MAIN CONTROLLER

Variation

(1) There are two controller models, as shown in the table

below. Each model has different module combination.

Hydraulic
Voltage Configuration
control

1 Chopper FC MT-1A, MH-1 and MC-1

80 V
2 Contactor MT-1A and MC-2

(2) There are one traction controller, one hydraulic

controller, and one contactor module.

Model Remarks

Traction MT-1A 80 V 400 A max.

Hydraulic MH-1 80 V 450 A max. selectable by

setup option group 3

Contactor MC-1 Line contactor, fuse (drive and

pump) and switches

(3) The setup options (group 3) are set according to vehicle

weight (3.0 and 3.5 ton). The maximum vehicle speed
varies depending on load weight, as shown in the table
below. The climbing ability is 15% for both models.

Truck model FB30K FB35K

Travel speeds
16 km/h (10 mph) 16 km/h (10 mph)
with load

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MAIN CONTROLLER

Outline of Traction Controller

The traction controller is the heart of the forklift truck

operating system.
The logic card contains judgement-making functions, and is
equipped with a battery discharge indicator and a
malfunction diagnostic function.
The traction controller is used to operate the drive motor.

208261

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 MAIN CONTROLLER

Outline of Hydraulic Controller

The hydraulic controller is connected with the traction

controller. The logic card contains judgement making
functions, and is equipped with a malfunction diagnostic
function. The hydraulic controller is used to operate the
pump motor and proportioning solenoids for finger control
system.

208262

3-3
MAIN CONTROLLER

Outline of Contactor Module

The contactor module has function of main switch and

circuit protector. One or two contactors are operated by the
traction controller. The DRS switch on this module will be
operated in setting, self-diagnostics and checking history
folder.

208263

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 MAIN CONTROLLER

Traction Controller Components

208261

1 Drive card 6 Drive IGBT (T1)

2 Temperature sensor 7 Current sensor (CS1, ARMATURE)
3 Head capacitor 8 Current sensor (CS2, FIELD)
4 Traction control logic card 9 H bridge card
5 Regeneration IGBT (T2)

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MAIN CONTROLLER

Hydraulic Controller Components

208262

1 Drive card 5 Hydraulic control logic card

2 Drive IGBT (T1P) 6 Pump diode (D1P, D2P)
3 Temperature sensor 7 Current sensor (CS)
4 Head capacitor

3-6
 MAIN CONTROLLER

Contactor Module Components

208263

1 Pump fuse (50A) 4 Line contactor

2 Steering fuse (325A) 5 DRS switch (for malfunction diagnostics and
3 Drive fuse (325A) program option setting)

3-7
MAIN CONTROLLER

Traction Control Logic Card

208265

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 MAIN CONTROLLER

Hydraulic Control Logic Card

208264

3-9
MAIN CONTROLLER

Drive Card

Traction controller

208266

Hydraulic controller

208267

3-10
 MAIN CONTROLLER

H bridge Card

208268

3-11
MAIN CONTROLLER

Operation Outline Drive System

(1) Power ON, default condition Neutral position

Turning on the key switch supplies power to the
logic card and display unit. The display unit shows
three hourmeters in sequence, then resumes the
normal display mode.
About one second after power is supplied to the
logic card, the controller turns the line contactor
ON to provide power to the main circuit. When the
line contactor turns ON, the steering motor starts
rotation.
By turning on power with the DRS switch set to D
or S, it is possible to activate the self-diagnostic
function, set vehicle characteristic parameters with
setup options and performance data. Remove all
fuses before conducting diagnostics.
(2) Normal mode (RUN mode)
When the forward/reverse lever is operated and the
accelerator pedal is pressed, the vehicle moves
forward or backward. During deceleration, the
motors conduct various regenerative operations
according to the settings.
Operating a hydraulic lever activates the pump
motor and provides hydraulic power.
The controller monitors operating conditions.
When an abnormality occurs, the display unit
When the forward/reverse lever is in the neutral
position and all of hydraulic levers are neutral, the
controller turns the line contactor OFF and cuts off the
current to the armature after a preset period.
Powering
(1) Outline
Powering is a condition in which the motors are
powered by the battery and the controller supplies a
current determined by the powering characteristic.
The powering characteristic is an electric current
curve relative to vehicle speed based on the
acceleration parameter, as shown in the diagram.
The current demand value is obtained from the
acceleration and vehicle speed.
The power characteristic can be selected from three
types SUO #9: Economy, Standard and High power
mode.
The current demand rise rate is selectable.
(Acceleration rate: SUO #8)
High power mode
Standard mode
100
Output Power [%]

indicates an error code and activates an appropriate 90

80
Economy mode
fail-safe function. The error code is stored in the
logic card memory.
50 Brake limit
30
Thermal and
batery [0] mode
0 16
Vehicle Speed [km/h]
208269

Powering characteristic

(2) Truck mode

Truck mode can be selected from A to E, each with
preset values for maximum vehicle speed,
acceleration rate, power, automatic regeneration
power, start lift speed, top lift speed and tilt speed.
SUO #1 is used for setting the truck mode. Detail
are shown on the next page.

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 MAIN CONTROLLER

Mode A b C d E
Feature/ Standard High Economy Long Short
Application Power Distance Shuttle
Vehicle speed Medium Fast Slow Fast Medium
Acceleration Medium Fast Slow Medium Fast
Power Medium High Low High Medium
Characteristic
Lift Medium Fast Slow Medium Fast
Tilt Medium Medium Medium Medium Medium
Regeneration Low Low Low Low Low SUO #
Top travel speed 14 16 12 16 12 7
Acceleration rate 2 3 1 2 3 8
Traveling start power
2 3 1 3 2 9
mode
Default value Traveling start lift speed 7 7 6 7 7 2
Top lift speed 9 10 8 9 10 3
Tilt speed 7 7 7 7 7 4
Automatic regeneration 3 3 3 3 3 23

When the truck mode is set, the values are entered in the applicable set option items.
When default settings are changed, the indication (A to E) flashed to indicate that the settings are modified.

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MAIN CONTROLLER

Regeneration

(1) Lever regeneration

When the forward/reverse lever is shifted into the position opposite to the vehicle’s traveling direction, the
regeneration function is activated. The amount of regeneration is determined by the lever regeneration
characteristic, as shown in the diagram.

(%)

100

Regenerating 75
Armature
Current
Instruction 50
Acceleration
25

0
5 10 15

Acceleration
208270

The regeneration characteristic curve is selected by SUO #22. The degree of acceleration serves as the
parameter. The harder the accelerator pedal is pressed, the higher the amount of regeneration is gained.
The lever regeneration function is always operative regardless of the regeneration mode.

(2) Auto regeneration

When the accelerator pedal is not pressed or the brake pedal is pressed, the regeneration function is activated.
The amount of regeneration is determined by the auto regeneration characteristic, as shown in the diagram. The
regeneration characteristic curve is selected by SUO #23.

