CONTROLLER

Outline of Controller ................................................................................ 1– 1

Outline of Contactor Module ................................................................. 1– 1 1
Logic Card ................................................................................................. 1– 2
MOS-FET Modules ................................................................................. 1– 4
Operation Outline .................................................................................... 1– 5
Drive System ............................................................................................ 1– 7
Hydraulic System .................................................................................... 1– 8
Fail-safe System ...................................................................................... 1 – 10
Malfunction Detection (Run Time Diagnostics) ................................. 1 – 11
Fault Data Record (History Folder) ..................................................... 1 – 11
Setup Option Setting .............................................................................. 1 – 12
Self-diagnostics ....................................................................................... 1 – 15
Other Functions ....................................................................................... 1 – 16
Table of Setup Options ........................................................................... 1 – 17
Table of Self-diagnostics ........................................................................ 1 – 20
Table of Run Time Diagnostics ............................................................. 1 – 22
Display Unit ............................................................................................... 1 – 23
Removal and Installation ........................................................................ 1 – 24
Controller Assembly .................................................................................. 1 – 24
Logic Card ................................................................................................ 1 – 26
MOS-FET Module ..................................................................................... 1 – 27
Basic Check .............................................................................................. 1 – 28
Testing Tools ............................................................................................. 1 – 28
Measurement of Logic Card Voltage ......................................................... 1 – 29
Checking Contactor Coil ........................................................................... 1 – 32
Checking Contactor Tip ............................................................................. 1 – 32
Checking Current Sensor of Controller ..................................................... 1 – 33
Checking MOS-FET Module ..................................................................... 1 – 35
Regeneration Check .................................................................................. 1 – 37
AC Motor System Basics ....................................................................... 1 – 38
 CONTROLLER

Outline of Controller
The controller is the heart of the forklift truck operation system.
The logic card contains decision making functions, and is equipped with a battery discharge indicator and a
malfunction diagnostic function.
The controller is used to operate the traction motor, pump motor and proportioning solenoids for the finger-tip control
system.

1
7

3 4 5 6

213476

1 Logic card 5 Current sensor (PUMP U phase)

2 MOS-FET module 6 Current sensor (PUMP V phase)
3 Current sensor (TRACTION U phase) 7 DRS switch
4 Current sensor (TRACTION V phase)

Outline of Contactor Module

The contactor module controls the function of the main 3

switch and circuit protector.
Two contactors are operated by the controller.

2
1 Line contactor
2 Line fuse (500 A)
3 Steering contactor

213477

1-1
CONTROLLER

Logic Card

3 1 4 2
CN5 CN6 CN7 CN8 CN9 CN10

CN3

CN1 CN2

213478

1 Traction control CPU

2 Hydraulic control CPU
3 GSE connector (Traction)
4 GSE connector (Pump)

There are two CPUs on the logic card: the traction control
CPU and hydraulic control CPU.
The traction control CPU controls the traction motor,
monitors the traction system for malfunctions (malfunction
diagnostic function), and checks the state of the battery.
The hydraulic control CPU controls the pump motor and
the proportioning solenoid valve in the finger-tip control
(FC) system, and monitors the hydraulic system for
malfunctions.

1-2
 CONTROLLER

Logic Card and Connectors

CN11 CN12 CN13

CN5 CN6 CN7 CN8 CN9 CN10

CN3

CN1 CN2
211676

25 23 21 19 17 15 13 11 9 7 5 3 1 47 45 43 41 39 37 35 33 31 29 27
26 24 22 20 18 16 14 12 10 8 6 4 2 48 46 44 42 40 38 36 34 32 30 28
Harness side CN14 Harness side CN15

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
Logic card side CN2

25 23 21 19 17 15 13 11 9 7 5 3 1 41 39 37 35 33 31 29 27
26 24 22 20 18 16 14 12 10 8 6 4 2 42 40 38 36 34 32 30 28
Harness side CN1 Harness side CN2

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
Logic card side CN1

19 17 15 13 11 9 7 5 3 1 5 3 1
20 18 16 14 12 10 8 6 4 2 6 4 2
Harness side J3 MOS-FET module side CN1

1 3 5 7 9 11 13 15 17 19 1 3 5
2 4 6 8 10 12 14 16 18 20 2 4 6
Logic card side CN3 Logic card side CN5, 6, 7, 8, 9, 10

1-3
CONTROLLER

MOS-FET Modules

XXXXXX

5 3 1
6 4 2
CN1

211677

MOS-FET
module

For traction motor For pump motor

213479

There are six MOS-FET modules located behind the logic card.

The MOS-FET modules convert the battery DC current into

AC current to supply the traction and pump motors. The
MOS-FET modules create single-phase alternating current.
Since the controller controls the two three-phase induction
motors (traction motor and pump motor), it requires six
MOS-FET modules. See the "AC motor system basics"
section on page 1-38.
1-4
 CONTROLLER

Operation Outline
(1) Power ON (2) Normal mode (RUN mode)
Turning on the key switch supplies power to the When the direction lever is engaged and the
logic card and display unit. The display unit shows accelerator pedal is pressed, the vehicle moves
three kinds of hourmeters (i.e., traction motor, forward or backward. During deceleration, the
pump motor and vehicle hourmeters) in sequence, traction motor conducts regenerative operation.
and then resumes the normal display mode (i.e., Moving the hydraulic lever activates the pump
clock). About one second (period for routine self- motor and provides hydraulic power.
diagnostics) after power is supplied to the logic The controller monitors operating conditions.
card, the controller turns both the line contactor and When an abnormality occurs, the display unit
the steering contactor ON to provide power to the indicates an error code and activates an appropriate
main circuit. When the steering contactor turns fail-safe function. The error code is stored in the
ON, the steering motor starts rotating. logic card memory.
By turning on power with the DRS switch set to D,
it is possible to activate the self-diagnostic
function. Before that, remove all fuses.
By turning on power with the DRS switch set to S,
it is possible to set vehicle characteristic parameters
with setup options (See NOTE) and performance
data.
For details of the self-diagnostics and setup
options, refer to pages 1-15 and 1-12, respectively.

