5km/h–12km/h).

Slow speed mode button

œWhen the slow speed mode button is turned on, the turtle mark is displayed on the monitor. O ff

On

w Mode select button. Change the select mode. Speed setting mode (SPEED) Power setting mode (POWER) Acceleration feeling mode (ACCEL)

Mode select button

M

e Up button (2 functions) Increase the parameter of each selected mode.



M

UP button

Showing the travel hour meter.



DISCHARGE

CAUTION

Be sure to check that the decimal point flashes when the hour meter counts by traveling or hydraulic operation.

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

5

O IL

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

ACCEL

100

SOFT

STD

FULL

TRAVEL

km

Travel hour meter

DISCHARGE

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

100

ACCEL

SOFT

TRAVEL

When hour meter counts, the decimal point flashes. – 1 –

STD

FULL

km

r Down button (2 functions). 



CAUTION

Decrease the parameter of each selected mode.

M Down button

Showing the hydraulic hour meter.

Be sure to check that the decimal point flashes when the hour meter counts by operating traveling or the hydraulic lever.

DISCHARGE

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

ACCEL

100

SOFT

STD

FULL

TRAVEL

km

Hydraulic hour meter

DISCHARGE

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

100

ACCEL

SOFT

TRAVEL

STD

FULL

km

When hour meter counts, the decimal point flashes.

1-2 How to set the each mode Mode select button

Press the mode select button M to adjust the each mode. œThe each mode can be changed by pressing the mode select button M as follows.

M

M

M

: Normal

M

: Speed setting mode

M

: Power setting mode

: Acceleration feeling mode

– 2 –

q Speed setting mode The travel speed can be set at 5km/h through 12km/h by every 1km/h. Up button for increasing, Down ton for decreasing.

NOTE

but-

M

When the slow speed mode button is off, the travel speed can not be regulated even if it is set. Also no display of preset speed and the “turtle” mark.

M

Down button

Up button

5

km/m

10

15

20

SPEED

POWER

50

75

100

ACCEL

SOFT

STD

FULL

w Power setting mode The power can be set at 3 steps, 100%, 75%, and 50% by pressing the Up button or Down button .

M

M

Down button

Up button

(50% – 75% – 100%)

The preset power is displayed “POWER” column on the display.

at

the

5

km/m

}

10

15

20

SPEED

POWER

50

75

100

ACCEL

SOFT

STD

FULL

Preset power

e Acceleration feeling mode The acceleration feeling mode can be set at 3 modes, Soft, Std (standard) and Full.

M

M

: Easy inching Down button : Normal

Up button

(SOFT – STD – FULL)

: Quick accelerator response 5

km/m

10

SPEED

NOTE

Better inching operation can be achieved by selecting the "soft" mode. The preset accelerator feeling is displayed at the “ACCEL” column on the display. – 3 –

POWER

50

75

100

ACCEL

15

20

} SOFT

STD

FULL

Preset accelerator feeling

r Option setting 1) Set the rotary switch RS1 to “7”, and turn the key switch on.

F 0 1 2

E

3

D

4

C

5

6 A 9 8 7

B

2) Press the mode select button M to shift the setting position. œThe setting position which flashes can be moved to the right by pressing the mode select button M.

Set RS1 to “7”

3) Press, the Up button to set : display “1”. the Down button to reset : display “0”. for each optional specification.

[

M

Mode select button NOTE

After finishing to set or reset, be sure to turn off the key switch and to return the rotary switch RS1 to “0”.

M NOTE

When replacing the MPU board, be sure to set the each function same as original setting.

Option Set

0

Not used – Over Drive without (Option) Hydrauric bywithout pass (Option) Regenerative with contactor Monitoring displayed Seat switch without Lift lock at off over discharge Not used –

M

Up button

Down button

1 –

DISCHARGE

TRAVEL

HYD

STEER

BATT

OIL

LOAD

BRAKE

with F 8 6 4 2 E

with without

0

km/m

5

10

15

20

SPEED

POWER

off with

50

75

100

ACCEL

SOFT

TRAVEL

STD

FULL

km

on –

If the bit of “Seat switch” is changed “0” to “1” on a standard truch, hydraulic system and indicator are normal, but the truck cannot travel. If all bits is changed “0” to “1” on the standard truck, 4 error messages appear on the indicator. A10 : FET7-OVER DRIVE B20 : FET4-HYD. BY pass D24 : PC. BOARD-AOS * TURN OFF KEY SWITCH *

Not used Over drive (Opt.) Hydraulic by-pass (Opt.) Regenerative contactor

Monitoring Seat switch Lift lock at over discharge Not used

NOTE

When replacing the MPU board, it is set “1” to each option setting for safety. Confirm the specification of the truck and set it properly.

NOTE

The option setting which is standard specification is set to “0”. For example, Regenerative braking system is equipped as standard. Therefore, setting “0” means “with regenerative brake” “1” means “without regenerative brake”. – 4 –

t Language selection on LCD display œEach language can be selected by this opera-

F 0 1 2

E

D

tion.

C

3

4

5

6 A 9 8 7

B

1) Set the rotary switch RS1 to “6” and turn the key switch on.

Set RS1 to “6”

2) Choose the each language shown below by pressing Up button or Down button .

M

M

Down button

NOTE

Up button

Displayed language when turning key switch on.

After finishing to set or reset, be sure to turn the key switch off and to return the rotary switch RS1 to “0”.

F 0 1 2

E

D

C

3

4

5

6 A 9 8 7

B

Set RS 1 to “5”

y Safety monitor symbol. œEach monitor symbol can be set by this operation

1) Set the rotary switch RS1 to “5”.

M

2) Use the mode select button M to shift the setting position.

Mode select button

œThe setting position which flashes can be

moved to the right by pressing the mode button M.

M DOWN button – 5 –

M

UP button

3) Press, the Up button to set : displayed “1”. the Down button to reset : displayed “0”. for each safety monitor symbol.

[

DISCHARGE

TRAVEL

F 8 6 4 2 E

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

100

ACCEL

SOFT

STD

TRAVEL

FULL

km

TRAVEL

: Travel BRAKE

HYD

: Hydraulic

Parking brake : LOAD

STEER

: Steering

Over load : OIL

BATT

: Battery

Oil level :

* For having GS battery and GS electrolyte level sensor only. NOTE

The symbol for Travel, Hyd, Steer and Brake are preset as a standard at the factory.(displayed “1”)

NOTE

After finishing to set or reset, be sure to turn the key switch off and to return the rotary switch RS1 to “0”.

1-3 Adjustment of starting current and current limitation q Zero(0) adjusting for installed Zero(0) adjusting is required for the installed current detector to adjust the starting current and current limitation correctly.

F 0 1 2

E

D

C

3

4

5

6 A 9 8 7

B

Battery electrolyte over 1.25 (at 20°C)

Set RS1 to “1”

1) Set the rotary switch RS1 to “1”, and turn the key switch on. 2) The each mode can be changed by pressing the mode select button M as follows.

M M

M

Mode select button

M M

– 6 –

3) Adjust If LEVEL, and Ia LEVEL to be “000A” at no motor current condition by pressing Up button or Down button CAUTION

As MPU board has an auto-zero level adjustment function, no need to re-adjust these mode normally. However, be sure to confirm it. 4) Press, the Up button when the indication shows minus( – ) value. the Down button when the indication shows plus (+) value.

M

M

Up button

Down button

Press Up button when indication on monitor shows minus( – ) value.

Press Down button when indication on monitor shows Plus (+) value.

5) After adjusting If GAIN and Ia GAIN, be sure to turn the key switch off and to set back the rotary switch RS1 to “0”. Initializing should be done by pressing the Up button and Down button simultaneously for approx. three (3) seconds. Then, each setting (SPEED, POWER, ACCEL) will be initial setting mode with showing “INITIALIZED” and a beep sound. NOTE

This "initialize" operation is also accepted by each manual setting of, SPEED : to 7km/h POWER : to 100% ACCEL : to STD

]

= “INITIALIZED”

M

Press Up and Down button simultaneously for approx. 3 seconds. 5

km/m

10

POWER

50

75

100

ACCEL

Initial setting mode

w Adjustment of starting current and current limitation 1) Be sure to check that the specific gravity of the battery electrolyte. It should be more than 1.25 at 20°C and the operation of “initialize” should be done, and initializing also finished. 2) Set the rotary switch RS1 to “2”, and turn the key switch on. œThe each mode can be changed by pressing the mode select button M as follows.

F 0 1 2

E

D

C

3

4

5

6 A 9 8 7

B

Set RS1 to “2”

M M

M Mode select button

– 7 –

15

20

SPEED

SOFT

STD

FULL

3) Adjusting staring current The “CURR START” will be shown after key switch on. 4) Operate the directional switch to forward, depress the foot brake. Then depress the accelerator pedal until the regenerative contactor just goes on, and hold at that position.

CAUTION

l l a W

When adjusting the starting current and current limitation, lock the traveling motor by operating as follows.  Park the truck against a wall, and touch the tip of forks to the wall.  Then apply the parking brake lever.  Depress the foot brake pedal.

5) Adjust the starting current on the monitor within specified range by pressing Up button or Down button . Model

Starting Current (A)

FB10P

35 ± 5

FB15P, 18P

45 ± 5

FB20P, 25P

50 ± 5

FB30P

45 ± 5

– 8 –

M

M

Down button

Up button

Press Down button when monitor indication shows higher than the specified value.

Press Up button when monitor indication shows lower than the specified value.

6) Adjusting current limitation Set the “CURR LIMIT” mode by pressing mode select button M. 7) Operate the directional switch to forward, depress the foot brake. Then depress the accelerator pedal all the way down and hold it. NOTE

CAUTION

l l a W

The current limitation should be read and adjusted within two (2) seconds, otherwise it will be increased by 130% for the automatic torque increase function. Then the forcible bypass contactor will be turned on.

When adjusting the starting current and current limitation, lock the traveling motor by operating as follows.  Park the truck against a wall, and touch the tip of forks to the wall.  Then apply the parking brake lever.  Depress the foot brake pedal. 8) Adjust the current limitation on the monitor within specified range by pressing Up button or Down button . Model

Current limitation (A)

FB10P

280 ± 5

FB15P, 18P

330 ± 5

FB20P, 25P

380 ± 5

FB30P

330 ± 5

M

NOTE

Use the clamp on meter as a reference when checking and adjusting. There may be some difference between the current value on monitor and the reading by the clamp on meter.

NOTE

After finishing the adjustment, be sure to return the rotary switch RS1 to “0”. – 9 –

M

Down button

Up button

Press Down button when monitor indication shows higher than the specified value.

Press Up button when monitor indication shows lower than the specified value.