208271

3-14
 MAIN CONTROLLER

Hydraulic System Fail Safe System

FC Control Model Output Power Control at Low Battery

This model is equipped with an FC control device, and
a joystick is used in lieu of hydraulic levers.
Chopper Model
Voltage
(1) Battery discharge characteristic
The BDI table shows the BDI indicator patterns on
the display and the corresponding voltage ranges.

The hydraulic levers are used to operate the pump BDI TABLE
motor. The fixed duties selected by the setup options (Normal)
below provide chopper control for the IGBTs.
BDI# 80 V
(1) Start lift speed (SUO #2) and top lift speed (SUO
#3) 0 - 76.4

The two stage lift lever is used to set the speed. 1 77.3 - 77.2
The first stage is for the start lift speed. Do not set 2 78.0 - 78.0
the start lift speed faster than the top lift speed. 3 78.7 - 78.7
(2) Tilt speed (SUO #4) 4 79.4 - 79.5
(3) Attach 1 speed (SUO #5), attach 2 (SUO #6), and 5 80.1 - 80.3
attach 3 (SUO #33)
6 80.8 - 81.1
(4) Priority
7 81.5 - 81.8
When two or more levers are operated at the same
8 82.2 - 82.6
time, the following priority order is effective.
9 82.9 - 83.4
10 83.6 -
(High priority) Tilt, Attach 1, Attach 2, Attach 3,
Lift (Low priority)
(French)
BDI# 80 V
0 - 78.3
1 78.3 - 78.8
2 78.9 - 79.4
3 79.5 - 80.0
4 80.1 - 80.6
5 80.7 - 81.1
6 81.2 - 81.7
7 81.8 - 82.3
8 82.4 - 82.9
9 83.0 - 83.5
10 83.6 -

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MAIN CONTROLLER

(2) Output power control Brush Wear

When the BDI indicator shows zero, the following
output power controls are activated. (1) Drive motor brush wear (Error codes: E4)

[Output power controls] Output power is controlled according to the

Drive system: Power is controlled according to the
powering characteristic.
Hydraulic system: For FC models, the output duty
is reduced for lift and attach operations, and the
output duty remains the same for tilt operations.
For the contactor model, duty control can not be
performed; therefore, operation stops after a
second. When the levers are returned to the neutral
position, operation can be conducted again for one
second.
Simultaneous operations: The drive system and
hydraulic system can not be operated
simultaneously.
Overheat
(1) Drive motor overheat (Error codes: E0)
Output power is controlled according to the
powering characteristic. (Same as the Output
power control described in the previous section.)
(2) Lift motor overheat (Error code: E2)
Same as the output power control described in the
previous section.
(3) Traction controller overheat (Error code: E3)
The output power of the drive motor is controlled
according to the output power control described
in the previous section.
(4) Hydraulic controller overheat (Error code: E7)
The output power of the pump motor is controlled
according to the output power control described
in the previous section. For the contactor model,
no output control is provided for the hydraulic
system.
powering characteristic. (Same as the output
power control described in the previous section.)
(2) Pump motor brush wear (Error code: E6)
Same as the output power control described in the
previous section.
Maximum Vehicle Speed Control (SUO
#7)
The setup option setting limits the maximum vehicle
speed.
Output Power Control During Braking
The maximum current is controlled 30% of command
during the use of the service brake and parking brake.
Chat Timer (SUO #24)
When the following conditions remain for the time
duration set by SUO #24, the line contactor turns OFF.
Accelerator: 0
Forward/Reverse lever: neutral
Lift, tilt and attach levers: OFF
Steering: not operated (exclude in 3 motor system)
Operating any of the above resets the line contactor.
Seat Switch Timer (SUO #25)
When the operator leaves the seat for the time duration
set by SUO #25, the line contactor turns OFF. When
the power switch is turned on without the operator
sitting contactor turns OFF. When the power switch is
turned on without the operator sitting on the seat, the
line contactor turns OFF and the ‘E’ indication flashes
on the display unit.
Place the accelerator at 0, forward/reverse lever in
neutral and hydraulic levers OFF, turn on the seat
switch to reset the line contactor.

3-16

Malfunction Detection (Run Time
Diagnostics)
If a malfunction is detected, the LED flashes and the
error code is indicated on the display unit. The
corresponding fail-safe function is also activated at the
same time.
For details, refer to the “Run Time Diagnostics” on
pages 3-25 and 3-26.
Malfunction Data Record (History
folder)
Data Storage
Errors are automatically stored in the logic card
memory. Stored data includes the following
information.
• Error code
• Battery discharge level at the time of error
generation
• Vehicle hourmeter reading at the time of error
generation
32 sets of data can be stored as the capacity maximum. If
this capacity is exceeded, the first error will be avoided.
Review of Stored Data
(1) To review data
• Set the DRS switch to D.
• With the lift and tilt levers pulled back in seat switch
OFF, turn on the key switch.
• The display unit shows the above mentioned data
(three types of information). To display previous
data, set the DRS switch to R then to D. When there
is no data to display, a ‘done’ indication appears.
The display does not repeat showing data from the
beginning.
(2) To delete data
• Operate the DRS switch until the display shows
‘done’.
• With ‘done’ on the display, hold the DRS switch in
the S position for more than one second, then return
it to R. This erases all stored data, and the ‘done’
indication flickers.
3-17
MAIN CONTROLLER
Setting
Setup Options
For detail, refer to the “Setup Options” tables as follows:
(1) To enter and exit setup option mode
Group 1: Set the DRS switch to S, and turn on the
key switch. The display shows ‘(option
#)1’.
Group 2: Set the DRS switch to S, and turn on the
key switch while keeping the lift and tilt
levers pulled back in seat switch OFF.
The display shows ‘(option #) 11’.
Group 3: Set the DRS switch to S, and turn on the
key switch while keeping the attach 1
lever pulled back in seat switch OFF.
The display shows ‘(option #) 40’.
To exit from setup mode, turn the key off.
(exception: Group 3 must proceed till ‘done’)
(2) To select option # and set data
• The option # is indicated on the speed indicator
on the display unit, and the data is shown on the
hourmeter.
• To select option #, set the DRS switch to R and
then to S.
• To set data, use the forward/reverse lever. To
increase the value, move the lever to F.
To decrease the value, move the lever to R.
(3) To register data
Setting the DRS switch to R and S registers the
data. When the DRS switch is set to R, the data is
written, and the display indicates triple bars. When
the last item is entered , the display indicates
‘done’.
(4) To set default values.
The following procedure sets default values in the
setup option values.
• Set the DRS switch to S.
• Shift the forward/reverse lever to R, hold the
accelerator pedal pressed in seat switch OFF,
then turn the key switch on. The display
indicates ‘done’.
• Set the DRS switch to R.
MAIN CONTROLLER

Self-diagnostics (5) Stall timer (SUO #20)

Check the input and output status. For details, refer to
the “Self-diagnostics” tables on pages 3-23 and 3-24.
Set the DRS switch to D, and turn the key switch on.
To conduct a diagnostics, set the switch to R then to D.
Be sure to remove all fuses before conducting
diagnostics.
To exit from diagnostics mode, turn the key off.
Other Function
This option adjust the time to shut down truck
when the drive motor current is too high.
(6) Auxiliary input for travel speed (SUO #30)
Auxiliary input to limit the maximum vehicle speed
or reduce output power.
(7) Auxiliary maximum travel setting (SUO #31)
This option determines the maximum travel speed
limit of #30. Displayed speed could not reach to
the speed because this function use internal speed
data.