NOTE
The maximum vehicle speed, acceleration rate, lift
and tilt speeds, and other operational characteristics
of the truck depends on setting of the truck
operation mode and setup option values stored in
the controller. The operation mode and setup
option values have been set to the default mode and
values before shipment from the factory but their
setting can be changed to make the truck operation
characteristics most suited to the working
conditions. The available truck operation modes,
the characteristic items that constitute each mode
and the default setup values for the items are shown
in the table on next page.

1-5
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 Slow Fast
Power Medium High Low Low High
Characteristic
Lift Medium Medium Slow Medium Medium
Tilt Medium Medium Medium Medium Medium
Regeneration Low Low Low Low High SUO #
Max vehicle speed 18 20 (18) *) 16 20 (18) *) 12 7
Acceleration rate 3 4 2 3 4 8
Traveling power 2 3 1 3 2 9
Default value Start lift speed 1 1 1 1 1 2
Top lift speed 9 9 8 9 9 3
Tilt speed 3 3 3 3 3 4
Automatic regeneration 7 7 7 7 7 23
*)
Max vehicle speed of 3.5 ton truck is 18 km/h.

When the truck operation mode (SUO #1) is set, the values above are entered in the applicable set option items.
When default settings are changed, the indication (A to E) flashes to indicate that the settings are modified.

1-6
 CONTROLLER

Drive System 3. Regeneration

(1) Lever regeneration
1. Neutral position
When the direction lever is shifted into the position
In case the direction lever is in the neutral position and opposite to the vehicle’s traveling direction, the
all of hydraulic levers are neutral for a preset period regeneration function is activated. The amount of
(chat timer SUO #24), the controller turns the line regeneration is determined by the lever regeneration
contactor OFF and cuts off the current to the motors. characteristic, as shown in the diagram.
2. Powering
(1) Outline 100 10
9
Powering is a condition in which the motors are
...
powered by the battery and the controller supplies
Amount of 5
current determined by the powering characteristic. ...
lever
The powering characteristic is a torque curve 2
regeneration
1
relative to vehicle speed based on the acceleration [%]
parameter, as shown in the diagram. The torque
demand value is obtained from the acceleration and
vehicle speed. 0
5 10 15
The power characteristic can be selected from three
Degree of acceleration pedal
types by SUO #9: ECONOMY, STANDARD and
HIGH POWER. 209548

The rate of output torque rise is selectable

The lever regeneration characteristic curve is
(acceleration rate: SUO #8).
selected by SUO #22. The degree of acceleration
Torque serves as the parameter. The more the accelerator
[%] Thermal or BDI [0]*2
is pressed, the higher the amount of regeneration
100 HIGH POWER
becomes.
STANDARD
ECONOMY The lever regeneration function is always operative
regardless of the regeneration mode.
Brake limit*1
(2) Auto regeneration
When the accelerator pedal is not pressed or the
Speed brake pedal is pressed, the regeneration function is
0 5 16 18 20 (km/h)
activated. The amount of regeneration is
Powering characteristic 209547
determined by the auto regeneration characteristic,
*1
Brake limit: Torque value resulting from reduction in as shown in the diagram. The auto regeneration
current when the service brakes or characteristic curve is selected by SUO #23.
parking brake are applied.
*2
Thermal or BDI [0]: Curve of limited torque under a SUO #23

condition of overheating or 10
battery voltage low. 9
8
Regeneration
Torque ...
...
2
1

Truck Speed
209549

1-7
CONTROLLER

Hydraulic System Current to

solenoid [%]
There are two types of control system for controlling the
hydraulic control valve: finger-tip control (FC) type and
100
mechanical control (MC) type. They are different in the
way of controlling the hydraulic cylinders.

1. FC type Current increases

drastically as lever
The speed of operation of the hydraulic cylinders depends movement angle
on the valve-opening amount and pump motor output. The increases.
valve-opening amount and pump motor output are
controlled electrically in proportion to the amount of 0
100 Lever angle [%]
movement of the FC lever.
209550
(1) Valve opening control
Current characteristics of proportioning solenoid
The amount of current to the proportioning solenoid valve
valve varies with the amount of movement of the FC
lever. A specific amount of current for each lever angle Pump motor
is preset appropriately for each hydraulic cylinder. (See output [%] SUO #3
the graph on the right.) (top lift speed)

(2) Pump motor output control 100 HIGH POWER 10

The output of the pump motor varies with the amount STANDARD 9
ECONOMY 8
of the FC lever movement. The amount of change in
SUO #2
motor output for a unit amount of lever movement can
(start lift speed)
be adjusted by changing the relevant setup option
value. The second graph on the right shows the pump 1
output characteristic curves in relation with the lift
lever angle. These curves are for the high-power, 0
100 Lever angle [%]
standard and economy settings selected using SUO #3.
At the start of pump motor rotation, the output levels 209551
for the three settings are the same. As the lever angle Pump motor output characteristics
increases, the pump motor outputs for the settings (FC type, lift-up operation)
become different, with that of the high-power setting
being the highest. During a lift-down movement, SUO #4 (Tilt), #5 (Attachment 1),
Pump motor
#6 (Attachment 2),
however, the pump motor output remains constant. output [%]
#33 (Attachment 3)
The third graph on the right shows the pump motor
output characteristic curves in relation with 100 10
tilt/attachment lever angles. The pump motor output is
high from very start of the motor when the relevant
SUO # value has been set high.