The specification of each adjustment for FB-DC70 g d n e i l e v e p a r s T

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/ / /

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5 . 2 1 / 0 . 5 1

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2 3

/ / /

2 3

/ / /

2 3

/ / /

D T L Y I H T

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/ / /

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/ / /

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/

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/ / /

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/ / /

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/ / /

g e n e c i n ) g k a ( m g a r t s u l b i P d

0 . 6 0 . 5

0 . 6 0 . 5

0 . 6 0 . 5

0 . 6 0 . 5

t n o n i t ) e a ( r t A r u i i C m l

0 1 ± 0 8 2

0 1 ± 0 3 3

0 1 ± 0 8 3

0 1 ± 0 3 3

g t n ) i n e t r A r r a u ( t c S

5 ± 5 3

5 ± 5 4

5 ± 0 5

5 ± 5 4

P 0 1 B F

P 8 1 , P 5 1 B F

P 5 2 , P 0 2 B F

P 0 3 B F

) V (

E H H H S S H N E I C A S I N L N M N C A G E R A T P N R E P U A E F G S D J

E S H H N H E S C A S I H N I N M N C A L G E R A T P A N R E P U J E F G S D : : : : : : 0 1 2 3 4 5

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t e 0 s g n i r o 1 t i n o 1 m ( 5 - 1 1 S 1 R

0 0 0 ) g n i t 0 e t y l o r t c C e 0 l e 2 f t o a n y 5 o t t i t i 2 . n % v n t a 1 a e e t r i r 0 g n r r r m u 0 u l c a c 1 c i r i f h t t i g n r e o w c e n e t r e i r t r r o o p o u a M P S m t S C / °

d e s u t o N

d e s u t o N

d e s u t o N

d e s u t o N

d e s u t o N

•

V 8 4

– 10 –

•

•

L E D I K A O A O R L B

S . G y d l n n o a r y r o e s t t n a e s b l S e v G l e g e n t i y L v l a o E R r h t V E T c A D E T r e o l R Y T A F e T H S B *

g h k c c n t i o r i l o t t i i w s f n t l o a e e g r M S a

•

0 4 6 9 A B C D E

l e d o M

e g a u g n a L

°

0 S R

) n o i t a m r i f n o C (

K K K O K O G K O O N R G U U O G N I E H R N I R L C O R T O O O A I T I R W N T I N T R O N N O O E M O M C B M E U

6 1 S R

/ / /

6 4 0

. D 3 Y T H T A

3

/ / /

n

e i o c r t r o a f e e n k e g a r e b R k c g a G b n i G G h g c g t U N i

E N E E T G A E R R

/ / /

n o h c t i w s y e k f o n o i t a c i d n I

t e s n 0 o i t p 0 O ( 7 - 0 1 S 0 R

d e s u t o . N n o i t h a c c i s f i i d c . r e d e p e v s l l O d a r t a s n d i n g a t i s n e r b o f n o 0 i t t p e o s e ) . e m t r b p o o s t d O ( c l u f a o s t o ) n h e . s t o s s p a p - c g a O y e i n c ( b v t n i t i e c t e v l d i i a r s 1 r u e e d s n o u r a r n i o t t e d e t o v y g p t e e N O H r O S ” “

” “

2. Adjustment for other functions qAuto-torque up A: Specific gravity of the battery electrolyte: more than 1.25 at 20°C B: Make an initializing (Initialize mode setting) 1) Check the current limitation. 2) Confirm that the current limitation should be increased by 130% of the value of current limCurrent 130% itation after 3 seconds. limitation

Forcible by-pass contactor on

100% 3sec 2sec

wSafety circuit for out of control (contactor tripping) 1) Be sure to check that the forward and backward contactor has not gone in. 2) Make a jumper wire between a main terminal of bypass contactor. (Wire size about 0.5mm2) 3) Be sure to check the warning beap sound and the error massage on the display. 4) Confirm that even though operate the accelerator, after that the forward (backward) contactor will not go in.

ePower setting Specific gravity of the battery electrolyte: more than 1.25 at 20°C Set the power setting to 50% 1) Check the current limitation. 2) Be sure to check that the motor current becomes to about 70% of the current limitation.

– 11 –

rHydraulic setting Be sure to check that the each setting is set as listed on “The specification of each adjustment for FB-DC70” (p.10).

F 0 1 2

E

D

C

3

4

5

6 A 9 8 7

B

Set the rotary switch RS1 to “3”

1) Set the rotary switch RS1 to “3”.

2) The each mode can be changed by pressing the mode select button M and adjust the setting by up button or down button .

M

Mode select button

NOTE

After finishing the adjustment, be sure to return the rotary switch RS1 to “0”.

M M M M M

M M M M

tSwitch back braking distance (Plugging/Regenerative braking) A: Specific gravity of the battery electrolyte: more than 1.25 at 20°C B: Flat ground, Unladen, Full speed

F 0 1 2

E

D

C

3

4

5

6 A 9 8 7

B


1) Set the rotary switch RS1 to “4”, and adjust the braking force by pressing up button or . The each mode can be down button changed by pressing the mode select button M. (either plugging or Regenerative brake) 2) Be sure to check the regenerative contactor goes off when switch back braking operation is done, and goes on just before starting on reverse.

M

Mode select button

M M

– 12 –

M

3) Adjust the plugging braking distance by press. ing up button or down button The braking distance will be, .  shorten by pressing up button .  longer by pressing down button NOTE


M

M

Up button

Down button

For shorter distance.

For longer distance.

yRegenerative braking force A: Specific gravity of the battery electrolyte: more than 1.25 at 20°C B: Flat ground, Unladen, Full speed 1) Traveling forward with middle speed and release the foot from the accelerator pedal. 2) Depress the foot brake pedal lightly. 3) Be sure to check the forward contactor is off and reverse contactor is on, Then regenerative braking is worked.

F 0 1 2

E

D

C

3

4

5

6 A 9 8 7

B


1) Set the rotary switch RS1 to “4”, and change the mode of “BRAKE TRQ” by pressing mode select button M.

M

Mode select button

M M

M

2) Adjust the regenerative braking force by . pressing up button or down button The braking force will be, .  Strong by pressing up button .  Poor by pressing down button NOTE


– 13 –

M

M

Down button

Up button

For poor braking effect.

For strong braking effect.

uAdjustment of brightness of the back light on monitor

Turning it clockwise for bright contrast.

Adjust the brightness of the back light on monitor by the volume VR0. Turning it clockwise for bright contrast.

CFL VR0

iChecking of speed sensor output

F 0 1 2

E

D

1) Set the rotary switch RS1 to “C” and turn the key switch on. The each mode can be changed by pressing the mode select button M as follows.

C

B

3

4

5

6

A 9 8 7

Set the rotary switch RS1 to “C”

M M

M Mode select button

Sensor output 1 : left side

Traveling direction F : Forward, R : Reverse

Sensor output 2 : right side

Sensor output total (value of output 1+2)

2) Set the “SPD” (Speed sensor checking) mode. 3) Check the indication of sensor output by traveling. œNormally, the value of sensor output 1 and 2 should be the same when traveling.

NOTE



In case that the value of sensor output 1 or 2 is not varied when traveling. (=always shown “0”) Check the sensor or its wire harness connected to MPU board.



In case that the value of sensor output 1 and 2 are the same with no changing. Check and adjust the potentiometor for sensor 1 or 2 by the shims.



In case that the value of sensor output 1 plus 2 does not make a sensor output total. (=output 1+2≠total) It may be influenced by the noise. Please check some wire near the wire of sensor 1 and 2.



In case that the indication of traveling direction is opposite from the actual moving direction. Check the connection of sensor 1 and 2, They may be opposite.

After confirming the working, be sure to turn the key switch off and return the rotary switch RS1 to “0”.

– 14 –

oHour meter working 1) Connect the wireharness of [Blue/Red 1] and [Black] located inside the front cover. 2) Be sure to check that the decimal point flashes when the hour meter counts by traveling or hydraulic operation.

!0Confirming the working of auto-power cut off function 1) Turn the key switch on. 2) Be sure to check that the main power will be cut off after approx.15minutes automatically if there is no operation either traveling or hydraulic operation.

!1Adjusting of battery voltage Item (function)

Condition for checking

Check and adjustment procedure 1) Check the battery voltage at, + : Hyd. fuse, - : Minus ( – ) terminal in the control unit. 2) Set the rotary switch RS1 to “A”, and turn the key switch on. 3) Set to “VB LEVEL” mode by pressing mode select button M.

Battery voltage (for battery capacity indicator)

MSpecific gravity : more than 1.25 at 20°C

M

M

4) Adjust the “VB LEVEL” to be the same value checked at 1) by pressing Up or Down button.

CAUTION

– 15 –

The VOLTAGE figure will not be changed even if adjusting the VB LEVEL.

3. Option qConfirming Over loading 1) Lift up to the end and make a relief condition. 2) Confirm the display *REDUCE THE LOAD *.

wConfirming the travel inhibit 1) Connect the - line (black) to the connector [CN4-4pin] on the MPU board. 2) Confirm that the tuck does not travel when operating the traveling.

eConfirming the lift locking working at over discharge 1) Set the rotary switch RS1 to “7” and turn the key switch on. 2) Set 2nd bit of the lift lock at over discharge to “1”. 3) Supply the voltage of 30 – 36V to the battery plug. 4) Confirm  Battery capacity indicator : [Red] lamp turning on.  Indication on display : * CHAGE THE BATTERY*

CAUTION

NOTE

Lifting speed will be half. Then after ten minutes operation,  Battery capacity indicator : [Red] lamp flashes.  Indication on display : ✳CHARGE THE BATTERY✳ and lifting will be suspended.


– 16 –

F 0 1 2

E

D

3

4

C

5

6

B

A 9 8 7


DISCHARGE

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

100

ACCEL

SOFT

STD

TRAVEL

FULL

km

The lift locking at over discharge (2nd bit)

rConfirming the seat switch working F 0 1 2

E

1) Set the rotary switch RS1 to “7” and turn the key switch on. 2) Set 1st bit of the seat switch to “1”. 1) Operate the traveling without sitting on the seat. 2) Confirm the truck does not travel. NOTE


3

D

4

C

5

6 A 9 8 7

B


DISCHARGE

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

100

ACCEL

SOFT

TRAVEL

STD

FULL

km

Seat switch (1st bit)

– 17 –

4. Outline of New EPS system for FB – DC70 4-1 Outline of New EPS system

steering gear box

controller

motor

actuator

rear axle

The EPS system is constructed with steering gear box, new design potentiometer actuator, and controller (new design) above. The torque sensor in the steering gear box detects the opposite force from the steering tire when the steering wheel is operated, and send the signal which is proportioned with the force and direction to the controller. The controller controlls the magnitude and direction of the steering motor current. The steering motor creates the force by this current to assist the steering operation. When the shock is applied to the tire, the torque sensor detects it and the actuator creates the equivalent force against it. So, no kick back force is applied to the steering wheel.