(1) Service indicator (SUO #10) (8) Auxiliary output power limit (SUO #32)
When the vehicle hourmeter indication reaches the This option determines the output power limit in %
set value, the service indicator turn ON to notify of #30.
the need for maintenance. Output power control
(9) Lowering speed adjusting (SUO #35)
can be also activated at the same time. The setting
can be made in a range of 100 to 500 at 50 This option determines the lowering speed. This
increments. The service indicator turn ON when option is available on FC type hydraulic control.
the hourmeter indication exceeds the value of the
current hourmeter reading plus the set value.
The indicator starts flickering 20 hours before the
set time, and remains lit when the hourmeter
indication reaches the set time. Setting ‘0.1’
activates the demo mode. In this mode, the output
power control is conducted six minutes after the
setting is made.

(2) Auxiliary input for function control (SUO #11,

#14, #17)
Auxiliary inputs to the logic card can be used to
limit the maximum vehicle speed, prohibit lift and
reduce output power.
The vehicle speed setting by auxiliary input has
precedence over the maximum vehicle speed set by
SUO #7.

(3) Speed alarm (SUO #26)

When the vehicle reaches the set speed, an alarm
signal (logic card hardware output signal) is
generated.

(4) Tire size adjustment (SUO #27)

This function provides a correction value to
compensate for a diameter change resulting form
tire wear. It is used to adjust the vehicle speed
data.
3-18
 MAIN CONTROLLER

Setup Options (Group 1)

Option Default
Title of Option Description Range
# value
#1 Application pre-sets There are 5 truck modes. This option A, B, C, D, E A
(truck operation sets combination of 7 option values, If any of these 7 option values are
mode) which are top travel speed, changed, A to E will flash.
Acceleration rate, Traveling power,
Regen adjustment, Start lift speed,
Top lift speed, Tilt speed.
#2 Start lift speed This option sets starting lift speed . 1 to 10 7
(when first lift switch is on)
Start lift speed cannot exceed top lift
speed.
#3 Top lift speed This option sets maximum lift speed. 1 to 10 9
(when second lift switch is on)
#4 Tilt speed This option sets tilt speed. 1 to 10 7
Tilt speed is prior to lift speed in case
the two levers are simultaneously
operated.
#5 Auxiliary 1 speed This option sets speed setting for 1 to 10 3
attachment 1.
#6 Auxiliary 2 speed This option sets speed setting for 1 to 10 1
attachment 2.
#7 Top travel speed This option sets maximum travel speed. 5 to 16 km/h (3 to 10 mph) 14
limit
#8 Acceleration rate This option determines of acceleration 1, 2, 3 2
rate. (slow, moderate, fast)
#9 Traveling power This option determines of powering 1, 2, 3 2
mode characteristic. (econo, standard, high
power)
#10 Service indicator This option sets the time which reminds 100 to 500 hours in 50-hr. increments. 0
the maintenance time. The time set Selecting ‘=’ attached number makes the
here is added to the truck’s hourmeter power reduction function effective.
at that time and that value is stored in Setting 0.1 makes the truck demo-mode.
memory as the maintenance time.
When the truck’s hourmeter reaches to 0: Disable
the maintenance time, service reminder
LED turns on. And it will flicker 20
hours before the time. You can reduce
the truck power when the LED is solid
by setting selection. You can also set
the demo-mode, which shows the
Service Indicator function in a short
period of time.

Note:
(1) In #1 Application Presents, we add Traveling Power to the Gemini’s function.

3-19
MAIN CONTROLLER

Setup Options (Group 2)

Option Default
Title of Option Description Range
# value
#11 Auxiliary input 1 This input disable lift. 0: Disabled 0
for lift 1: Disable lift (on close)
2: Disable lift (on open)
#12 (Delete)
#13 (Delete)
#14 Auxiliary input 2 This input disable lift. 0: Disabled 0
for lift 1: Disable lift (on close)
2: Disable lift (on open)
#15 (Delete)
#16 (Delete)
#17 Auxiliary input 3 This input disable lift. 0: Disabled 0
for lift 1: Disable lift (on close)
2: Disable lift (on open)
#18 (Delete)
#19 (Delete)
#20 Stall timer This option adjust the time to shut down 2 to 10 sec 5
truck when the traction motor current is
too high.
#21 Regen function This option enables one of two Regen 1: Brake regen (accelerator must be off) 2
Mode. 2: Accelerator regen (also called “auto
reg”)
#22 Regen adjustment 5 curves for regen power on lever regen 1 to 5 4
for lever regen
#23 Regen adjustment 5 curves for regen power on brake/auto 1 to 5 3
for auto regen regen
#24 Chat timer Sets the amount time required to enter 0 to 40 sec 20
chat mode. 0: Disable
#25 Seat switch timer This option sets the amount of time 3 to 15 5
required to turn off line contactor,
when the operator leaves the seat.
#26 Speed alarm If a truck reaches the speed set here, 5 to 16 km/h (3 to 10 mph) 12
the controller outputs a speed alarm
signal, which is for alarm lamp or relay.
#27 Tire size adjustment Adjusts the amount of tire wear. 0 to 40 20
It changes truck’s speed recognition.

3-20
 MAIN CONTROLLER

Setup Options (Group 2) (Continued)

Option Default
Title of Option Description Range
# value
#30 Auxiliary input for This input is used in conjunction with 0: Disabled 0
travel speed option #31, #32 to limit travel speed 1: Maximum travel speed limit by #31
and/or output power. on close
2: Output power reduction set by #32
on close
3: Maximum travel speed limit by #31
on open
4: Output power reduction set by #32
on open
#31 Auxiliary maximum This option determines the maximum 5 to 16 km/h (3 to 10 mph) 12
travel speed setting travel speed limit of #31.
#32 Auxiliary output This option determines the output 0 to 100 % 70
power limit power limit in % of #31.
#33 Attach 3 speed This option sets speed setting for 1 to 10 3
attachment 3.
#34 Speed alarm 2 If a truck reaches the speed set here, 5 to 16 km/h (3 to 10 mph) 12
the controller outputs a speed alarm 2
signal, which is for alarm lamp or relay.
#35 Lowering speed In this option, the display shows value 0 to 15 15
adjusting for lowering speed adjustment. 0: Maximum decrement
Moving FNR lever from N to F, the 15: Maximum increment
number is increment. From N to R, the
number is decrement.