2
1

0
100 Lever angle [%]
209552

Pump motor output characteristics

(FC type, tilt and attachment 1, 2 and 3
operations)
1-8
 CONTROLLER

2. MC type Pump motor

(1) Valve opening control output [%]

The opening of the hydraulic control valve is HIGH POWER SUO #3

controlled mechanically by moving the MC lever. 100 STANDARD
ECONOMY 10
(2) Pump motor output control 9
During lift-up operation, the pump motor output is 8
SUO #2
controlled in two stages according to the amount of
movement of the MC lever. (See the first graph on the
right.)
During tilt operation or attachment operation, the pump 0
motor output is constant. (See the second graph on the 100 Lever angle [%]
right.) 209553
The output of the pump motor can be adjusted by Pump motor output characteristics
changing the setup option value. (MC type, lift-up operation)
NOTICE: The pump does not operate during lift-
down operation.

Pump motor
output [%]

SUO #4, #5, #6, #33

100 10
9

0
100 Lever angle [%]

209554

Pump motor output characteristics

(MC type, tilt and attachment 1, 2 and
3 operations)

1-9
CONTROLLER

Fail-safe System (2) Pump motor overheat (Error code: E2)

The output power of the pump motor is controlled
1. Output power control at low battery voltage according to the output power control described in
the previous section.
(1) Battery discharge characteristic
(3) Traction module overheat (Error code: E3)
The BDI table shows the BDI indicator patterns on
the display and the corresponding voltage ranges. The output power of the traction motor is
controlled according to the output power control
BDI TABLE described in the previous section.
(Normal) (Tubular) (4) Hydraulic module overheat (Error code: E7)
BDI# 80 V BDI# 80 V The output power of the pump motor is controlled
0 - 76.4 0 - 78.2 according to the output power control described in
1 76.5 - 77.2 1 78.3 - 78.8 the previous section.
2 77.3 - 78.0 2 78.9 - 79.4
3 78.1 - 78.7 3 79.5 - 80.0 3. Maximum vehicle speed control (SUO #7)
4 78.8 - 79.5 4 80.1 - 80.6 The setup option setting limits the maximum vehicle
5 79.6 - 80.3 5 80.7 - 81.1 speed.
6 80.4 - 81.1 6 81.2 - 81.7
4. Output power control during braking
7 81.2 - 81.8 7 81.8 - 82.3
8 81.9 - 82.6 8 82.4 - 82.9 The maximum current is controlled 40 % of command
9 82.7 - 83.4 9 83.0 - 83.5 when using the service brake and parking brake. See
10 83.5 - 10 83.6 - the speed-torque graph of powering characteristic on
page 1-7.

(2) Output power control 5. Chat timer (SUO #24)

When the BDI indicator shows 0, the following When the following conditions remain for the time
output power control is activated. duration set by SUO #24, the line contactor turns OFF.

[Output power control] Accelerator: 0

Drive system – Power is controlled according to the Direction lever: Neutral

powering characteristic. (See the speed-torque Lift, tilt and attachment levers: OFF
graph of powering characteristic on page 1-7.) When any of the above are operated, the line contactor
Hydraulic system – The output is reduced during is closed.
lift and attachment operations, and the output
6. Seat switch timer (SUO #25)
remains the same during tilt operations and lift
down operations. When the operator leaves the seat for the time duration
set by SUO #25, the line contactor and steering
Simultaneous operations – The drive system and
contactor turn OFF. When the power switch is turned
hydraulic system cannot be operated
ON without the operator sitting on the seat, the line
simultaneously.
contactor keeps OFF and the “E” indication flashes on
2. Overheat the display unit.
(1) Traction motor overheat (Error code: E0) With the accelerator at 0, the direction lever in neutral
The output power of the traction motor is and the hydraulic levers OFF, turning ON the seat
controlled according to the output power control switch resets the line contactor.
described in the previous section.

1-10
 CONTROLLER

Malfunction Detection (Run Time

Diagnostics)

If a malfunction is detected, the LED flashes and 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 page 1-22 and
“Troubleshooting for Control Circuit”.

Run position
Fault Data Record (History Folder)
Setup
R
position Diagnostics position
1. Storage of fault data S D
Pull up the
tamped mark stopper, then
When any of the faults listed in the Run Time Diagnostics tilt the switch
table on page 1-22 occurs, the three items of data indicated to the desired
below will be stored in the memory of the logic card. The D R S position.
maximum number of faults that can be stored in the
memory is 32. When faults exceeding 32 occur, overflow
data will be erased on the “first-in, first-out” basis. The
209436B
fault data items are as follows:
• Error code Operating DRS switch
Starting fault data review: Set the switch to D.
• Battery discharge indicator at the time of fault Reviewing the next older fault data:
• Vehicle hourmeter reading at the time of fault Cycle the switch D→R→D. Repeat this cycle for
further older fault's data.

2. Reviewing stored fault data

Battery discharge indicator
Error code
Follow the steps below to review the stored fault data. at the time of fault

(1) Set the DRS switch in the D (diagnostics) position.

(2) Turn OFF the seat switch.
(3) With the lift and tilt levers pulled back, turn the key
switch to the ON position.
(4) The data on the latest fault will appear on the display
unit. The data will contain the three items of
information listed in paragraph 1 above. (See the
illustration on the right.) If there are no data items
stored for the fault, “donE” will appear in the Vehicle hour-meter reading at the time of fault
hourmeter display area. After reaching the oldest fault data stored,
(5) To review the data of the next older fault, move the “donE” will appear in this area. 209556
DRS switch from the D position to the R position and
then back to the D position. Every time this cycle of NOTE
switch operation is performed, the display will go to
Fault data review is a one-way operation. You
the next older fault. When the cycle is performed after
can only proceed to the next older fault but
the oldest fault has been reached, “donE” will appear in
cannot go back to the newer fault. When
the hourmeter display area.
reviewing the data of a newer fault again, first
(6) To exit from the fault data review mode, turn OFF the terminate the review operation and then start
key switch and then set the DRS switch to R. another review operation.
1-11
CONTROLLER