– 18 –

4-2 Operation Actuator Ass’y Torque sensor

Steering Operation

+ –

Controller

Actuator

w

e

r

t

Torque sensor output

Motor current control

Output of motor torque

Assist force

Wheel steering

y

1) When the key switch is turned on, the contactor is activated and the power is supplied. 2) When the steering wheel is operated, the steering force is detected by the torque sensor and output the voltage corresponded for it. 3) The output voltage from the torque sensor is applied to the controller and converted to the current for the motor on the actuator. 4) The motor creates the output torque which is proportioned with the input current. 5) The output force of the actuator assists to steer the wheels. 6) The steering force is reduced by this assist force.

4-3 Feature qProtection of overheat for motor When the motor current continues over 25A for about 5 seconds, the motor output will be turned off automatically. When put back the input of torque sensor to neutral, it returns at normal control condition.

wSelf diagnosis function

DISCHARGE

1) If the problem is occurred at the torque sensor, scrolls the message of [C29:SENSOREPS TORQUE] on the display (Torque sensor error).

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

ACCEL

100

SOFT

STD

FULL

TRAVEL

2) If the problem is occurred at a main FET circuit in the EPS controller, scrolls the message of [C30: TR-EPS MAIN] on the display (chopper error).

DISCHARGE

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

100

ACCEL

SOFT

TRAVEL

– 19 –

km

STD

FULL

km

4-4 Checking and Adjustment

EPS controller

qNeutral adjustment of torque sensor 1) Turn the key switch off. 2) Jack up the rear wheels from the ground. 3) Open the side cover at right side. 4) Put the clamp meter to the wire [yellow] or [green] between EPS controller and EPS motor [DC range] 5) Turn the key switch on and measure the indication at the clamp meter without steering operation. (= at neutral steer) If the indication shows 0A, it is normal. 6) If any current is flown, adjust the potentiometer by the following procedure.

n e e r g

w o l l e y A

clamp meter d e r

k c a l b

EPS motor

1) Turn the key switch off and disconnect the battery plug. 2) Disconnect the 3P water proof type connector of EPS sensor. 3P water proof type connector (tab side)

1.5

k

potentiometer

EPS sensor ass’y

+ –

3) Check the resistance at sensor side (tab side) between, • q pin (Orange) and e pin (Black/Red) = Approx. 5k ............... A • q pin (Orange) and w pin (Green/Red) = Approx. 2.5k ...........B • w pin (Green/Red) and e pin (Black/Red) = Approx. 2.5k ......C

From EPS sensor (potentiometer)

q Orange w Green/Red e Black/Red

These should be even value.

q Blue 3

Tab

Rece

w Green/Blue 1 e White

To EPS controller

3P water proof type connector

4) Adjust it by removing or inserting a shim to be the even value between B and C above. NOTE

The resistance value may depend on the type of tester and each unit. – 20 –

5) Connect the battery plug and turn the key switch on. Check and confirm that there is no EPS motor current at the neutral steer by the above procedure, .

wChecking by voltage When it is difficult to adjust the torque sensor very precisely. Use this method. Neutral adjustment of the potentiometer can be checked by its output voltage. 1) Turn the key switch off. 2) Disconnect the connector of the torque sensor and put the adaptor for measuring voltage. NOTE

As the connector of the torque sensor is waterproof type, it is impossible to put the tester probe. Make an adapter by using the same type adapter.

3) Check the voltage at w pin [Green/Red or Green/Blue 1] of the adaptor. 4) Turn the key switch on and operate the steering wheel from right side end to left side end, then check the voltage. The following values are the standard.

right side end

0.8 V ± 0.3

neutral

2.5 V ± 0.3

left side end

4.2 V ± 0.3

From EPS sensor (potentiometer)

q Orange

q Blue 3

w Green/Red

Tab

e Black/Red

w Green/Blue 1

Rece

e White

3P water proof type connector

q pin w pin

Rece

e pin

Tab

Adaptor

Tab + probe to w pin (output)

– probe to e pin (negative) V

+ –

– 21 –

To EPS controller

5. Self diagnosis history memory and I/O check. 5-1 Self diagnosis history memory The total 34 error histories which have occurred at least once can be memorized. There are two (2) kind of information for this function. The one is to memorized the operated condition when the trouble has occurred (called “Format 1”), the other one is to memorize the each malfunction (called “Format 2”). œThe basic system of “Format 2” is same as the one adopted on SICOS 50/60 and A-SICOS for FBR-60 series.

OS C I -S W NE

DISCHARGE

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

OIL

5

LOAD

BRAKE

15

20

10

DISCHARGE

F 8 6 4 2 E

SPEED

POWER

50

75

100

ACCEL

SOFT

TRAVEL

STD

FULL

TRAVEL

HYD

STEER

0

km/m

BATT

OIL

5

LOAD

BRAKE

15

20

10

SPEED

POWER

50

75

100

ACCEL

km

SOFT

TRAVEL

STD

FULL

km

Memory and display for the operated condition when the trouble has occurred.

Memory and display for the each malfunction. *same as SICOS 50/60 and A-SICOS or FBR-60 series.

– 22 –

1) Set the rotary switch RS1 to “B”, and turn the key switch on. 2) Press the mode select button M to call the each mode.

F 0 1 2

E

D

C

3

4

5

6 A 9 8 7

B

Set RS 1 to “B” NOTE

Do not turn the key switch on/off when the rotary switch RS0 is set to “F” as the history memory is cleared.

M CAUTION

The truck can be moved even though the history memory is called. Mode select button

A: Format 1 of history memory 3) Press Up or Down the each history No..

button to change

M

M

DOWN button

UP button

History memory No. can be changed (called) by pressing Up/Down button.

DISCHARGE

F 8 6 4 2 E

TRAVEL

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

10

BRAKE

15

20

SPEED

POWER

50

75

100

ACCEL

SOFT

STD

TRAVEL

[1] : History No. (0-9) Each error is displayed in order. 0 : Latest error 9 : Oldest error * It is naturally cleared for the errors over 11th. The history No. can be changed by pressing UP/Down button.

FULL

km

[5] : Traveling mileage Traveling mileage will be displayed when some trouble happen.

[4] : Hydraulic motion mode No. Hydraulic motion (condition) is displayed when the trouble has occured. (see the page24 [2] Hydraulic motion (condition) mode No. in details) “

”

[3] : Traveling motion mode No. Traveling motion (condition) is displayed when the trouble has occured. (see the page24 “[1] Traveling motion (condition) mode No.” in details) [2] : Error No. (If “00” is displayed, there is no error memory) Error No. of error message is displayed (see the page35 table)

– 23 –

[1] Traveling motion mode No. Mode No.

Content

00

Neutral

01

Forward mode: Regenerative contactor OFF

02

Forward mode: Traveling contactor ON

03

Forward mode: Regenerative contactor ON

04

Forward mode: Traveling speed control

05

Forward mode: Bypass contactor ON

06

Forward mode: Bypass contactor OFF

07

Forward mode: Bypass control

08

Forward mode: Over driving contactor ON

09

Forward mode: Over driving contactor OFF

0A

Forward mode: Over driving control

0B

Forward mode: Pre-energizing

0C

Forward mode: Regenerative control

11

Reverse mode: Regenerative contactor OFF

12

Reverse mode: Traveling contactor ON

13

Reverse mode: Regenerative contactor ON

14

Reverse mode: Traveling speed control

15

Reverse mode: Bypass contactor ON

16

Reverse mode: Bypass contactor OFF

17

Reverse mode: Bypass control

18

Reverse mode: Over driving contactor ON

19

Reverse mode: Over driving contactor OFF

1A

Reverse mode: Over driving control

1B

Reverse mode: Pre-energizing

1C

Reverse mode: Regenerative control

[2] Hydraulic motion mode No. Mode No.

Content

0

Hydraulic neutral

1

Hydraulic control

2

Hydraulic bypass contactor ON

3

Hydraulic bypass contactor OFF

4

Hydraulic bypass control

– 24 –

B: Format 2 of history memory 3) Press Up or Down button to change (call) the each Error memory No..

M

If there has been a problem at least once, the bit shows “1”. If not, it shows “0” on the monitor.

M

DOWN button

trouble [ ““10”” . . .. .No .Troubled (at least once)

History memory No. can be changed (called) by pressing Up/Down button.

DISCHARGE

F 8 6 4 2 E

Error memory No.

7th bit

6th bit

TRAVEL

HYD

SPEED LIMIT

POWER

5th bit

STEER

0

50

BATT

OIL

LOAD

40 40

60

80

30

75

100

4th bit

ACCEL

SOFT

BRAKE

%

STD

2nd bit

A1 : FUSETRAVEL

A5 : A6 : FET9CONTACTORREVERSE FORWARD

A4 : FET10FORWARD

A3 : A2 : FET6CONTACTORREGEN REGEN

ERR1

A14 : SENSOR- A13 : ACCELCURRENT ACCELERATOR (ARMATURE)

A12 : TR-REGEN MAIN

A11 : TR-TRAVEL MAIN

ERR2

B21 : B22 : TR-HYD SWITCH-LIFT MAIN

B20 : FET4HYD. BYPASS

B19 : B18 : FET5CONTACTOR- HYD HYD

ERR3

*REDUCE THE LOAD*

ERR4

Not u sed

Not used

Not u sed

Not u sed

Not used

Not used

– 25 –

FULL

3rd bit

ERR0

*REFILL HYDRAULIC OIL*

UP button

1st bit

*FAIL HYD*

0 bit

*FAIL TRAVEL*

A10 : FET7- A9 : A8 : FET8CONTACTOR OVER DRIVE BYPASS BYPASS

A7 : CONTACTORREVERSE

B17 : FUSE HYD

A16 : SENSORSPEED

A15 : SENSORCURRENT (FIELD)

C30 : TR-EPS MAIN

C29 : SENSOREPS TORQUE

C31 : FUSE EPS

Not use d

Not use d

Not used

*REPLENISH *REFILL REFINED WATER FOR BRAKE OIL* BATTERY*

1) Turn the key switch OFF.

OFF

ON START

2) Set the rotary switch RS0 to “F”. F 0 1 2

E

3

D

C

B

4

5

6

A 9 8 7

Set the rotary switch RS0 to “F”

3) Turn the key switch ON. (To START) OFF

ON START

4) Turn the key switch OFF.

OFF

5) Set the rotary switch RS0 at the original position.

6) Make sure to be clear it.

– 26 –

ON

5-2 I/O check I/O (Input/Output) check is the function that the input and output signal for the microcomputer can be displayed on the LCD by the binary code of [1] or [0] to check if each part is normal. Approx. 90 points of input/output signals can be checked.

Set RS 1 to “E” F 0 1 2

E

1) Set the rotary switch RS1 to “E”, and turn the key switch on.