3-21
MAIN CONTROLLER

Setup Options (Group 3)

Option Default
Title of Option Description Range
# value
#40 Truck type This option is used to set the size and III: No setting –
type of the truck. P20: FB20
P25: FB25
P30: FB30
P35: FB35
#41 Battery voltage This option is used to set the voltage of 72: 72 V –
the Battery. 80: 80 V
#42 Battery type This option is used to set the type of the 0: Normal BDI –
Battery. 1: Tubular BDI
French BDI: For battery with different
discharge characteristic.
#43 Hydraulic control This option is used to set the type of the 0: FC –
selection Hydraulic control. 1: Chopper
2: Contactor
#44 Mast type This option is used to set the type of the 2FF: Two-stage full-free –
Mast. 3FF: Three-stage full-free
2SP: Two-stage panorama
#45 Value section This option is used to set the number of 1: 3 ways (lift, tilt, attach 1) –
valve section. 2: 4 ways (lift, tilt, attach 1, attach 2)
3: 5 ways (lift, tilt, attach 1, attach 2,
attach 3)
#46 Battery voltage In this option, the display shows battery
adjustment voltage which controller recognized.
Using a tester (or a multi-meter), adjust
the value on the display to actual value.
Moving FNR lever from N to F, the
number is increment (0.1 V). From N – –
to R, the number is decrement (0.1 V).
Depress the acceleration pedal while
FNR lever is in F, the number is
increment (10 V). Depress the
acceleration pedal while FNR lever is in
R, the number is decrement (10 V).
#47 Foot direction This option is used to enable the 1: Disable (normal) –
function for Foot Direction op. 2: Enable

Note:
(1) In Group 3, all options have no default value.
(2) All options must be set by Maker or Dealer at first POWER-ON.
(3) If SUO data in logic card is out of proper range, “III” is displayed.

3-22
 MAIN CONTROLLER

Self-diagnostics

Step Checking Do this Controller check this Result Display Motion

0 Power line Turn on key. Close the line contactor and Pass 1 Close the line
voltage check the power line voltage. contactor
(fuse check) momentarily
Fail dd
1 Seat switch Press and release Input OFF → ON → OFF Pass 2
seat switch.
Fail 1
2 Direction Cycle direction lever. Input changes as Pass 3
switch N→R→N→F N→R→N→F→N
Fail 2
3 Parking brake Depress and release Input OFF → ON → OFF Pass 4
parking brake.
Fail 3
4 Service brake Depress and release Input OFF → ON → OFF Pass 5
service brake.
Fail 4
5 Accelerator Depress accelerator Pass Flash 0 ~ 15 as the accelerator is
and release. pressed. ON or OFF is indicated
according to accelerator position.
Fail —
→ RUN → DIAG — 6
6 Battery voltage (Automatic) Check the voltage: Pass 7
36/48/72/80 V
Fail 6
7 Lift switch Pull and release the FC: Check the lever input.
lift lever. MC – Chopper: Pass 8
Check the 2-stage switch input.
Contactor:
Fail 7
Check the switch input.
8 Tilt switch Pull and release the FC: Check the lever input. Pass 9
tilt lever. Other: Check the switch input.
Fail 8
9 Auxiliary 1 Pull and release FC: Check the lever input. Pass 10
switch Aux. 1 lever. Other: Check the switch input.
Fail 9
10 Auxiliary 2 Pull and release FC: Check the lever input. Pass 11
switch Aux. 2 lever. Other: Check the switch input.
Fail 10
11 Auxiliary 3 Pull and release FC: Check the lever input. Pass 12
switch Aux. 3 lever. Other: Check the switch input.
Fail 11
12 Hydraulic Pull any lever and Pass FC/MC – Chopper:
speed check see display. Flashing pump speed value.
Contactor: (skip).
Fail Other than above
→ RUN — 13

3-23
MAIN CONTROLLER

Self-diagnostics (Continued)

Step Checking Do this Controller check this Result Display Motion

13 Line contactor → DIAG See contactor close. Pass 13 Close the
contactor
Fail 13 Open the
contactor
→ RUN See contactor open. Pass Done Open the
(FC/MC – chopper) contactor
14
(Contactor)
Fail 13
14 Pump contactor → DIAG See contactor close. Pass 14 Close the
contactor
Fail 14 Open the
contactor
→ RUN See contactor open. Pass Done Open the
contactor
Fail 14