3. Deleting stored fault data Step 1 (after review of all stored fault data)
R
Stored fault data can be deleted as follows after all of them S
have been reviewed: Pull Wait
(1) With “donE” displayed in the hourmeter area in the more than
1 second
display unit, set the DRS switch in the S (set) position
and wait for more than one second.
Step 2 Step 3 (exit from review mode)
(2) Place the DRS switch in the R (run) position. R
(3) The hourmeter area displays flashing “donE”, showing S

that all the stored data have been deleted. Pull

NOTICE: It is generally not recommended to erase fault

data. Fault data are useful as aids for proper Flashes
management of the truck. 211679

Stored data erasing steps

Setup Option Setting

The tables on pages 1-17 to 1-19 show the setup options

classified in three groups. They include the number
assigned to each setup option (SUO #), its value set before
shipment from the factory (default value), and points to be
noted when changing the default value.
First SUO # of each group
To change a default value, use the following procedure: “01” for group 1
“11” for group 2
1. Entering and exiting from setup option mode “40” for group 3
To enter the mode:
The method to enter the mode (to cause the initial display
to appear) differs from group to group. Perform any of the
following operations as appropriate.
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 with the seat switch OFF. The display
shows “(option #) 11”. Current set value for SUO #11*
209558
Group 3: Set the DRS switch to S, and turn on the key
switch while keeping the attachment 1 lever First SUO # of Group 2 setup options (example)
pulled back with the seat switch OFF. The
*The current value is displayed. For the meaning
display shows “(option #) 40”. of each number or symbol displayed, refer to the
To exit from the mode: “Range” column of the relevant Setup Options
For the groups 1 and 2, turn the key switch OFF. For the table and Notes below the table.
group 3, advance the SUO # until “donE” appears.
The steps described above are collectively shown in the
following table:

DRS switch
Mode Seat switch Other condition
position
Setup option group 1 (1 to 10) S – –
Setup option group 2 (11 to 33) S OFF Pull back lift lever and tilt lever
Setup option group 3 (40 to 47) S OFF Pull back attachment 1 lever

1-12
 CONTROLLER

2. Selecting SUO # and changing set value

How to change set value
The set value change procedure consists of selecting the When changing setting of SUO #20 (stall timer) from
desired SUO # using the DRS switch, changing the set default 5 seconds to 3 seconds:
value by moving the direction lever, and registering the
new value. Step 1. Since SUO #20 belongs to Group 2 setup
options, the first SUO # “11” of the group
appears on the screen when using the procedure 1
• Cycle the DRS switch S → R → S. The set value on page 1-12.
displayed on the screen is registered. The SUO # on the
screen then advances to the next SUO #. Changing the
set value is now possible for the SUO #.
The first half of the DRS switch operation (S→R) is for Step 2. Move the DRS switch as follows to change the
overwriting the previous value with the value on the current setting for the SUO #20.
screen (registering). When the value is registered, a set R (1) Move the DRS switch S →R.
of three dotted lines appears on the screen as shown in S
The display changes as shown
the illustration on the right. The second half of the Pull below. The set value (0) for
operation (R→S) is for advancing the SUO #. the SUO #11 is overwritten
simultaneously.
• Every time the DRS switch is cycled S → R → S, the
SUO # increments. When advancing the SUO # without
changing the set value, simply repeat by cycling the
switch as many times as necessary. When the last SUO
# is reached, “donE” appears in the set value display
area. R (2) Move the DRS switch R →S.
S
Pull The display shows the current
• Use the direction lever to change the set value. The
setting for the next SUO #14.
value increases when the lever is cycled N→F→N; it
decreases when the lever is cycled N→R→N. In either
increasing or decreasing direction, the value returns to
the first or last value in the available value range.

(3) Cycle the DRS switch S→R→S twice to cause the

SUO #20 to appear on the screen.

Default value 5 for SUO #20

Step 3. Change the set value from 5 to 3 by moving the

direction lever N→R twice.

Value increases.
Direction F
lever
N
R
Value decreases.
Step 4. Register the new value by cycling the DRS
switch S → R → S. The current value is
overwritten with the new value. The screen
shows the next SUO #21. 213480
1-13
CONTROLLER

3. Returning setting from option value to default value

Use the following procedure to return an optionally set
value to the default value (factory set value) due to
occurrence of error code 61 or 65, or some other reasons.
(1) Turn OFF the seat switch.
(2) Set the DRS switch in the S position.
(3) Place the direction lever in the R position, keep the
accelerator pedal depressed, and turn ON the key
switch.
(4) The set value area in the display shows “donE”.
(5) Set the DRS switch in the R position.
The default value is now set again.