D

C

Select the port No.

M After confirming the I/O check, be sure to turn the key switch off and return the rotary switch RS1 to “0”.

M

DOWN button

For example, in case of the port No.10 (=IOM10), the following screen is displayed.

DISCHARGE

F 8 6 4 2 E

T RAVEL

HYD

STEER

0

km/m

BATT

5

OIL

LOAD

10

15

BRAKE

20

SPEED

POWER

50

75

1 00

ACCEL

SOFT

T RAVEL

Directional switch for reverse 1 : ON 0 : OFF

STD

FULL

km

Not used Not used

Directional switch for forward 1 : ON 0 : OFF Directional switch for neutral 1 : Neutral 0 : Not Neutral

– 27 –

4

5

6 A 9 8 7

B

2) Select the port by pressing Up or Down button. Refer to the I/O table for the detail of each port. NOTE

3

Not used Not used Not used

UP button

I/O TABLE (1) PORT NO.

RS1-E NO.OD

RS1-E NO.OE

RS1-E NO.OF

RS1-E NO.OC

BIT

IN/OUT

0

IN

Button

[UP]

0: Up [brake closed]

1

IN

Button

[Mode select]

0 : select

2

IN

Button

[Down]

0 : Down

3

IN

Button

[Slow speed]

1 : Slow speed

4

IN

Hydraulic oil level

0 : Detection

5

IN

Brake oil level

0 : Detection

6

IN

Overload

0 : Detection

7

IN

Not used

0

IN

Switch

[Brake]

0 : ON [brake closed]

1

IN

Switch

[Lift 1]

1 : ON

2

IN

Switch

[Lift 2]

1 : ON

3

IN

Switch

[Tilt]

1 : ON

4

IN

Switch

[Attachment 1]

1 : ON

5

IN

Switch

[Attachment 2]

1 : ON

6

IN

Switch

[Attachment 3]

1 : ON

7

IN

Switch

[Parking brake]

1 : ON

0

IN

Contact

[Regenerative]

1 : ON

1

IN

Contact

[Hydraulic]

1 : ON

2

IN

Contact

[Forward]

0 : ON

3

IN

Contact

[Reverse]

0 : ON

4

CONTENTS

REMARKS

Not used

5

IN

Fuse

[Travel]

0 : Fault

6

IN

Fuse

[Hydraulic]

0 : Fault

7

IN

Fuse

[EPS]

0 : Fault

0

IN

Rotary switch RS-0

EX) 0000 : "0"

1

IN

Rotary switch RS-0

0000 : "1"

2

IN

Rotary switch RS-0

0000 : "3"

3

IN

Rotary switch RS-0

0000 : "8"

4

IN

Rotary switch RS-1

EX) 0000 : "0"

5

IN

Rotary switch RS-1

0001 : "1"

6

IN

Rotary switch RS-1

0011 : "3"

7

IN

Rotary switch RS-1

1000 : "8"

– 28 –

I/O TABLE (2) PORT NO.

RS1-E NO.10

RS1-E NO.11

RS1-E NO.00 NO.01

BIT

IN/OUT

CONTENTS

1

IN

Not used

2

IN

Not used

3

IN

Not used

4

IN

Not used

5

IN

Directional

[Neutral]

1 : Neutral

6

IN

Directional

[Forward]

1 : Forward

7

IN

Directional

[Reverse]

1 : Reverse

0

Not used

1

Not used

2

Not used

3

Not used

4

IN

Hour mete clear

1 : Clear

5

IN

Hour meter count stop

1 : Stop

6

IN

Hour meter option

1 : Counting

7

OUT

Current [Armature] Use 10 bits by binary system. "1 and 0 bits of NO.01 and 7 to 0 bits of NO.00" \ \ \ \ \ \ \ \ \ \

bit

1 0 NO.01

7 6 5 4 3 2 1 0 NO.00

1.2 - 4.0V

/

\ \ \ \ \ \ \ \ \ \

bit

1 0 NO.03

7 6 5 4 3 2 1 0 NO.02

0 - 500A

1.2 - 4.0V

/

Voltage [Battery] Use 10 bits by binary system. "1 and 0 bits of NO.05 and 7 to 0 bits of NO.04" \ \ \ \ \ \ \ \ \ \

bit

1 0 NO.05

7 6 5 4 3 2 1 0 NO.04

Analog / Digital conversion

RS1-E NO.06 NO.07

0 - 500A

Current [Field] Use 10 bits by binary system. "1 and 0 bits of NO.03 and 7 to 0 bits of NO.020"


RS1-E NO.04 NO.05

[Hydraulic]

Not used


RS1-E NO.02 NO.03

REMARKS

0 - 55V

0 - 5V

/

Voltage [Battery capacity] Use 10 bits by binary system. "1 and 0 bits of NO.07 and 7 to 0 bits of NO.06" \ \ \ \ \ \ \ \ \ \

bit

1 0 NO.07

7 6 5 4 3 2 1 0 NO.06

Analog / Digital conversion – 29 –

44.6 - 55V

1.2 - 4.0V

/

I/O TABLE (3) Accelerator voltage 1 Use 10 bits by binary system. "1 and 0 bits of NO.09 and 7 to 0 bits of NO.08"

RS1-E NO.08 NO.09

\ \ \ \ \ \ \ \ \ \

bit

1 0

7 6 5 4 3 2 10

NO.09

NO.08


0 - 0.5V

Accelerator voltage 2 Use 10 bits by binary system. "1 and 0 bits of NO.0B and 7 to 0 bits of NO.0A"

RS1-E NO.0A NO.0B

\ \ \ \ \ \ \ \ \ \

bit

1 0

7 6 5 4 3 2 10

NO.0B

NO.0A


PORT NO.

RS1-E NO.18

0 - 0.5V

BIT

IN/OUT

0

OUT

Contactor select

[Forward]

1 : ON

1

OUT

Contactor select

[Reverse]

1 : ON

2

OUT

Contactor select

[By-pass]

1 : ON

3

OUT

Contactor select

[Overdrive]

1 : ON

4

OUT

Contactor select

[Regenerative]

1 : ON

5

OUT

Contactor select

[Hydraulic]

1 : ON

6

OUT

Contactor select

[Hydraulic by-pass]

1 : ON

7

CONTENTS

Not used

– 30 –

REMARKS

6. Practical trouble shooting (How to find the cause of problem) 6-1 Before starting Basically the same procedure can be used as the previous SICOS-50 for the troubleshooting. However, the display unit, MPU board, accelerator etc. are changed in design and some new functions are added. I/O checking also has the different procedure to recall on the display unit. The details of the procedure are explained in the following sections. In this section, the following matters should be understood.

qLocation of negative circuit Fit the negative(–) probe of circuit tester to; Minus (–) terminal in the control unit or the ribbon wire of M4 contactor when checking the voltage. Battery : 48V(FB10-25P) 72V (FB30P) (The auxiliary 48 volts output is equipped in the case of the 72 volts battery.

V

Capacitor : 100V A V

F1

N

2200µF X 1 (FB10/15/18P) X 2 (FB20/25P) X 3 (FB30P)

A N

D1

275A

D2

C V

M4

M1 A

M3

IF

IA

: r ) o 5 t s 2 - ) i s 0 0 e ( 3 ( r 1 g 4 2 n i X X z i Ω Ω g r 2 . 2 . e 2 n 2 e - W D e r 0 W 0 R P 3 4

FC1 M2

H W

D3

<(–) line>

PB83-62 Pre-energizing

BU

( – ) terminal or ribbon wire of M4 contactor

Capacitor : 100V 2200µF X 1 (FB10/15/18P) X 2 (FB20/25P) X 3 (FB30P)

D4 F2 PA

M7 FC2

(–) probe

Battery ( – ) terminal

M4 contactor ribbon Wire (Bypass contactor)

– 31 –

wLayout of the connectors on MPU board and others 1) MIC connector MPU board

PB84-XX

CN1

CN2

CN3

CN4

CN5

CN6

A 6 5 4 3 14 13 12 11 10 9

CN1

2 8

1 7

4 3 10 9

10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

CN2

CN5

CN6

10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

CN3

CN4

8

7

2 6

1 5

View from A (receptacle/harness side) Each No. in the connector indicates pin No. For example, CN3-6 Pin No. (see picture in above) Connector No. (CN1-CN6)

NOTE

Pin location for connectors are shown from insertion side of pins.

– 32 –

2) Waterproof type connector Each No. in the connector indicates pin No. . 12 pin type

10 pin type

8 pin type

6 pin type

3 pin type

2 pin type

Rece side

6 5 4 3 2 1 12 11 10 9 8 7

5 4 3 2 1 10 9 8 7 6

4 3 2 1 8 7 6 5

3 2 1 6 5 4

3 2 1

2 1

Tab side

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8

1 2 3 4 5 6

1 2 3

1 2

3) Other connector Each No. in the connector indicates pin No. . 6 pin type

Rece side

1 4

2 5

3 6

Tab side

3 6

2 5

1 4

4 pin type (1)

1

2

3

4

4 pin type (2)

1 3

2 4

2 4

1 3

6-2 Attention for the troubleshooting NOTE

Initially correctly understand content and phenomena of problems. After understanding customer’s operator sayings and actual forklift truck status as correctly as possible ( including problems that often occur).

qVisual checking The visual checking may help to find the main cause, check the each parts carefully. Example) Is there any parts or wire which is burned out ? How about the looseness of connector ?

– 33 –

2 pin type

1 2

wFault finding When the cause is unknown even after visual check, safety guard

1) Place the rigid blocks under the outer mast to stable the truck. 2) Tilt the mast forward by pushing the tilt lever to rise the front wheels. NOTE

Place the safety guards for safety !  Do not rotate the drive wheels off the floor at high speed, because the drive motor and internal parts of the gear box could be damaged.  Measurement of voltage should be done in a short time.  Be sure to disconnect the battery plug when connecting the volt-ohm meter, repairing and replacing parts. 

– 34 –

Rigid block

eError message and Possible defective part Error No. and error message is displayed. Symbol Error (Flash for defect) No.

Message

Possible defective part

3

* FAIL TRAVEL. *

FET, D2, MPU board ... etc.

4

* FAIL HYD. *

FET, MPU board ... etc.

* TURN OFF KEY SWITCH *

linked with other message

5

A1 : FUSE-TRAVEL.

Travel fuse

6

A2 : FET6-REGEN.

Regen. contactor coil, MPU board

7

A3 : CONTACTOR-REGEN.