3-24

Run Time Diagnostics
Fault
Drive Motor, Overheating
Pump Motor, Overheating
Traction Controller, Overheating
Drive Motor Worn Brushes
Pump Motor Worn Brushes
Brake Oil Low Level
Hydraulic Controller Overheating
Alarm Output Fault
Drive Motor Armature Fault
Drive IGBT Breaking
Drive IGBT Short Circuit
Drive IGBT Drive Fault
Drive Current Sensor Fault
Drive Motor Armature Over-current More than 640 A (48 V), 480 A (80V)
Drive Stall Timer
Drive Motor Field Fault
Drive Motor Field Drive Fault
DriveMotor Field Over-current
Pump Motor Fault
Pump IGBT Breaking
Pump IGBT Short Circuit
Pump IGBT Drive Fault
Pump Motor Current Sensor Fault Check the current sensor output
Pump Motor Over-current
Drive Field Current Sensor Fault
Line Contactor Fault
Pump Contactor Fault
Drive Motor Open Circuit
Pump Motor Open Circuit
Accelerator Sensor Fault
Vehicle Speed Sensor A Fault
Vehicle Speed Sensor B Fault
FC Lever Fault
FC Solenoid Fault
How to detect
Thermal contact (150ºC)
Thermal contact (150ºC)
Thermistor (80ºC)
Brush wear sensor
Brush wear sensor
Level sensor (Contact)
Thermistor (80ºC)
Output current sensor
Compare real current with demand
Check voltage of power circuit
Check voltage of power circuit
Fault signal from the drive card
Check the current sensor output
Measure the time (set by SUO #20) while stalling *
Compare real current with demand
Fault signal from the H bridge card
More than 64 A (48 V), 48 A (80 V)
Compare real current with demand
Check voltage of power circuit
Check voltage of power circuit
Fault signal from the drive card
more than 490 A (48 V), 310 A (80 V)
Check the current sensor output
Check voltage of power circuit
Check voltage of power circuit
Check voltage of power circuit
Check voltage of power circuit
Out of normal range
Check breaking and short
Check breaking and short
Fault signal from Load controller
Fault signal from Load controller
3-25
MAIN CONTROLLER
Display
LED
To Return
Result
Service Indicator
to normal
Parking Brake
Code
Battery Low
Over Temp.
Brake Oil
Error
BWI
* E0 Power reduction Cooling
* E2 Power reduction Cooling
* E3 Power reduction Cooling
* E4 Power reduction Turn off key
* E6 Power reduction Turn off key
* Turn off key
* E7 Power reduction Cooling
* E8 Alarm output off Turn off key
* 10 Line contactor off (*) Turn off key
* 11 Line contactor hold. Turn off key
* 12 Line contactor off (*) Turn off key
* 13 Line contactor off (*) Turn off key
* 14 Line contactor off (*) Turn off key
* 15 Line contactor hold. Turn off key
16 Line contactor hold. Turn off key
* 17 Line contactor off (*) Turn off key
* 18 Line contactor off (*) Turn off key
* 19 Line contactor hold. Turn off key
* 30 Line contactor off (*) Turn off key
* 31 Line contactor hold. Turn off key
* 32 Line contactor off (*) Turn off key
* 33 Line contactor off (*) Turn off key
* 34 Line contactor off (*) Turn off key
* 35 Line contactor hold. Turn off key
* 36 Line contactor off (*) Turn off key
* 40 Line contactor off (*) Turn off key
* 42 Line contactor off (*) Turn off key
* 47 Line contactor hold. Turn off key
* 49 Line contactor hold. Turn off key
* 51 Line contactor hold. Turn off key
* 52 Line contactor hold. Turn off key
* 53 Line contactor hold. Turn off key
* 54 Disable the lever op. Turn off key
* 55 Disable the solenoid. Turn off key
MAIN CONTROLLER
Run Time Diagnostics (continued)
Fault
FWD/REV Lever and Accel.
Faulty setting
Seat Switch Faulty Setting
Lift Lever Faulty Setting
Tilt Lever Faulty Setting
Attach 1 Lever Faulty Setting
Attach 2 Lever Faulty Setting
Attach 3 Lever Faulty Setting
Display Communication Fault
EEPROM Abnormality
Controller Communication Fault
Logic Card Initialize Failure
Traction Controller Fault
Hydraulic EEPROM Abnormality Parity check of SUO data
Battery Voltage Too Low
Battery Voltage Too High
Hydraulic Controller Fault
Contactor Coil Fault
Battery Consumption Much
Battery Consumption Too Much
Notes:
(1) E0 to E8 do not appear on the display, but are stored in the history folder.
(2) E, (E), H1 to H5, Lo appear on the display, but no history folder. (E) means flashing.
(3) ‘Line contactor off (*)’ means that the contactor will open immediately when a fault is detected.
Display
LED
To Return
How to detect Result
Service Indicator
to normal
Parking Brake
Code
Battery Low
Over Temp.
Brake Oil
Error
BWI
The lever/accel is not neutral at power-on E Line contactor off Neutral
The switch is off at power-on (E) Line contactor off Switch on
The lever is not neutral at power-on H1 Line contactor off Lever off/Neutral
The lever is not neutral at power-on H2 Line contactor off Lever off/Neutral
The lever is not neutral at power-on H3 Line contactor off Lever off/Neutral
The lever is not neutral at power-on H4 Line contactor off Lever off/Neutral
The lever is not neutral at power-on H5 Line contactor off Lever off/Neutral
When serial communication is not going on * 60 Indicate if it possible Turn off key
Parity check of SUO data * 61 Line contactor off Turn off key
When serial communication is not going on * 62 Line contactor off Turn off key
SUO Gr #3 is not set * 65 Line contactor off Turn off key
Sum check of ROM and RAM * 66 Line contactor off Turn off key
* 67 Line contactor off Turn off key
Voltage class is not correct * 68 Line contactor off Turn off key
Voltage class is not correct * 69 Line contactor off Turn off key
Fault signal from Load controller * 70 Line contactor off Turn off key
Contactor coil current sensor * 72 Line contactor off (*) Turn off key
Much consumption with small capacity Battery (*) Power reduction Regain battery
voltage
Too much consumption with small capacity * (Lo) Line contactor off (*) Turn off key
Battery
3-26
 MAIN CONTROLLER

Display unit Action Indicator (LEDs)

BDI (Battery Discharge Indicator)
The battery discharge level is indicated by the 10-
segment LCD. This indication is based on the BDI
characteristic. When the BDI shows only one segment,
the LED starts flashing to notify the low battery power
level. When the BDI indication disappears, the LED
remains lit and the output control is activated.
The BDI turns OFF when not necessary, such as during
option setting ane self-diagnostic operation.
Hourmeters and Time Display
The display indicates vehicle speed under normal
condition. They do not turn on during setup option
setting or self-diagnostic operation.
(1) Service indicator (SUO #10)
The indicator starts flashing 20 hour before
maintenance is required and remains lit when the
set time is reached.
(2) Motor brush
The indicator turns ON when the motor brush needs
replacement.
(3) Thermal

(1) Normal operation The indicator turns ON when a motor or the

controller overheats.
When the power switch is turned on, the
hourmeters for the drive motors, pump motor and (4) Battery
vehicle are indicated in sequence. The houmeters
The indicator starts flashing when the BDI shows
for the motors show cumulative operating hours,
only one segment, and remains lit when the BDI
and the vehicle hourmeter indicates cumulative line
has no segment indication.
contactor ON hours.
A clock display is shown under normal condition. (5) Brake oil
The indicator flashes when the brake oil level
(2) During setup option setting and self-diagnostic
becomes low.
operation
The hourmeters are not displayed when the power (6) Parking brake
switch is turned on. The indicator flashes when the parking brake is
Data are indicated on the display. engaged.

(7) Error
Vehicle Speed and Error Code Display The indicator flashes when a malfunction is
detected. Refer to the “Run Time Diagnostics” on
The display indicates vehicle speed under normal
pages 2-25 and 2-26.
condition, and shows an error code when an
abnormality occurs.
The display shows item number during setup option
setting and self-diagnostic operation.

3-27
MAIN CONTROLLER

Removal and Installation

Removal and Installation of Controller

WARNING
Disconnect the battery plug before approaching
the controller.

(1) Removal of rear cover

(a) Turn the key switch off.
(b) Disconnect the battery plug.
(c) Remove the rear cover of the counterweight. Counterweight
208272
(2) Removal of controller

CAUTION
Be sure to regularly check the tightened torque
of the high-tension battery cable terminals. If
the cables are loosely connected, excessive
contact resistance results, and it can cause
over heating and lead to a fire in the worst case.
When checking or adjusting the cable routing,
avoid pulling the cables. If cables move even
slightly at the terminals loose connections will
result. While working with the cables, be sure
to tighten the terminal connections.

Remove the power cables (for battery and motors).

11.8 ± 2.0 N·m

Tightening torque for
(1.2 ± 0.2 kgf·m)
stud terminal (M6)
[8.7 ± 1.5 lbf·ft]

(a) Note that a flat washer and a disc spring are

installed on each connector terminal. (See the
illustration at right.)