1-14
 CONTROLLER

Self-diagnostics (3) When all the step items have been checked through,
turn OFF the key switch and place the DRS switch
By monitoring input and output signals of the in the R position. Do not forget to reinstall the 500
controller, the CPU of the controller checks operation A line fuse.
of various switches, contactors and other components
on the truck under the control of the stored diagnostics
• Turn OFF the key switch to exit from the
program. The check items are shown in detail in the
diagnostics mode.
Self-Diagnostics table on page 1-20. It is
recommended to check the conditions of the truck’s • Repair all faults found immediately after
components using the diagnostics function of the diagnostics.
controller at the time of planned maintenance.
Perform diagnostics using the following procedure.
R
1. Preparatory operations
S D
(1) Place the parking brake lever in the locked position.
Pull
(2) Turn OFF the key switch.
(3) Disconnect the battery plug.
(4) Place the direction lever in the N position.
211196
(5) Set the DRS switch to the D (diagnostics) position.
(6) Remove the line fuse (500 A).
(7) Connect the battery plug. Diagnostics procedure requires moving the DRS switch
to the D or R position. Follow the instructions in the
2. Diagnostics procedure diagnostics procedure guide above as well as those in
Perform the procedure using the Self-Diagnostics table the applicable boxes in the “Do this” column.
in accordance with the following guide.
(1) Start diagnostics with the Step 0 item in the table. Diagnostics result indication
Turn ON the key switch according to the
instruction in the “Do this” box on the Step 0 line.
If the item passes the check without any problem,
the next step number “01” appears on the display.
If the item involves any problem and fails in the
check, “dd” is shown on the display. The display
also shows “dd” when diagnostics is started without
209561
removing the fuse. In this case, diagnostics is
prohibited from going even to the first step.
(2) When the Step 0 item has passed the check,
diagnostics may advance to the next Step 1 item
(seat switch). Cycle the seat switch
OFF→ON→OFF according to the instruction in the
“Do this” box on the Step 1 line. If the item passes
the check, the next step number “02” appears on the
display. Do likewise for the succeeding items,
following the instructions in the “Do this” column
boxes. If the item of a step fails in the check,
diagnostics does not advance automatically. In this
case, diagnostics can be forcibly advanced to the
next step by cycling the DRS switch D→R→D.
1-15
CONTROLLER

Other Functions

1. Service indicator (SUO #10)

When the vehicle hourmeter indication reaches the set
value, the service indicator turns ON to notify the need for
maintenance. Output power control can be also activated at
the same time. The setting can be made in a range of 100
to 500 at 50 hour increments. The service indicator turns
ON when the hourmeter indication exceeds the value of the
current hourmeter reading plus the set value.
The indicator starts flashing 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 prohibit
lift.

3. Stall timer (SUO #20)

This option adjusts the time to shut down the truck when
the traction motor torque is too high.

4. Tire size adjustment (SUO #27)

This function provides a correction value to compensate for
a diameter change resulting from tire wear. It is used to
adjust the vehicle speed data.

5. Auxiliary input for travel speed (SUO #30)

Auxiliary input to limit the maximum vehicle speed or
reduce output power.

6. Auxiliary maximum travel speed setting (SUO #31)

This option determines the maximum travel speed limit of
#30.

7. Auxiliary output power limit (SUO #32)

This option determines the output power limit in % of #30.

1-16
 CONTROLLER

Setup Options (Group 1)

SUO Default
Title of Option Description Range
# Value
#1 Application pre-sets There are 5 truck modes and each has 7 A, b, C, d, E A
(truck operation option values: If any of these 7 option values are
mode) Top travel speed, Acceleration rate, changed, A through E will flash in
Traveling power, Regen adjustment, order to show that the truck mode is not
Start lift speed, Top lift speed, in default setting.
Tilt speed.
#2 Start lift speed Lift speed when the first lift switch 1 to 10 1
closes. Start lift speed cannot exceed
top lift speed.
(1: SLOW → 10: FAST)
#3 Top lift speed Lift speed when the second lift switch 1 to 10 9
closes.
#4 Tilt speed Tilt speed is prior to lift speed in case 1 to 10 3
that the two levers are simultaneously
operated.
#5 Auxiliary 1 speed Speed setting for attachment 1 1 to 10 3
#6 Auxiliary 2 speed Speed setting for attachment 2 1 to 10 1
#7 Top travel speed Maximum travel speed 5 to 20 km/h 18
limit
#8 Acceleration rate Choice of acceleration rate 1 to 5 3
(1: SLOW → 5: FAST)
#9 Traveling power Choice of powering characteristic 1, 2, 3 2
(1: ECONOMY, 2: STANDARD,
3: HIGH POWER)
#10 Service indicator This option sets the maintenance time 100 to 500 hours in 50-hr. increment. 0
which is a reminder for service Selecting “=” attached number makes
personnel. The time set here is added to the power reduction function effective.
the truck’s hourmeter and that value is Selecting 0.1 makes the truck
stored in memory as the “maintenance demo-mode.
time”. When the truck’s hourmeter 0: Disable
reaches maintenance time, the service
indicator LED turns on. It will flash 20
hours before maintenance time.
You can reduce the truck power when
the LED is solid on by setting selection.
You can also set the demo-mode, which
shows the Service Indicator function in
a short period of time.

NOTE
(1) The service indicator shows the set value, not the current value. If the key switch is turned off without
entering data (without setting the switch to R), the current value is maintained.
(2) The output power control function of the service indicator is the same as the output power control that is
activated when the battery voltage level drops.
(3) When the truck mode is selected, all data is replaced by the set values of the selected mode. When the set
values are changed, the truck mode indicator (A to E) flashes to indicate that the settings are modified.

1-17
CONTROLLER

Setup Options (Group 2)

SUO Default Harness

Title of Option Description Range
# Value Pin No.
#11 Auxiliary input 1 When the auxiliary input signal is on, 0: Disabled 0 CN14-8
for lift the controller will inhibit lifting 1: Inhibit lifting (switch closed)
according to the selection. 2: Inhibit lifting (switch opened)
#14 Auxiliary input 2 Same as #11 Same as #11 0 CN14-9
for lift
#17 Auxiliary input 3 Same as #11 Same as #11 0 CN14-10
for lift
#20 Stall timer This option adjusts the time to shut 2 to 10 sec 5 –
down the truck when the traction
motor torque is too high.
#21 Regen function This option enables one of two Regen 1: Brake regen 2 –
Modes. (accelerator must be off)
2: Accelerator regen
(also called “auto regen”)
#22 Regen adjustment 10 steps for regen power on lever 1 to 10 7 –
for lever regen regen
#23 Regen adjustment 10 steps for regen power on brake/ 1 to 10 7 –
for auto regen auto regen
#24 Chat timer The amount of time required entering 0 to 40 sec 20 –
chat mode 0: Disable
#25 Seat switch timer The amount of time required turning 3 to 15 sec 5 –
off the line contactor, when the
operator leaves the seat.
#27 Tire size adjustment Adjusts the amount of tire wear. 0 to 40 20 –
It changes truck’s speed recognition.
#30 Auxiliary input for This input is used in conjunction with 0: Disabled 0 CN1-11
travel speed option #31 or #32 to limit travel 1: Travel speed limit set by #31
speed or output power. (switch closed)
2: Power reduction set by #32
(switch closed)
3: Travel speed limit set by #31
(switch opened)
4: Power reduction set by #32
(switch opened)
#31 Auxiliary maximum This option determines the maximum 5 to 20 km/h 12 CN1-11
travel speed setting travel speed limit of #30.
#32 Auxiliary output This option determines the output 0 to 100 % 70 CN1-11
power limit power limit in % of #30.
#33 Auxiliary 3 speed Speed setting for attachment 3 1 to 10 3 –