Regen. contactor, MPU board

8

A4 : FET10-FORWARD

Forward contactor coil(Left), MPU board

9

A5 : CONTACTOR-FORWARD

Forward contactor

10

A6 : FET9-REVERSE

Reverse contactor coil (Left), MPU board

11

A7 : CONTACTOR-REVERSE

Reverse contactor

12

A8 : FET8-BYPASS

Bypass contactor coil, MPU board

13

A9 : CONTACTOR-BYPASS

Bypass contactor, MPU board

14

A10 : FET7-OVER DRIVE

15

A11 : TR-TRAVEL. MAIN

FET, Bypass contactor, MPU board

16

A12 : TR-REGEN. MAIN

Pre-energizing board, Resistor

17

A13 : ACCEL-ACCELERATOR

Accel., Directional sw.

18

A14 : SENSOR-CURRENT (ARMATURE)

Current sensor (Ia)

19

A15 : SENSOR-CURRENT (FIELD)

Current sensor (If)

20

A16 : SENSOR-SPEED

Speed sensor

21

B17 : FUSE-HYD.

Hydraulic fuse

22

B18 : FET5-HYD.

Hydraulic contactor coil, MPU board

23

B19 : CONTACTOR-HYD.

Hydraulic contactor, MPU board

24

B20 : FET4-HYD. BYPASS

25

B21 : TR-HYD. MAIN

Hydraulic FET, MPU board

26

B22 : SWITCH-LIFT

Lift micro switch (1), (2)

27

B23 : SENSOR-CURRENT (HYD.)

TRAVEL

HYD

Remarks

Half speed

Half speed

Half speed

Half speed

Half speed

D24 : PC. BOARD-AOS * FAIL AOS * D25 : TR-AOS D26 : RELAY-AOS D27 : POTENTIO-HYD. LEVER D28 : POTENTIO-MAST STEER

34

C29 : SENSOR-EPS TORQUE

35

C30 : TR-EPS MAIN

36

C31 : FUSE-EPS

37

C32 : FET3-EPS

38

C33 : CONTACTOR-EPS

* The following parts cannot be diagnosed and displayed. 1) Diodes : D1, D2, D3 and D4 5) Motors 2) Capacitors for surge absorbing 6) A part of MPU board 3) A part of current sensor 7) A part of microswitches 4) A part of pre-energizing board 8) Wire harness

9) Connectors 10) Back contacts of forward / reverse contactror 11) LCD display

* The error messages for the current sensor an d the pre-energizing board are depend on the defect conditions to display. – 35 –

Symbol Error (Flash for defect) No.

Message

Possible defective par t

Remarks

39

* REFILL HYDRAULIC OIL *

Shortage of hydraulic oil

40

* REDUCE THE LOAD *

Overloaded

Opt.

41

* REFILL BRAKE OIL *

Shortage of brake oil

Opt.

42

* REPLENISH REFINED WATER FOR BATTERY *

Shortage of battery electrolyte

* CHARGE THE BATTERY *

Need to charge battery

* RELEASE ACCEL. TO NEUTRAL *

Accelerator is operated before power on

* OFF HYD. LEVER TO NEUTRAL *

Hyd. lever is operated before power on

6-3 Troubleshooting Procedure Correct understanding of the content and phenomena of the problems is a great prerequisite. However, after understanding them, the indications on the display (safety monitor, error message, I/O checking ) become effective means.

An indication is not made on the LCD display. No indications or abnormal.  Indication of the LCD display is normal. No error message appears.  Indication of the LCD display is normal. Error messages appears. 

These cases are assumed. Considering them and referring to the error messages and circuit diagram (system wiring), trace the malfunctions. Approximate guess is required. Thoughtless tracing greatly wastes time. The basic considerations are the same as the SICOS50/60. However, glance over this manual and roughly take note of the key matters.

6-4 Analysis of malfunction causes It was previously stated that initial understanding of the content and phenomena of the problems is an important point in finding the malfunctions. With prerequisite that a malfunction results in any error, the following checkings lead to a start for the procedure. – 36 –

GS batt.

Check for truck status  LCD display status 1) Check to ensure that the display is normal. (Ordinary display or non-display) 2) Check to ensure that the display indicates error messages. 

Next, the malfunctions can be classified mainly into following three:  No indications are made on the LCD display.  Indication of the LCD display is normal, but the truck abnormally travels.  On the LCD display, error messages appear. The following are the counter measures.

qNo indications are made on the LCD display. In this case, only the display does not make an indication. Whether the forklift truck normally travels or not is a judgement diverge. 1) If only indication problems exist;  LCD display  MPU board that is controlling LCD.  Cables including connector between MPU and LCD shall be checked. 2) Without LCD indications, the forklift truck abnormally travels. (In many cases, the truck does not travel quite). The power circuits seem to have problems.  At the LCD lighting on the MPU board, the MPU board, wirings or fuses are judged to have problems. PROCEDURE:Example, No LCD

Can truck travel and operate hydraulics normally?

Are all lit? LED0:12V LED1: 5V LED2:CPU run

No

Yes

Replace LCD dispraly. Yes

Yes

Checking for power line. F4 fuse, Mctt replay, CN2-6 pin, CN5-20 pin, CN5-10 pin.

Is LCD indication made? Yes

Check for MPU board or wirings.

– 37 –

No Replace MPU board.

wIndication of the LCD display is normal, but the truck abnormally travels. In this case, especially checking for malfunctions of the truck must be done. They are largely classified into two(2): Traveling and Hydraulic malfunctions. 1) Truck traveling status  The truck does not travel.  The truck rushes out.  The electric braking (plugging) force is weak. If the LCD display indication is normal and the traveling system has an error, the following checkings must be initially done.  Check to ensure that all adjustments have been done. (See 1-3 Adjustment of starting current and current limitation)  Check to ensure that the option setting is correct.  Check to ensure that the hour meter display is normal. Check for the parts which are not self-diagnosed regarding travel, (See 6-2 eError message and Possible defective part) 2) Hydraulic malfunctions  A hydraulic motion is not made.  The hydraulic speed control is impossible. If the hydraulic systems have errors, perform checking in the same way as the traveling systems.  Check to ensure that all adjustments have been done. (See 1-3 Adjustment of starting current and current limitation)  Check for malfunctions of the option and hour meter display.

eOn the LCD display, error messages appear. In this case, with reference to Section 6 Practical trouble shooting. Please try checking. The detailed procedure will be notified to you soon later. Main signal lines for error message will be attached to the system wiring base. Please refer to it.

– 38 –

6-5 Flowchart for troubleshooting q Check point 1) Is model select correct? 2) Check the specification.  With option.  Special truck? After checking the above, start to troubleshoot.

CAUTION

CAUTION

When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.

1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit.

w Contents of flowchart ERROR NO.1 ERROR NO.2 ERROR NO.3 ERROR NO.4 ERROR NO.5 ERROR NO.7 ERROR NO.9 ERROR NO.11 ERROR NO.13 ERROR NO.16 ERROR NO.18 ERROR NO.20 ERROR NO.22 ERROR NO.24 ERROR NO.26 ERROR NO.35

*RELEASE ACCEL TO NEUTRAL* *OFF HYD. LEVER TO NEUTRAL* *FAIL TRAVEL* *TURN OFF KEY SWITCH* *FAIL HYD.* *TURN OFF KEY SWITCH* A1:FUSE-TRAVEL ERROR NO.6 A3:CONTACTOR-REGEN. ERROR NO.8 A5:CONTACTOR-FORWARD ERROR NO.10 A7:CONTACTOR-REVERSE ERROR NO.12 A9:CONTACTOR-BYPASS ERROR NO.15 A12:TR-REGEN. MAIN ERROR NO.17 A14:SENSOR-CURRENT(ARMATURE) ERROR NO.19 A16:SENSOR-SPEED ERROR NO.21 A18:FET5-HYD. ERROR NO.23 B20:FET4-HYD. BYPASS ERROR NO.25 B22:SWITCH-LIFT ERROR NO.34 C30:TR-EPS MAIN ERROR NO.36

– 39 –

A2:FET6-REGEN. A4:FET10-FORWARD A6:FET9-REVERSE A8:FET8-BYPASS A11:TR-TRAVEL MAIN A13:ACCEL-ACCELERATOR A15:SENSOR-CURRENT(FIELD) A17:FUSE-HYD. B19:CONTACTOR-HYD. B21:TR-HYD. MAIN C29:SENSOR-EPS TORQUE C31:FUSE-EPS

Error No.1

* RELEASE ACCEL TO NEUTRAL *

LCD Display

*RELEASE ACCEL TO NEUTRAL* Operate Accelerator before turning on Key switch?

No

No

Slit plate normal? Yes

Yes

Return the accelerator to the neutral position. Then operate it again.

Adjust.

Replace the accelerator printed board.

Operation become normal?

No

Yes

This situation is occurred by the neutral safety function. This is not problem. This function warns to the operator to take the correct procedure to operate.

END

No

Repair.

The following each wiring between Accelerator and MPU board is normal? Accelerator PB-CN3-4 (Red4) Accelerator PB-CN 3-5 (Brown/Yellow1) Accelerator PB -CN3-14 (Black/Yellow) Accelerator PB-CN4-1 (Red/Green3) Accelerator PB-CN4-2 (Green/Black1) Accelerator PB-CN4-9 (Black1) Yes

Replace MPU board.

CAUTION

CAUTION


1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 40 –

Error No.2

* OFF HYD. LEVER TO NEUTRAL *

LCD Display

*OFF HYD. LEVER TO NEUTRAL* No

Operate the hydraulic lever before turning the key switch?

Turn off key switch.

Yes

Return the hydraulic lever to the neutral position. Then operate it again.

Set RS1 at [E].

Turn on key switch.

This situation is occurred by the neutral safety function. This is not problem. This function warns to the operator to take the correct procedure to operate.

Select [IOM 0E].

No

Release the hydraulic lever. Any bit shows [1]?

Replace MPU board.

Yes No Hyd. micro switch normal?

Repair.

Yes The following wiring between Hyd. Micro SW and MPU board are normal? Lift1 micro SW-CN6-6 (Brown/Red1) Lift2 micro SW-CN6-14(Blue/Yellow2) Tilt micro SW-CN6-7 (Red3) Reach micro SW-CN6-15 (Yellow/Black) Attachment micro SW-CN6-8 (Green/White3) Attachment micro SW-CN6-16 (Blue/Yelloew3)

No

Yes

7 6 5 4 3 2 1 0 Replace Micro SW of the bit that shows [1].

IOM 0E/

W W S S T T W W M M S W W E E H S S S 1 M M C T 2 T T H H A L I F F I C C E T I L L A A R T T T T A A

No Operation become normal? Yes END

– 41 –

Replace MPU board.

Repair.

Error No.3

* FAIL TRAVEL* *TURN OFF KEY SWITCH*

LCD Display FAIL TRAVEL * * TURN OFF KEY SWITCH * *

The other error messages appear at the same time?

No

The contact of M4 Bypass contactor is welded?

Yes

See the flowchart in which the error message appears and check it.

No

Yes

The “Green/Blue” wire between drain of Travel FET and CN3-19 pin is normal?