208273

3-28
 MAIN CONTROLLER

Disconnect connectors CN1, CN2 and CN3. (for

Hydraulic: CN14, CN15 and CN16)

NOTE
• Hold the connectors to unplug. Do not pull the
harnesses to disconnect the connectors.
Remove the controller mounting screws (M10: 6
places), and remove the controller.
• There is thermal cement between counterweight and
controller. It is important to cooling the controller. 208275
Keep the thermal cement for reinstallation.

Remove the controller mounting screws (M10: 6 locations

for traction controller and hydraulic controller. 3 locations
for contactor plate), and remove the controller.

208274

(3) Installation of controller

Follow the removal procedure in reverse.

NOTE
There is thermal cement between counterweight and
controller. It is important to cooling the controller.
Spread the thermal cement flatly then mount controller
on it.
208276

3-29
MAIN CONTROLLER

Removal and Installation of Logic Card

(1) Removal of controller cover

Remove the cover mounting screws (M5: 4 places),
and remove the controller cover.

208277

(2) Removal of logic card

(a) Disconnect J1, J2 and J3 (for Hydraulic: J1 only).
(b) Remove the logic card bracket mounting screws
(M4: 2 places), and remove the logic card with
bracket.
(c) Remove the logic card mounting screws (M3: 5
places), and the heat-sink mounting screws (M4: 2
places behind the bracket), and remove the logic
card.
208278

(3) Installation
Follow the procedure in reverse.

Removal and Installation of Drive Card

(1) Disconnect J4 (for Hydraulic: J2).
(2) Remove the logic card mounting screws (M3: 4
places), and remove drive card.
(3) Installation
Follow the removal procedure in reverse.

208279

3-30
 MAIN CONTROLLER

Removal and Installation of H bridge card

(1) Disconnect J5.
(2) Remove the head capacitor unit mounting screws (M6:
2 or 4 places), and remove the head capacitor unit.
(3) Remove BUS BAR (TB+ and TB-).
(4) Remove BUS BAR (TM-) mounting screws (M6: 1
place), and remove BUS BAR.
(5) Remove heat-sink mounting screws (M4: 2 places),
remove H bridge card mounting screws (M3: 4 places)
and remove H bridge card.
208280
(6) Installation
Follow the removal procedure in reverse.

CAUTION
Your body could pick up a large static charge.
Keep this in mind you when you handle
controller and its component by hand. Never
touch the leads of MOSFET, or your body
charge will rupture some of the electrical
elements.

Removal and Installation of IGBT or

Diode
(1) Remove IGBT or Diode mounting screws (M6: 2 or 4
places), and remove IGBT or Diode.
(2) Installation
Follow the removal procedure in reverse.

NOTE
There is a thermal sheet between plate and IGBT or
Diode, It is important to cool the IGBT or Diode.
Keep the thermal sheet for reinstallation.
Use the thermal sheet for mounting IGBT or Diode.
208281

CAUTION
Your body could pick up a large static charge.
Keep this in mind you when you handle
controller and its component by hand. Never
touch the gate and emitter of IGBT, or your
body charge will rupture some of the electrical
elements.

3-31
MAIN CONTROLLER

Basic Check

Always following 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.

Testing Tools
(a) Circuit tester
(b) Clamp meter (b)
(c) IC tip
(a)
NOTE
(c)
The illustrations show digital circuit testers. In these
testers, the positive (+) terminal is applied with positive
charge, and the negative (-) terminal with negative
charge. It should be noted that the terminals must be
connected inversely when using an analog meter tester.
208282

WARNING
Disconnect the battery plug before inspecting
or adjusting the controller.

Measurement of Logic Card Voltage

WARNING
To prevent accidental movement of the vehicle,
place wood blocks under the vehicle to lift the
front wheels off the ground. Do not stand close
to the front wheels.

3-32
 MAIN CONTROLLER

(a) Place wood blocks under the vehicle to lift the front
wheels off the ground.
(b) Turn the key switch off.
(c) Disconnect the battery plug.
(d) Remove the rear cover from counterweight.
(e) Reconnect the battery plug.
(f) Turn the key switch on. Connect the negative terminal
of the circuit tester to the NEG terminal of the
controller.
(g) Set the circuit tester to the 50- or 100- VDC range.
(h) Connect the positive terminal of the circuit tester to
each pin of connectors CN1, CN2, and CN3. (for
Hydraulic: CN14, CN15, and CN16)

NOTE
Be careful not to short circuit pins. For the normal
voltage value, refer to the logic card voltage chart on
the following pages.

3-33
MAIN CONTROLLER

Traction logic measured voltage chart

Stand-by Activate
No. Name Note
voltage voltage
CN3-1, 2 VPOW (FROM KEY) Vbatt Vbatt 0 V: Key OFF, Vbatt: Key ON
CN3-3, 4 VPOW Vbatt Vbatt 0 V: Key OFF, Vbatt: Key ON
CN3-5 ACCEL IDLE SW Open 0V
CN3-6 BRAKE FLUID SW Open 0V
CN3-7 FORWARD SW Open 0V
CN3-8 PARK BRAKE SW Open 0V
CN3-9 REVERSE SW Open 0V
CN3-10 SEAT SW Open 0V
CN3-11 SERVICE BRAKE SW Open 0V
CN3-12 LIFT2 Open 0V
CN3-13 TRAC BWI SW Open 0V
CN3-14 TRAC THERMAL SW Open 0V
CN3-15 PUMP BWI SW Open 0V
CN3-16 PUMP THERMAL SW Open 0V
CN3-17 LIFT SW Open 0V
CN3-18 LIFT STOP SW Open 0V
CN3-19 SPEED LIMIT SW Open 0V
CN3-20 TILT SW Open 0V
CN3-21 to 24 GND 0V 0V
CN3-25, 26 N.C. 0V 0V
CN2-27 POS VOLTAGE Vbatt Vbatt 0 V: Key OFF, Vbatt: Line contactor ON
CN2-28 POS Vbatt Vbatt 0 V: Key OFF, Vbatt: Line contactor ON
CN2-29, 30 VPOW Vbatt Vbatt 0 V: Key OFF, Vbatt: Key ON
CN2-31 LINE CONTACTOR Vbatt 0V
CN2-32 PUMP CONTACTOR (Vbatt) (0 V)
CN2-33, 34 GND 0V 0V
CN2-35 DIAG Open 0V
CN2-36 SET Open 0V
CN2-37, 38 GND 0V 0V
CN2-39 PUMP CURRENT 0V 0 to 5 V
CN2-40 PUMP THERMAL 2.8 to 4.9 V 2.8 to 4.9 V
CN2-41, 42 GND 0V 0V
CN1-43 GND 0V 0V
CN1-44 VPOW Vbatt Vbatt
CN1-45 SPEED ALARM 1 (Vbatt) 0V
CN1-46 SPEED ALARM 2 (Vbatt) 0V
CN1-47 SEAT SW OUT (Vbatt) 0V
CN1-48 5 V ACCEL 5V 5V
CN1-49 ACCEL ANGLE 1V 1 to 4 V
CN1-50 AGND ACCEL 0V 0V
CN1-51 TRAC SPEED A+ 1 to 4 V 0.3 to 30 V
CN1-52 TRAC SPEED A- 1 to 4 V 0.3 to 30 V
CN1-53 TRAC SPEED B+ 1 to 4 V 0.3 to 30 V
CN1-54 TRAC SPEED B- 1 to 4 V 0.3 to 30 V