1-18
 CONTROLLER

Setup Options (Group 3)

SUO 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 80: 80 V –
the battery.
#42 Battery type This option is used to set the type of the 0: Normal BDI –
battery. 1: Tubular BDI
Tubular BDI: For the battery with
different discharge characteristic.
#43 Hydraulic control This option is used to set the type of the 0: FC –
selection hydraulic control. 1: MC
#44 Mast type This option is used to set the type of the 2FF: 2-stage full-free –
mast. 3FF: 3-stage full-free
2SP: 2-stage panorama
#45 Valve section This option is used to set the number of 1: 3 ways (lift, tilt, attachment 1) –
valve sections. 2: 4 ways (lift, tilt, attachment 1,
attachment 2)
3: 5 ways (lift, tilt, attachment 1,
attachment 2, attachment 3)
#46 Battery voltage In this option, the display shows battery
adjustment voltage which the controller recognizes.
Using a multimeter, adjust the value on
the display to actual value.
Moving the direction lever from N to F
increases the number (+0.1 V).
Moving it from N to R decreases the – –
number (-0.1 V). Depress the
acceleration pedal while the direction
lever is in F to increase the number
(+10 V). Depress the acceleration pedal
while the direction lever is in R to
decrease the number (-10 V).
#47 Foot direction This option is used to enable the 1: Standard direction lever –
function for foot direction control. 2: Foot Directional Control (FoDiCo)

NOTE
(1) In Group 3, all options have no default value.
(2) All options must be set at first POWER-ON.
(3) If SUO data is out of proper range, “III” is displayed.

1-19
CONTROLLER

Self-diagnostics

Step Checking Do this Controller check this Result Display Motion

0 Power line Turn on the key switch. Close the line contactor and Pass 01 Line contactor
voltage check the power line voltage. closes and
(fuse check) opens
Fail dd
1 Seat switch Release and press and Input OFF → ON → OFF Pass 02
release the seat switch.
Fail 01
2 Direction Cycle the direction lever: Input changes as Pass 03
switch N → R → N → F → N. N → R → N → F → N.
Fail 02
3 Parking brake Release and apply Input OFF → ON → OFF Pass 04
and release the
parking brake. Fail 03
4 Service brake Depress and release Input OFF → ON → OFF Pass 05
the service brake.
Fail 04
5 Accelerator Depress the accelerator Pass Number 0 to 15 flashes as the
and release. accelerator is pressed.
Fail —
DIAG → RUN — 06
6 Battery voltage (Automatic) Check the battery voltage: Pass 07
RUN → DIAG (62 V to 110 V)
Fail 06
7 Lift switch Pull and release the Input OFF → ON → OFF Pass 08
lift lever. Fail 07
8 Tilt switch Pull and release the Input OFF → ON → OFF Pass 09
tilt lever.
Fail 08
9 Auxiliary 1 Pull and release Input OFF → ON → OFF Pass 10
switch Aux. 1 lever.
Fail 9
10 Auxiliary 2 Pull and release Input OFF → ON → OFF Pass 11
switch Aux. 2 lever.
(DIAG → RUN → Fail 10
DIAG) (*)
11 Auxiliary 3 Pull and release Input OFF → ON → OFF Pass 12
switch Aux. 3 lever.
(DIAG → RUN) (*) Fail 11
RUN → DIAG — 00
12 Hydraulic Pull any lever and see Pass Flashing pump speed value
speed check the display.
Fail Other than above
DIAG → RUN — 13
(*)
In case of no Auxiliary 2 or 3 switch, skip 10 or 11.

1-20
 CONTROLLER

Self-diagnostics (Continued)

Step Checking Do this Controller check this Result Display Motion

Line contactor → DIAG See the line contactor closes. Pass 13 Contactor
closes.
Fail 13 No operation
13
→ RUN See the line contactor opens. Pass 14 Contactor
opens.
Fail 13 No operation
Steering → DIAG See the steering contactor Pass 14 Contactor
contactor closes. closes.
Fail 14 No operation
14
→ RUN See the steering contactor Pass 98 Contactor
opens. opens.
Fail 14 No operation
98 Drive controller RUN → DIAG → See the software version No. in — 99
software version RUN the hourmeter
99 Pump controller RUN → DIAG → See the software version No. in — done
software version RUN the hourmeter