Replace the contact of Bypass contactor.

No

Yes

Repair. No

q Turn off key switch. w Disconnect


the connector of Travel FET “4P Green”.

Yes

Turn on key switch. END No

The error messages “*FAIL TRAVEL*” appears? Yes

Replace MPU board. Replace Travel FET.

CAUTION

CAUTION



Error No.4

* FAIL HYD.* *TURN OFF KEY SWITCH*

LCD Display FAIL HYD. * * TURN OFF KEY SWITCH * *

The other error messages appear at the same time?

No

No

Hyd. Bypass installed? Yes

Yes

See the flowchart in which the error message appears and check it.

No

The contact of M7 contractor welded? Yes

The “Green/White” wire between drain of Hyd. FET and CN3-10 pin is normal?

No

Yes

Repair. Replace M7 contractor.

q Turn off the key switch.

w Disconnect the connector. (2P Black)

Turn on key switch.

No

The error message “*FAIL HYD.* *TURN OFF KEY SWITCH*” appears? Yes

Replace MU board. Replace Hyd. FET.

– 43 –

Error No.5

A1:FUSE TRAVEL

LCD Display A1:FUSE TRAVEL


Fuse F1 for travel is normal?

No

Yes q Turn off the key switch.

Replace Fuse for travel.

w Set RS1 at [E]. e Turn on key switch and

select I/O port [IOM 0F].

This bit 5 shows [1] on LCD display? LCD display

7 6 5 4

3 2 1 0

No

IOM 0F 1:normal

0:abnormal

The Brown/White wire between F1 (fuse) and CN2-1 pin is normal? “

Yes

”

No

Yes

Replace MPU board.

Repair. Replace MPU board.

CAUTION

CAUTION



Error No.6

A2:FET6-REGEN.

LCD Display A2:FET6-REGEN. OPTION SET Adjust. RS1

Regenerative function installed?

[7]

7 6 5 4

Check OPTION SET.

3 2 1 0

No

OPTION

Yes Bit 4 shows [0]?

The error message appears after turning on key switch Yes without traveling?

Yes

No

Replace MPU board. q Set the bit 4 at [0].

Then reset RS1 at [0]. w Turn off and on key switch.

q Turn off key switch. w Disconnect CN1 from MPU

board. Replace MPU board.

The “Red/Green1” wire between coil of M3 contactor and CN1-3 pin is normal?

Yes

The coil resistance of M3 contactor is normal? 32.5-35.5Ω Yes

No

Repair.

No

Replace MPU board.

– 45 –

Replace M3 contactor and MPU board at the same time.

Error No.7

A3:CONTACTOR-REGEN.

LCD Display A3:CONTACTOR-REGEN. OPTION SET Adjust.

Regenerative function is

No

installed?

RS1

[7]

7 6 5 4

Check OPTION SET.

3 2 1 0

OPTION Yes Bit 4 shows [0]? Yes


q Set the bit 4 at [0].

The contact of Regen. contactor (M3) is welded?

Then reset RS1 at [0]. w Turn off and on key switch. No

Yes

Replace M3 Contactor.

Replace MPU board.

The error message appears at the moment when key switch, Foot switch and Accelerator are turned on?

No


Yes


The “Blue2” wire between contact of M3 contactor and CN4-15 pin is damaged?

No

Yes

No

END

Yes

Replace MPU board. Repair. The connection of M3 contactor is bad ?

No

Yes

Replace MPU board.


– 46 –

No

Error No.8

A4:FET10-FORWARD

LCD Display A4:FET10-FORWARD

The error message appears after turning on key switch without traveling.

No

Replace MPU board.

Yes


board.

The “Red1” wire between coil of M1 contactor and CN2-3 pin is normal?

No

Repair.

Yes

The coil resistance of M1 contactor is normal? 32.5-35.5Ω

No


Yes

Replace MPU board.

CAUTION

CAUTION


1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner par ts of Control unit. – 47 –

Error No.9

A5:CONTACTOR-FORWARD

LCD Display A5:CONTACTOR-FORWARD

Turn on key switch. Yes

The truck can travel when operating the accelerator after pushing the lever forward?

No

Replace M1 contactor.

Yes

The “Yellow/White2” wire between contact of M1 contactor and CN3-18 pin is normal? And also the “Green/Blue2” wire between contact of M2 contactor and CN3-9 pin is normal?

No

Repair.

Yes

Replace MPU board.

CAUTION

CAUTION



Error No.10

A6:FET9-REVERSE

LCD Display A6:FET9-REVERSE


No

Replace MPU board.

Yes


board.

The “Red/White1” wire between coil of M2 contactor and CN2-4 pin is short-circuited with the other wire?

No

Repair.

Yes


No


Yes

Replace MPU board.

– 49 –

Error No.11

A7:CONTACTOR-REVERSE

LCD Display A7:CONTACTOR-REVERSE


The truck can travel when operating the accelerator after pushing the lever forward?

No


Yes

The “Yellow/White2” wire between contact of M1 contactor and CN3-18 pin is normal? And also the “Green/Blue2” wire between contact of M2 contactor and CN3-9 pin is normal?

No

Repair.

Yes

Replace MPU board.

CAUTION

CAUTION



Error No.12

A8:FET8-BYPASS

LCD Display A8:FET8-BYPASS


No

Replace MPU board.

Yes


board.

The “Red/Black1” wire between coil of M4 contactor and CN1-1 pin is short-circuited with the other wire?

No

Repair.

Yes


No


Yes

Replace MPU board.

– 51 –

Error No.13

A9:CONTACTOR-BYPASS

LCD Display A9:CONTACTOR-BYPASS

The error message of “*FAIL TRAVEL*” appear at the same time?

No


Yes

The contact of M4 contactor welded?

No

Yes

The “Green/Blue” wire between drain of Travel FET and CN3-19 pin is normal?

Replace the contact of M4 contactor.

No

Repair.

Yes No

q Turn off key switch


w Disconnect the connector of

Travel FET (4P Green).

Yes

END Turn on key switch.

The error message of “*FAIL TRAVEL*” appear?

No

Yes


CAUTION

CAUTION



Error No.15

A11:TR-TRAVEL MAIN

LCD Display A11:TR-TRAVEL MAIN

The error message of “*FAIL TRAVEL*” appears at the same time?

No

The “Green/Blue” wire between contactor of Travel FET and CN3-19 pin is normal?

Yes

No

Repair.

Yes

Replace Travel FET.

The contact of M4 contactor welded?

No

Yes

Replace the contact of M4 contactor.

The “Green/Blue” wire between contactor of Travel FET and CN3-19 pin is normal?

No

Operation become normal? Yes

No

Repair.

Yes

END

q Turn off key switch w Disconnect the connector of

Travel FET (4P Green).

Turn on key switch.

The error message of “*FAIL TRAVEL*” appears?

No

Yes


– 53 –

Error No.16

A12:TR-REGEN. MAIN

LCD Display A12:TR-REGEN. MAIN No

Regen. contactor (M4) is installed?

Replace MPU board.

Yes

Resistors for pre-energizing are normal? 48V : 2.2Ω, 30W (4 pcs.) 24V : 1.0Ω, 30W (2 pcs.)

No

Replace.

Yes

The following 2mm2 wires are normal? (short-circuited or broken?) q “Red” wire between contact of M3 contactor and the resistors for pre-energizing. w “Blue” wire between the resistors and pre-energizing PB. e “White” wire between pre-energizing PB and D2 [A].

No

Repair.

Yes

The following wires are normal? (short-circuited or broken?) q “Blue/Red” wire between pre-energizing PB and MPU board (CN4-8 pin). w “White/Red1” wire between pre-energizing PB and MPU board (CN4-16 pin). e “Brown/White” wire between D2 [K] and MPU board (CN2-1 pin).

No

Repair.

Yes

Replace pre-energizing PB.

No


Replace MPU board.

Yes

END

CAUTION

CAUTION



Error No.17

A13:ACCEL-ACCELERATOR 7 6 5 4 3 2 1 0

LCD Display IOM 10

A13:ACCEL-ACCELERATOR

L D D A R W A B F T N

D E Accel, bit S U (Gray code) O N DECIMAL

q Turn off key switch. w Set RS1 at [E].

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

e Turn on key switch, and

select I/O port [IOM 10].

Bit1-Bit4 change like the right table when pulling and/or pushing Accelerator? No Bit Push Release Pull

7 0 0 1

6 1 0 0

5 0 Forward 1 Neutral 0 Backward Yes

0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1

0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0

0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0

0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0

Turn off key switch. Connector 6P MPU board of Accelerator 1 pin – CN3-14 (Black/Yellow) 2 pin – CN3-5 (Brown/Yellow1) 3 pin – CN3-4 (Red4) 4 pin – CN4-9 (Black1) 5 pin – CN4-2 (Green/Black1) 6 pin – CN4-1 (Red/Green3) Each wire of the above is broken or bad connector?

Micro switch of Directional switch is normal?

No

No

Yes

Adjust or Replace.

Repair.

Yes

Directional MPU board switch Forward – CN6-12 (Brown2) Backward – CN6-5 (White/Red2) Neutral – CN6-4 (Brown/Black1) Each wire of the above is broken or bad connector?

Replace Accelerator PB.


No

No

Yes Yes

Replace MPU board. END

CAUTION

I/O check of Accelerator signal is displayed by Gray code. It is not Binary code. Pay attention. – 55 –

Replace MPU board.

Repair.

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Error No.18

A14:SENSOR-CURRENT (ARMATURE)

LCD Display A14:SENSOR CURRENT (ARMATURE)

Turn off key switch. [la] level can be adjust as 0[A]?

No

Yes

q Set RS1 at [1]. w Turn on key switch.

Adjust at 0[A].

[la] level of current sensor is 0[A]?

No

The following wires are normal? q “Red/Black3” wire between Current sensor and CN3-1 pin. w “Blue” wire between Current sensor and CN3-2 pin. e “Black/Red1” wire between Current sensor and CN3-11 pin.

Yes

Replace MPU board.


No

Yes

Yes

END

No

Repair.

Replace Current sensor [la]. Replace Current sensor [la]. Operation become normal?

No

Yes

END

CAUTION

CAUTION

Replace MPU board.



Error No.19

A15:SENSOR-CURRENT (FIELD)

LCD Display A15:SENSOR CURRENT (FIELD)

Turn off key switch. [lf] level can be adjust as 0[A]?

No

Yes

q Set RS1 at [1]. w Turn on key switch.

Adjust at 0[A].

[lf] level of current sensor is 0[A]?

No

The following wires are normal? q “Red/Yellow3” wire between Current sensor and CN3-3 pin. w “Yellow/Red2” wire between Current sensor and CN3-12 pin. e “Black2” wire between Current sensor and CN3-13 pin.

Yes

Replace MPU board.