3-34
 MAIN CONTROLLER

Traction logic measured voltage chart (continued)

Stand-by Activate
No. Name Note
voltage voltage
CN1-55 GND 0V 0V
CN1-56 DISPLAY 0V 0V
CN1-57 DISPLAY TXD 0 to 12 V 0 to 12 V
CN1-58 DISPLAY RXD 0 to 12 V 0 to 12 V
CN1-59 CONTROLLER TXD -10 to 10 V -10 to 10 V
CN1-60 CONTROLLER RXD -10 to 10 V -10 to 10 V
CN1-61 CONTROLLER GND 0V 0V
CN1-62 READY RTN 0V 0V
CN1-63 PUMP ALM 0V 0V
CN1-64 PUMP READY 0V 0V

Pump logic measured voltage chart

Stand-by Activate
No. Name Note
voltage voltage
CN16-1, 2 VPOW (FROM KEY) Vbatt Vbatt 0 V: Key OFF, Vbatt: Key ON
CN16-3 LIFT LIMIT SW 1 Open 0V
CN16-4 LIFT LIMIT SW 2 Open 0V
CN16-5 LIFT LIMIT SW 3 Open 0V
CN16-6 PUMP BWI SW Open 0V
CN16-7 PUMP THERMAL SW Open 0V
CN16-8 LIFT SW 1 Open 0V
CN16-9 LIFT SW 2 Open 0V
CN16-10 TILT SW Open 0V
CN16-11 AUX SW 1 Open 0V
CN16-12 AUX SW 2 Open 0V
CN16-13 AUX SW 3 Open 0V
CN16-14 STEERING SW Open 0V
CN16-15 SPEED SW Open 0V
CN16-16 (UP SW) Open Open
CN16-17 (DOWN SW) Open Open
CN16-18 PUMP READY 0V 0V
CN16-19 (PUMP SPEED+) Open Open
CN16-20 GND (PUMP SPEED-) 0V 0V
CN16-21 (PUMP SPEED 15 V) 15 V 15 V
CN16-22 AUTO LIGHT RELAY Open 0V
CN16-23 AUTO LIGHT 15 V 15 V 15 V
CN16-24 AUTO LIGHT SENSOR Open 14 V
CN16-25 PUMP ALM 0V 0V
CN16-26 ALM RTN 0V 0V
CN15-27 LIFT JOYSTICK 2.5 V 0.2 to 4.8 V
CN15-28 LIFT GND 0V 0V
CN15-29 LIFT 5 V 5V 5V

3-35
MAIN CONTROLLER

Pump logic measured voltage chart (continued)

Stand-by Activate
No. Name Note
voltage voltage
CN15-30 TILT 5 V 5V 5V
CN15-31 TILT JOYSTICK 2.5 V 0.2 to 4.8 V
CN15-32 TILT GND 0V 0V
CN15-33 ATTACH 1 JOYSTICK 2.5 V 0.2 to 4.8 V
CN15-34 ATTACH 1 GND 0V 0V
CN15-35 ATTACH 1 5 V 5V 5V
CN15-36 ATTACH 2 5 V 5V 5V
CN15-37 ATTACH 2 JOYSTICK 2.5 V 0.2 to 4.8 V
CN15-38 ATTACH 2 GND 0V 0V
CN15-39 ATTACH 3 JOYSTICK 2.5 V 0.2 to 4.8 V
CN15-40 ATTACH 3 GND 0V 0V
CN15-41 ATTACH 3 5 V 5V 5V
CN15-42 GND 0V 0V
CN14-43 12 V (EMERGENCY) 12 V 12 V
CN14-44 VALVE POW (12 V) (12 V) Open: Emergency ON
CN14-45 LIFT VALVE A 12 V 0 to 12 V Open: Emergency ON
CN14-46 LIFT VALVE B 12 V 0 to 12 V Open: Emergency ON
CN14-47 LIFT COM 0V 0V
CN14-48 TILT COM 0V 0V
CN14-49 TILT VALVE A 12 V 0 to 12 V Open: Emergency ON
CN14-50 TILT VALVE B 12 V 0 to 12 V Open: Emergency ON
CN14-51 ATTACH 1 VALVE A 12 V 0 to 12 V Open: Emergency ON
CN14-52 ATTACH 1 VALVE B 12 V 0 to 12 V Open: Emergency ON
CN14-53 ATTACH 1 COM 0V 0V
CN14-54 ATTACH 1 COM 0V 0V
CN14-55 ATTACH 2 VALVE A 12 V 0 to 12 V Open: Emergency ON
CN14-56 ATTACH 2 VALVE B 12 V 0 to 12 V Open: Emergency ON
CN14-57 ATTACH 3 VALVE A 12 V 0 to 12 V Open: Emergency ON
CN14-58 ATTACH 3 VALVE B 12 V 0 to 12 V Open: Emergency ON
CN14-59 ATTACH 3 COM 0V 0V
CN14-60 POS VOLTAGE Vbatt Vbatt 0 V: Key OFF, Vbatt: Line contactor ON
CN14-61 CONTROLLER TXD -10 to 10 V -10 to 10 V
CN14-62 CONTROLLER RXD -10 to 10 V -10 to 10 V
CN14-63 GND 0V 0V
CN14-64 N.C. 0V 0V

3-36
 MAIN CONTROLLER

Measurement of Head Capacitor

CAUTION
Disconnect the battery plug before close the
controller.

NOTE
Handle with care for the head capacitor.

Turn the key switch off. Disconnect the battery plug. 208283
Check voltage of head capacitor. If it is not 0 V, discharge
voltage with resister. (ex: 100 ohm) Remove the head
capacitor with busbar.
Check the head capacitor visually. (break or melt)
Measure resistance of Head Capacitor. (It must be over 10
k ohm)
• If you find any troubles, replace the capacitor.

Check Contactor Coil

CAUTION
Disconnect the battery plug before close the
controller.

Disconnect the lead wire of coil. Set the circuit tester to

200 ohm range. Measure coil resistance. (It must be 118 to
145 ohm)
• If the measured value deviates from the above range,
replace the contactor assembly.
With the lead wire of contactor coil connected, set the
circuit tester to 200 VDC range.
Connect the negative (-) terminal of the circuit tester to the
negative-side coil terminal (small fasten terminal) and the
positive (+) terminal of the circuit tester to the positive-side
coil terminal (large fasten terminal).
Connect the battery, and operate the control device that
activates the contactor.
The circuit tester should indicate a value between 23.4 and
52 V after the contactor the contactor operates. When the
contactor is found normal in the coil resistance test and if
the measured voltage is not within this range, replace the
logic card.