1-21
CONTROLLER

Run Time Diagnostics

Display

LED

Steering operation
Fault How to detect To return

Service Indicator
Result

Parking Brake
to normal

Battery Low
Code

Brake Fluid

Over Temp.
Error
Traction Motor, Overheating Thermal contact (170ºC) * E0  Power reduction Cool
Pump Motor, Overheating Thermal contact (150ºC) * E2  Power reduction Cool
Traction Module, Overheating Thermistor (MOS 110ºC, C 100°C) * E3  Power reduction Cool
Brake Fluid Low Level Level sensor (Contact) *  Turn key off
Pump Module, Overheating Thermistor (MOS 105ºC, C 95°C) * E7  Power reduction Cool
Traction Motor Fault Compares real current with command current. * 10 X Line contactor off (*) Turn key off
Traction Motor Driver U Fault Fault signal from the MOS-FET module U * 11 X Line contactor off (*) Turn key off
Traction Motor Driver V Fault Fault signal from the MOS-FET module V * 12 X Line contactor off (*) Turn key off
Traction Motor Driver W Fault Fault signal from the MOS-FET module W * 13 X Line contactor off (*) Turn key off
Traction Motor Current Sensor Fault Out of normal range * 14 X Line contactor off (*) Turn key off
Traction Motor Over-current More than 640 A (80V) * 15  Line contactor hold Turn key off
Traction Stall Timer Measures the time (set by SUO #20) while stalling. * 16  Line contactor hold Turn key off
Pump Motor Fault Compares real current with command current. * 30 X Line contactor off (*) Turn key off
Pump Motor Driver U Fault Fault signal from the MOS-FET module U * 31 X Line contactor off (*) Turn key off
Pump Motor Driver V Fault Fault signal from the MOS-FET module V * 32 X Line contactor off (*) Turn key off
Pump Motor Driver W Fault Fault signal from the MOS-FET module W * 33 X Line contactor off (*) Turn key off
Pump Motor Current Sensor Fault Out of normal range * 34 X Line contactor off (*) Turn key off
Pump Motor Over-current More than 610 A * 35  Line contactor hold Turn key off
Line Contactor Fault Checks voltage of power circuit. * 40 X Line contactor off (*) Turn key off
Accelerator Sensor Fault Out of normal range * 51  Line contactor hold Turn key off
FC Lever Fault Out of normal range * 54  Disable the lever op. Turn key off
FC Solenoid Fault Out of normal range * 55  Disable the solenoid Turn key off
FC Solenoid Current Leak Current is detected when current command is zero. * 56  Disable the solenoid Turn key off
Pump Motor Speed Sensor Fault Input is absent or out of normal range. * 57  Line contactor hold Turn key off
Traction Motor Speed Sensor Fault Out of normal range * 58  Line contactor hold Turn key off
Direction Lever or Accelerator, Faulty The lever/accelerator is not neutral at E X Line contactor off Neutral
Setting power-on.
Seat Switch Faulty Setting The switch is off at power-on. (E) X Line contactor off Switch on
Lift Lever Faulty Setting The lever is not neutral at power-on. H1 X Line contactor off Lever off/Neutral
Tilt Lever Faulty Setting The lever is not neutral at power-on. H2 X Line contactor off Lever off/Neutral
Attachment 1 Lever Faulty Setting The lever is not neutral at power-on. H3 X Line contactor off Lever off/Neutral
Attachment 2 Lever Faulty Setting The lever is not neutral at power-on H4 X Line contactor off Lever off/Neutral
Attachment 3 Lever Faulty Setting The lever is not neutral at power-on H5 X Line contactor off Lever off/Neutral
Display Communication Fault When serial communication is not going on. * 60  Indicates if it possible Turn key off
EEPROM Fault Sum check of SUO data * 61 X Line contactor off Turn key off
Logic Card Initialize Failure SUO Gr. #3 is not set. * 65 X Line contactor off Turn key off
Controller Fault Sum check of ROM & RAM * 66 X Line contactor off Turn key off
Battery Voltage Too Low Voltage class is not correct. * 68 X Line contactor off Turn key off
Contactor Coil Fault Contactor coil current sensor * 72 X Line contactor off Turn key off
Capacitor Charge Fault Abnormal charging/discharging of capacitor * 73 X Line contactor off (*) Turn key off
Battery Consumption Much Much consumption with small capacity battery (*)  Power reduction Charge battery
Battery Consumption Too Much Too much consumption with small capacity * (Lo) X Line contactor off (*) Turn key off
battery

NOTE
(1) E0 to E7 don’t appear on the display, but are stored in the history folder.
(2) E, (E), H1 to H5 and (Lo) appear on the display, but not stored in the history folder. (E) means flashing. “” means that the
steering operation is operable and “X” means that it is inoperable.
(3) ‘Line contactor off (*)’ means that the contactor will open immediately after a fault is detected. ‘Line contactor off’ means that
the contactor will open after the current goes to 0.

1-22
 CONTROLLER

Display Unit

1. 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 indicate low battery power
level. When the BDI indication disappears, the LED
206798
remains on and the output control is activated.
The BDI turns OFF when not necessary, such as during
4. Action indicators (LEDs)
setup option setting and self-diagnostics operation.
The indicators are activated when an error is detected
2. Hourmeters and time display during normal condition. They do not turn on during
(1) Normal operation setup option setting or self-diagnostics operation.
When the key switch is turned on, the hourmeters (1) Service indicator (SUO #10)
for the traction motor, pump motor and vehicle are The indicator starts flashing 20 hours before
indicated in sequence. The hourmeters for the maintenance is required and remains lit when the
motors show cumulative operating hours, and the set time is reached.
vehicle hourmeter indicates cumulative line
(2) Over temp
contactor ON hours.
The indicator turns ON when a motor or the
A clock display is shown under normal condition.
controller overheats.
(2) During setup option setting and self-diagnostics
(3) Battery low
operation
The indicator starts flashing when the BDI shows
The hourmeters are not displayed when the key
only one segment, and remains lit when the BDI
switch is turned on.
has no segment indication.
Data are indicated on the display.
(4) Brake fluid
3. Vehicle speed and error code display The indicator flashes when the brake fluid level
The display indicates vehicle speed under normal becomes low.
condition, and shows an error code when a malfunction (5) Parking brake
is detected.
The indicator flashes when the parking brake is
The display shows item number during setup option engaged.
setting and self-diagnostics operation.
(6) Error
The indicator flashes when a malfunction is
detected. Refer to the malfunction detection table.