No

Yes

Yes

END

No

Repair.

Replace Current sensor [lf]. Replace Current sensor [lf]. Operation become normal?

No

Yes

END

– 57 –

Replace MPU board.

Error No.20 A16:SENSOR-SPEED

LCD Display A16:SENSOR-SPEED

Speed sensor1 and Speed sensor2 are installed normally?

No

Adjust.

Yes

The following wires are normal? q “White1” wire between Speed sensor1 and MPU board (CN5-3 pin). w “Black/White1” wire between Speed sensor1 and MPU board (CN5-13 pin). e “White2” wire between Speed sensor2 and MPU board (CN5-4 pin). r “Black/Yellow1” wire between Speed sensor2 and MPU board (CN5-14 pin).

No

Repair.

Yes

Replace Speed sensor1 and Speed sensor2.

No


Replace MPU board.

Yes

END

CAUTION

CAUTION


1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit.

– 58 –

Error No.21

B17:FUSE-HYD.

LCD Display B17:FUSE-HYD.


Hyd. fuse F2 is normal?

No

Yes q Turn off the key switch.

Replace.



This bit6 shows [1] on LCD display? LCD display

7 6 5 4

3 2 1 0

No

IOM 0F/ 1:normal

0:abnormal Yes

The Green/Black wire between F2 (fuse) and CN2-5 pin is normal? “

”

No

Yes

Replace MPU board.

Replace MPU board.

– 59 –

Replace. (Damage or bad connection)

Error No.22

B18:FET5-HYD.

LCD Display A18:FET-HYD.

The error message appears when turning on key switch without traveling.

No

Replace MPU board.

Yes


board.

The “Red2” wire between coil of M6 contactor and CN1-4 pin is normal?

No

Repair.

Yes


No

Replace MPU board.

Yes


CAUTION

CAUTION



Error No.23

B19:CONTACTOR-HYD.

LCD Display A19:CONTACTOR-HYD.

No

No

Hyd. operation is normal?

Hyd. contactor (M6) can work?


Yes

Yes

The contact of M6 contactor is conductive?

No


Yes

The “Brown/Red” wire between contact of M6 contactor and CN3-8 pin is normal?

No

Repair.

Yes

Replace MPU board.

The contact of M6 contactor is welded?

No

The “Brown/Red” wire between contact of M6 contactor and CN3-8 pin is normal?

Yes


Yes

Replace MPU board.

– 61 –

No

Repair.

Error No.24 B20:FET4-HYD. BYPASS

LCD Display B20:FET4-HYD. BYPASS

Hyd. bypass system is installed?

OPTION SET Adjust. No

RS1

[7]

7 6 5 4

Check OPTION SET.

3 2 1 0

No

OPTION Yes Bit 5 shows [0]?

Turn off key switch. Yes

The error message appears after turning on key switch without traveling?

Replace MPU board. No

Replace MPU board. q Set the bit 5 at [0].

Yes

Then reset RS1 at [0]. w Turn off and on key switch.

q Turn off key switch. w Disconnect CN1 from

MPU board.

The “Red/White2” wire between coil of M7 contactor and CN1-5 pin is normal?

No

Repair.

Yes


No

Replace MPU board.

Yes


CAUTION

CAUTION



Error No.25

B21:TR-HYD. MAIN

LCD Display B21:TR-HYD. MAIN

The error message of “*FAIL HYD.*” appears at the same time?

No


No

Repair.

Yes

Yes

Replace Hyd. FET. Hyd. bypass system is installed.

No

Yes

Hyd. bypass contactor is welded?


No

Yes

No

Repair.

Yes q Turn off key switch. w Disconnect Gate “4P Red” of


Hyd. FET.

No

Turn on key switch.


The error message of “*FAIL HYD.*” appears on LCD?

No

Yes

END

Replace MPU board. Replace Hyd. FET.

– 63 –

Error No.26

B22:SWITCH-LIFT

LCD Display B22:SWITCH-LIFT

Lift(2) Micro switch is installed normally?

q Turn off key switch. w Set RS1 at [E].

No

Adjust.

Yes

The “Green/Yellow” wire between Lift(2) and CN6-14 pin is normal?


No

Repair.

Yes

Bit2 shows [0] when not operating Hyd. levers? LCD display

7 6 5 4

No

Replace Lift (2) Micro switch.

3 2 1 0

IOM 0E/

No


Yes

Replace MPU board. Bit2 changes to [1] after Bit1 changes to [1] when operating Hyd. levers? LCD display

7 6 5 4

3 2 1 0

END

No

IOM 0E/

7 6 5 4

3 2 1 0

IOM 0E/ Yes

Micro switch which does not change to [1] is installed normally?

No

Adjust.

Yes

The wire of which Micro switch is abnormal? q Between Lift(1) and CN6-6 “Brown/Red1”. w Between Lift(2) and CN6-14 “Blue/Yellow2”.

No

Yes

Replace MPU board. Replace the Micro switch which is abnormal.

Repair.

No


Replace MPU board. END

– 64 –

Error No.34

C29:SENSOR-EPS TORQUE

LCD Display C29:SENSOR-EPS TORQUE


The “Yellow/White1” wire between 4 pin of 10 P water-resistant connector of EPS controller and CN5-15 pin is normal?

No

Repair.

Yes

The “Blue3”, “Green/Blue1”, “White” wires between EPS controller and EPS sensor is damaged or broken?

No

Repair.

Yes

Check the resistance at sensor side (tab side) between, • q pin (Orange) and e pin (Black/Red) = Approx. 5kΩ ................... A • q pin (Orange) and w pin (Green/Red) = Approx. 2.5kΩ .............. B • w pin (Green/Red) and e pin (Black/Red) = Approx. 2.5kΩ .............. C

No

Adjust EPS sensor by removing or insterting a shim to be even value between B and C.

Yes NOTE

Replace EPS controller.

Refer to page 20.

No


Replace MPU board.

Yes

END

CAUTION

CAUTION



Error No.35

C30:TR-EPS MAIN

LCD Display C30:TR-EPS MAIN

The “Blue/Black” wire between 2 pin of 10 P water-resistant connector and CN5-5 pin is shortcircuited with other wires?

No

Replace EPS controller.

Yes

No


Replace MPU board.

Yes

Repair.

END

CAUTION

CAUTION



Error No.36

C31:FUSE-EPS

LCD Display C31:FUSE-EPS


EPS fuse F3 is normal?

No

Yes q Turn off the key switch

Replace EPS fuse.



Bit 7 shows [1] on LCD display? LCD display

7 6 5 4

3 2 1 0

No

IOM 0F/ 1:normal

0:abnormal

The Brown/Yellow wire between F3 (fuse) and CN2-2 pin is normal? “

Yes

”

No

Yes

Replace MPU board.

Repair. Replace MPU board.

– 67 –

7. Wiring and layout of control unit

– 68 –

FB10-25P FB30P

<5>

Note: 1.Terminal symbols :Terminal :Lead bar :Plug :Receptacle

<2>

> > 6 4 < <

M1

M3 <8>

2P

2P

WH

WH

2P

2P

2 H W E Y

WH

M4

M2

2P > 7 <

WH

2.The terminal is fixed in place by the fitting for the connector. 3. Connect only if a GS battery is installed.

M6

2P

2 U B N G

WH

170020-2 170021-2

2P WH

WH D R N B

> > 3 3 < 1 <

<6>

CF

4PWH

F

FB10P

FB20/25/30P

F

WH*

A

<3>

PA > 4 <

WHRD1

A

Only FB30P

D1

4PWH

PF

> 2 1 <

S+

> 3 1 <

> 2 <

Controller Ass y.,EPS

H+

’

<9>

40A

275A

D R

275A

4 K B U B

<11>

<5>

FB15/18

FET Comp.

D+

FET Comp.

M7

RD*

<10> > 1 <

<8>

2 B U

E Y N B

2P

E Y D R

Only FB10-25P (FB30P has no this line)

WH > 7 <

A

Refertonote2

Pre-energizing ✻

H W K B

> 1 <

H W E Y

BU

T+ H W N B

Board Comp.,MPU

4P GN

GN

RD

4P

4P

1 Refertonote3

1

1

3

Harness,Controller

Harness mark/color Red Black Green Yellow White Brown Blue Gray Pink

2

RD BK GN YE WH BN BU GY PK

FB10-25P : 24200-68871 FB30P : 24200-68941

Wire, Lead ( <1>-<13> ) 4P

2P

4P

6P

WH

WH

WH

WH

FB10-25P

FB30P

Ex) BKWH (=Black/White) Black colored harness with White line.

White line Black color

To Harness,Body

For Std.

10P Water resistant

2P TipeX

FB10P

24200-68792

FB15/18P

24200-68802

FB20/25P

24200-68812

FB30P

24200-68822

For EEC

24200-68832 24200-68842

24200-68852 24200-68862

FB10-30P-DC70 CONTROL UNIT WIRING

– 75 –

B Contactor



1 2

1 2

Plug 2P WH

Plug 2P WH

30B 29B

23B 25B

1 2

16B A

A

A

1

2

3


3

A

1

2

3

1 N U B G H D R W

1 2

Plug 2P WH

Plug 2P WH

2 H W E Y

28B 37B

32B 35B

3

A

A

1

2

3

1 K D B R H W

A

8

2 U B N G

24B 27B

NOTE: 1. Lead wire # :AVS 0.3mm 2 2 ✻ :AVS 0.85mm :KIV 2.0mm 2 Others :AV S0.5mm 2

15B

A

Plug 2P WH

8

A

1 2

17B

3

A

A

1

2

3

1 1 H H W W D N R B

3

A

A

1

2

3

1 N K G B H D R W

*

8

D R N B

2. The location of the pin is as viewed from the inserting side. : Braid wire under 25mm pitch.

3.