3-37
MAIN CONTROLLER

Check Contactor Tip

Turn key switch off. Disconnect battery plug. Check
voltage of contactor terminal.
Check the tip condition and the movement.
Check the gap. It must be 3.15 ± 0.1 mm (0.124 ± 0.004
in.).
• If the contactor shows any fault, replace or correct the
contactor.
208284

Check Current Sensor of Traction Controller

Turn the key switch off. Disconnect battery plug.
WARNING
Disconnect current sensor connector.
To prevent the vehicle from moving suddenly,
Location Connector name lift the front wheels off the ground by placing
wood blocks under the vehicle. Do not
Traction armature J8
approach the front wheels during testing.
Traction field J7
Turn the key switch off and disconnect the battery plug.
Set the circuit tester to 20 VDC range. Connect the Connect current sensor connector.
positive (+) terminal of the circuit tester to No. 4 pin. Place wood blocks under the vehicle to lift the front
Connect the negative (-) terminal of the circuit tester to wheels off the ground. Engage the parking brake.
the NEG terminal.
Set the circuit tester to 20 VDC range. Connect the
positive (+) terminal of the circuit tester to No. 2 pin of
Standard
Location Pin No. condition current sensor.

Traction armature J8-4GR 14 to 16 V Standard

Location Pin No. condition
Traction field J7-4GR 14 to 16 V
Traction armature J8-2YR 2 to 3 V
Connect the battery plug and turn the key switch ON. Traction field J7-2BrY 2 to 3 V
• If values measured in the above step deviate from the
specified ranges, replace the traction logic card. Connect the battery plug and turn the key switch ON.

Then, connect the positive (+) terminal of the circuit • If values measured in the above step deviate from the
tester to No. 2 pin. specified ranges, replace the current sensor.
Shift the forward/reverse lever to Forward. Gradually
Standard depress the accelerator pedal (with front wheels
Location Pin No. condition stationary) and read the voltage change.
Traction armature J8-2YR 4 to 6 V
Standard
Location Pin No. condition
Traction field J7-2BrY 4 to 6 V
Traction armature J8-2YR Increase
• If values measured in this step deviate from the
specified ranges, replace the traction logic card. Traction field J7-2BrY Increase

• If values measured in this step deviate from the

specified condition, replace the current sensor.

3-38
 MAIN CONTROLLER

Check Current Sensor of Hydraulic Controller

Turn the key switch off. Disconnect battery plug.
Disconnect current sensor connector J4.
Set the circuit tester to 20 VDC range. Connect the
positive (+) terminal of the circuit tester to J4-4GR.
Connect the negative (-) terminal of the circuit tester to
the NEG terminal.
Connect the battery plug and turn the key switch ON.
Pin No. Standard condition
J4-4GR 14 to 16 V
• If values measured in above deviate from the
specified ranges, replace the hydraulic logic card.
Then, connect the positive (+) terminal of the circuit
tester to J4-2YR.
Connect the battery plug and turn the key switch ON.
• If values measured in the above step deviate from the
specified ranges, replace the current sensor.
Shift the forward/reverse lever to Forward. Gradually
depress the accelerator pedal (with front wheels
stationary) and read the voltage change.
Pin No. Standard condition
J4-2YR Increase
• If values measured in this step deviate from the
specified condition, replace the current sensor.

Pin No. Standard condition

J4-2YR 4 to 6 V

• If values measured in this step deviate from the

specified ranges, replace the logic card.

WARNING
To prevent the vehicle from moving suddenly,
lift the front wheels off the ground by placing
wood blocks under the vehicle. Do not
approach the front wheels during testing.

Turn the key switch off and disconnect the battery plug.
Connect current sensor connector.
Place wood blocks under the vehicle to lift the front
wheels off the ground. Engage the parking brake. Set
the circuit tester to 20 VDC range. Connect the
positive (+) terminal of the circuit tester to No. 2 pin of
current sensor.

Pin No. Standard condition

J4-2YR 0 to 0.3 V

3-39
MAIN CONTROLLER

Check H bridge Card

Turn the key switch off. Disconnect the battery plug.
After removing the traction motor harness, check continuity
by circuit tester.
Set the circuit tester diode range.

+ of tester - of tester Display

TB+ to TB- TB+ TB- OL
TB+ to TF+ TB+ TF+ OL
TB+ to TF- TB+ TF- OL
TF+ to TB+ TF+ TB+ 0.2 to 0.9 V
TF+ to TF- TF+ TF- OL
TF+ to TB- TF+ TB- OL
TF- to TB+ TF- TB+ 0.2 to 0.9 V
TF- to TF+ TF- TF+ OL
TF- to TB- TF- TB- OL 208285

TB- to TB+ TB- TB+ 0.2 to 1.8 V

TB- to TF+ TB- TF+ 0.2 to 0.9 V
TB- to TF- TB- TF- 0.2 to 0.9 V

• If faulty, replace H bridge card.

Check Traction Drive Card

Turn the key switch on.
Set the circuit tester 200V DC range.
Measure the gate-emitter voltage by voltage of zener
diodes.

+ of tester - of tester Display

Accel OFF anode of ZD4 anode of ZD5 -9 to -12
V
Accel OFF anode of ZD104 anode of ZD105 -9 to -12
V
208286

• If faulty, replace traction drive card.

NOTE
Be careful not to short circuit pins.

3-40
 MAIN CONTROLLER

Check Pump Drive Card

Turn the key switch on.
Set the circuit tester 200V DC range.
Measure the gate-emitter voltage by voltage of zener
diodes.

+ of tester - of tester Display

Accel OFF anode of ZD4 anode of ZD5 -9 to -12
V
208287
• If faulty, replace pump drive card.

NOTE
Be careful not to short circuit pins.

Check Diode
After removing diode, check continuity by circuit tester.
Set circuit tester diode range.

+ of tester - of tester Display

Forward Anode Cathode 0.1 to 0.8 V
Reverse Cathode Anode OL

• If faulty, replace diode.

208288

3-41
MAIN CONTROLLER

Check IGBT

WARNING
Disconnect the battery plug before approaching
the controller.

Turn the key switch off.

Disconnect the battery plug.
Remove all busbar and harness from th IGBT.
Short terminals G and E with a wire.
208289
Set circuit tester 200 ohm range, and measure resistance
between the following terminals.

+ of tester - of tester Display

Terminal C Terminal E OL
Terminal E Terminal C 1 to 4 M ohm

NOTE
Handle the G and E terminals with extreme care since
they can be easily damaged by static electricity. (Do
not touch the G and E terminals.)

Remove wire from G and E terminals, and measure

resistance between terminals G and E.

+ of tester - of tester Display

Gate Emitter OL

• If you find any troubles, replace IGBT.

3-42