3

2 D D R R H W

4. Do not use sure-plugs and receptacles.

White line Black color

A MPU board # # 3 1 K # D B 1 R D U K R B B 0 1

# 3 E Y D R

0 0 1 1

0 1

# 1 D # R 2 E K Y B

1 2 3 4

A

A

A

A

1B

3B

5B

4B

2B

6B

Plug 2P WH

F Terminal

10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11

14P

10P

20P

A

8

35A

33A

31A

29A

27A

25A

12D

21C

21A

18A

16A

14A

12A

10A

8A

6A

4A

2A

B

H

H

B

B

B

H

H

H

K

B

M

K

N

H

E

E

E

4 K B U B

37A

32A

30A

28A

26A

24A

23A

22A

20A

19A

17A

15A

13A

11A

9A

7A

5A

3A

1A

B

B

B

B

C

B

B

C

C

M

B

B

M

K

H

H

E

E

E

14 7 13 6 12 5 11 4 10 3 9 2 8 1 4 1

1 2

F

26B

I

39B 38B

1 2 3 4

C Fuse

3

5 4 3 2 1 10 9 8 7 6

2

40B

4P A

2

7 6 5 4 3 2 1 14 13 12 11 10 9 8

3

1

I,H A

E

3

8

J

A

4P

* * D U R B

0 0 1 1

1 2 3 4

1 2 3 4

1

1 D * R H H W W

G Resistor

N G H W

4 4 4 4 4 1 1 1 1 1

4 1

D 1 2 2 1 U R D D K N B H R R B G H D D W N G R R W

4 1

1 K B D R

10 5 9 4 8 3 7 2 6 1

3

G

F

38A

40A

✻

4 4 E E H Y Y W D D K K R R B B

2 U B 8

3 3 3 3

H

43B

H

42B

Plug 4P GN

* D R 8

8

20B

E Y N B

4 E Y D R

6 6 6

6 6 6 6

6 6 6 6

6 6 6 6

6 6 6

6

A

8

H W N B

# # # # # # H U 2 2 D D H K U H 1 E 4 2 E Y D 3 1 1 1 3 B B W B U H R R W W K R K E D U D K N K U E Y N N B N B B Y R B R B N W E B B B Y B G G G Y D E K D R Y B R

G

1 D D H R R W 2 H U U D B W B R 3

3

3

3

✻

1 2 1 E E K D 4 Y Y B R D N K D N R B B R G 3

3

3 3

3

1 2 3 4

1 2 3 4

1 2 3 4 5 6

C

J

A

L

44A

41B

I

42A

C

K,A

44C

12C

43A

A

7B

8B

F

A,A

A

A

40C

21B

9B

31B

D H H W R W K N U B G B

U B K N U B G B 3

3

3

3

1 2 3 4

A

A,H

33B

12B

3

H W E Y

3

1

1 2 3 4

A

A

11B

14B

A

1

A

13B

18B

I Pre-energizing PB J Diode

19B

CONTROL UNIT HARNESS

8

10B 10C

H

N

41A

L Battery( – )

6

Plug 4P WH

Cap 4P WH

Cap 6P BK

Cap 4p GN

Cap 4P RD

1 2 3 4

2 1 4 3

3 2 1 6 5 4

2 1 4 3

2 1 4 3

N

10D

H External terminal FB10-25P-DC70

H W K B

A

H W E Y

A

39A

1 2 3 4

– 76 –

H,H

8

Current sensor

3

1 2 3 4

44B

A

20 10 19 9 1 8 8 1 7 7 1 6 6 1 5 5 1 4 4 1 3 3 1 2 2 1 1 1

4 4 4 4 4 4 4 4 4 4 1 1 1 1 1 1 1 1 1 1

1 4 K 1 K 1 H E H H H K B H B D W Y W B H W R N W W D B D N U W N B D R R B B R

D * R * U U H B B W 3

22B

K

FET comp. (travel)

N Body earth Refer to note 4

M

FET comp. (hidraulic)

B Contactor



1 2

1 2

Plug 2P WH

Plug 2P WH

30B 29B

23B 25B

1 2

16B


A

1

2

3

3

1

2

3

1 U N B G H D W R

White line

A

Plug 2P WH

Plug 2P WH

28B 37B

32B 35B

3

A

A

1

2

3

1 K D B R H W

A

8

24B 27B

2 H W E Y

NOTE: 1. Lead wire # :AVS 0.3mm 2 2 ✻ :AVS 0.85mm :KIV 2.0mm 2 Others :AV S0.5mm 2

15B

A

Plug 2P WH

8

A

1 2

17B

A

A

1 2

2 U B N G

3

A

A

1

2

3

1 1 H H W W D N R B

3

A

1

2

3

1 N K G B D H R W

*

8

A

D R N B

2. The location of the pin is as viewed from the inserting side. : Braid wire under 25mm pitch.

3.

3

2 D D R R H W

4. Do not use sure-plugs and receptacles.

Black color

A MPU board # # 3 1 K # D B 1 R D U K R B B 0 1

# 3 E Y D R

0 0 1 1

0 1

# 1 D # R 2 E K Y B

1 2 3 4

A

A

A

A

1B

3B

5B

4B

8

I,H

A

A

2B

6B

1 2 3 4

3

4P

A

1 2 3 4

2

J

I

Plug 2P WH

36A

35A

D

B

33A

10P

G

A

31A

H

29A

H

27A

B

Resistor

25A

B

12D

B

20P

21C

H

21A

H

18A

H

16A

K

14A

B

12A

M

8

10A

K

8A

N

6A

H

4A

E

4 K B U B

2A

E

E

34A

32A

30A

28A

26A

24A

23A

22A

20A

19A

17A

15A

13A

11A

9A

7A

5A

3A

1A

B

D

B

B

B

C

B

B

C

C

M

B

B

M

K

H

H

E

E

E

4 4 1 1

1 2

N E G Y H U B W

4 4 4 4 4 4 4 1 1 1 1 1 1 1

D 2 1 2 2 1 U R H D D K N B R R B G H H W D N D D W W R G R R

4 1

1 K B D R

10 5 9 4 8 3 7 2 6 1

6 6 6

1 4 K 1 K 1 H E H H H K B H B D Y W W B H W R W W D N D N N U D W R B R B B B R

6 6 6 6

6 6 6 6

6 6 6 6

6 6 6

3

3

1 2 3 4 G

F

38A

40A

H W K K B B

8

H

43B

✻

2 U B

H

42B

* D R 8

Plug 4P

GN

G

3 3

1 2 L

1 D D H 2 R R W U H U D B W B R 3

3

J

41B

3

3

1 2 3 4 I

42A

3

A

7B

8B

I Pre-energizing PB

J Diode

8

H W N B

6

3

3

3

D H H W R W K N U B G B

Plug 2P WH

34B 36B A

A

1

2

3

3

2 H E W Y D U R B

3

3

1 2 3 4

A

A,H

33B

12B

3

H W E Y

3

1

1 2 3 4

A

A

11B

14B

1

A

H W E Y

13B

K,A

F

A,A

A

A

A

A

12C

40C

21B

9B

31B

18B

19B

39A

1 2 3 4

E Y N B

A

# # # # # H U 2 2 D D H K U H 1 E 4 # E Y D 2 3 1 1 1 3 B B W B U H R R W W R K E D U D K N K U E Y K N N B N W B B Y R B R B B B B Y N G G G E D E K D B Y R Y B R

U B K N U B G B

1 2 3 4 5 6 A

43A

3 3

20B 8

✻

1 2 1 E E K D 4 Y Y B R D N K D N R B B R G 3

1 2

A

20 10 19 9 1 8 8 1 7 7 1 6 6 1 5 5 1 4 4 1 3 3 1 2 2 1 1 1

4 4 4 4 4 4 4 4 4 4 1 1 1 1 1 1 1 1 1 1

D * R * U U H B B W 3

D Contactor

26B

37A

14 7 13 6 12 5 11 4 10 3 9 2 8 1

E Current sensor

C Fuse

3

10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11

22B

14P

39B 38B

F

2

5 4 3 2 1 10 9 8 7 6

3

1

40B

F Terminal

1

7 6 5 4 3 2 1 14 13 12 11 10 9 8

* * D U R B

0 0 1 1

1 2 3 4

4P

1 D * R H H W W

H W K B

A

8

10B

H

10C

41A

N

L Battery( – )

6 Plug 2P WH

Cap4P

Cap 6P

WH

BK

Cap 4P RD

Cap 4P GN

N

10D

1 2

2 1 4 3

3 2 1 6 5 4

H External terminal

2 1 4 3

K

FET comp. (travel)

2 1 4 3

N Body earth Refer to note 4

M

FET comp. (hidraulic)

FB30P-DC70 CONTROL UNIT HARNESS

– 77 –

Reference Connector for MPU board Double lock plate pushing part

1. Pin layout of housing

Locking lever Rib for preventing inverse insertion

6 5 4

Double lock plate

3 2 1

14 13 12 11 10 9 8 7

CN1 (gray) [P/No.37010-21040] Ratchet part 4 3

Plug housing

2 1

CN3, 4, 5 6

10 9 8 7 6 5

CN2 (gray) [P/No.37010-21030]

(2) Crimping terminals 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11

CN3 (black) CN5 (black) [P/No.37010-21020]

Housing lance fixing part

Contacting part (inside box)

Wire barrel 8 7 6 5 4 3 2 1

Insulation barrel

16 15 14 13 12 11 10 9

CN1&CN2 [P/No. 37010-21480]

CN4 (black) CN6 (black) [P/No.37010-21010]

2. Names of parts (1) housing

Housing lance fixing part

Contacting part (inside box) Wire barrel

Double lock plate pushing part

Insulation barrel

Locking lever

CN3, 4, 5, 6 [P/No. 37010-21490]

Double lock plate

Ratchet part

Plug housing

CN1&CN2

– 79 –

3. Insertion terminal into housing (1) With the locking lever of housing upward and the crimping part of terminal upward, insert the housing into corresponding port. (Fig.1) CAUTION

When it is impossible to insert the terminal easily, do not force to insert it. At first, check the corresponding port. When inserting forcedly, the housing will be damaged at the housing. Pay attention to insertion of terminal.

Locking lever Plug housing

(3) Press the crimping part of the double lock plate. The plate will go down and release from the ratchet part and will sound snapping. And after finishing the inserting the terminal, pull the wire lightly to make sure the locking. When the double lock plate would work correctly, the condition would be like as Fig.4.

CAUTION

When there are some unlocked terminals, the double lock plate would not work correctly, the plate would be one side locking and the ratchet would be raised at one side Remove the terminal by using the ejection tool and do over again correctly.

Double lock plate pressed part Double lock part Double lock part

Pull the wire lightly

Crimping part

Insulation barrel Housing lance

Terminal

[Completed double locking]

Fig.1

(2) Verify the terminal is locked correctly into the housing. When inserting the terminal like as Fig.2, the terminal which the crimping part is placed in the middle of the retainer would come to lose, insert the terminal into the housing like as Fig.3. When the terminal is locked, it would sound snapping. And after inserting the terminal, pull the wire lightly to make sure the locking it.

Fig.4

There a gap on normal condition

The inserting groove for ejection tool

[Completed double locking]

[Incompleted detente locking] [One side locking of ratchet] Fig.5

4. Pulling terminal CAUTION

When remove the terminal for doing over again, use the specified pulling tool.

Pull the wire lightly

(1) Release the double locking (Fig.6) q Insert the jig into the groove . w Lay it to the direction of arrow and bend the wall of housing, and then rise the plate crimping part and remove the ratchet. Repeat the same way at the opposite side also. CAUTION

[Unlocked condition of terminal]

[Correct locked condition of terminal]

Fig.2

Fig.3

– 80 –

Do not vent the wall of housing strongly, it will come to be damaged.

Fb10 30p Dc70 Series Trs

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