1-23
CONTROLLER

Removal and Installation

Removal and Installation of Controller

Assembly
Tightening torque
! WARNING
Size N·m kgf·m lbf·ft
Disconnect the battery plug before working on the
controller. M3 0.98 ± 0.20 0.10 ± 0.02 0.72 ± 0.15
M4 1.47 ± 0.20 0.15 ± 0.02 1.08 ± 0.15
NOTE
M5 2.94 ± 0.49 0.30 ± 0.05 2.17 ± 0.36
See the table on the right for the tightening torque of
the controller terminal nuts, contactor terminal nuts M6 4.41 ± 0.49 0.45 ± 0.05 3.25 ± 0.36
and controller component mounting screws. M8
stud terminal 11.77 ± 1.96 1.20 ± 0.20 8.68 ± 1.45
M8
1. Removal of rear cover 1.23 ± 0.45 0.13 ± 0.05 0.91 ± 0.33
nut
(1) Turn the key switch off.
(2) Disconnect the battery plug.
(3) Remove the rear cover of the counterweight.

2. Removal of controller assembly

(1) Disconnect connectors CN1, CN2, CN14 and CN15.

NOTE
Hold the connectors to unplug. Do not pull the
harnesses to disconnect the connector.
Rear cover
208272

! 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 overheating
and lead to a fire in the worst case scenario.
When checking or adjusting the cable routing,
avoid pulling the cables. If cables move even
slightly at the terminals, loose connections will
result. When working with the cables, always be
sure to retighten the terminal connections.

(2) Remove the power cables (for battery and motors).

8 x M8 stud terminals on controller
3 x 1/4-20 terminals on contactor plate

209527A

1-24
 CONTROLLER

• Controller stud terminal

The stud terminal sections have resin parts.
When tightening the nut, hold the resin parts
with a wrench (21 mm size). (Indicated by the
arrow in the illustration on the right.)
• When installing the stud terminal on the
aluminum plate, apply Loctite to threads of the
terminal and tighten the terminal to a torque
within the range shown below.

M8
11.77 ± 1.96 N·m
Tightening torque for
(1.2 ± 0.2 kgf·m) Nut
stud terminal (M8)
[8.7 ± 1.4 lbf·ft]

(3) Remove the controller assembly.

Remove the controller mounting bolts (M10: 6 places
for controller. 4 places for contactor plate), and
remove the controller.
Aluminum
plate
39 ± 7.8 N·m 209562
Tightening torque for
(4 ± 0.8 kgf·m)
mounting bolt (M10)
[29 ± 6 lbf·ft]

3. Installation of controller assembly

To install, follow the reverse of removal procedure, and
follow the instructions below.

NOTE
Unit: mm (in.)
There is a silicon grease between the counterweight 480 (18.9)
10 (0.4) 10 (0.4)
10 (0.4)

and controller. It is important to cool the controller.

Spread the silicon grease evenly, then mount the
controller on it.
275 (10.8)
10 (0.4)

Hatched area
must be coated
thin with silicon
grease. 209563

1-25
CONTROLLER

Removal and Installation of Logic Card

1. Removal of controller cover

Remove the cover mounting screws (M6: 6 places),
and remove the controller cover.

2. Removal of logic card

(1) Disconnect connectors CN3, CN5, CN6, CN7,
CN8, CN9 and CN10.
(2) Remove the logic card bracket mounting screws
(M6: 4 places marked A in the illustration below),
and remove the logic card with bracket.
(3) Remove the logic card mounting screws (M3: 7
places marked B in the illustration below), and the
heat-sink mounting screws (M4: 2 places marked
C in the illustration below), and remove the logic
card.

A A

C
CN5 CN6 CN7 CN8 CN9 CN10
B B B

B B CN3
B

A A
The screws marked A are for mounting the logic card bracket. The screws marked B and C are for mounting
the logic card.
213481

3. Installation of logic card

Follow the removal procedure in reverse.

1-26
 CONTROLLER

Removal and Installation of MOS-FET Module

D E Bus bar (POS) D

F MOS-FET
module

Never remove any

of the screws with
a white insulator
under the head.

D Bus bar (NEG) D

213482

(1) Removal of controller cover (7) Installation of MOS-FET modules

Remove the cover mounting screws (M6: 6 Follow the removal sequence in reverse. Also
places), and remove the controller cover. follow the instructions below.
(2) Disconnect connectors CN3, CN5, CN6, CN7,
CN8, CN9 and CN10, and cut the cable tie on both NOTE
sides of the CN1. (See the logic card removal There is silicon grease between the MOS-FET
procedure on page 1-26.) module and base plate. It is important to cool the
(3) Removal of logic card controller. Spread the silicon grease uniformly,
then mount the MOS-FET module on it.
Remove the bracket mounting screws (M6: 4
places marked D in the illustration above), and Use only “Shin-Etsu Silicon G747” grease or
remove the logic card with brackets. equivalent.
(4) Remove bus bars (POS, NEG) mounting screws
(M5: 12 places marked E in the illustration above,
M8 stud: 2 places marked F in the illustration
above), and remove bus bars.
(5) Disconnect connectors J5, J6, J7 or J8 of the
current sensor input connector if necessary.
(6) Remove MOS-FET module mounting screws (M4:
3 places marked G in the illustration above), and
remove the MOS-FET module. There are three
mounting screws for each MOS-FET module. They
are identified by arrows on the molding of the Apply a thin coat of grease here.
module. Never remove any of the screws that have 209566
a white insulator under the head.

1-27
CONTROLLER

Basic Check

Always follow basic troubleshooting steps.

• Talk to the operator.
• Confirm the operator’s description of the problem with
an operational check.
• Visually inspect cables, connectors, contactor tips, etc.
• Perform basic battery cables to frame resistance test. (at
least 20 k ohm)
• Check battery condition.
Always check each option and write down the reading.

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

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

1-28
 CONTROLLER

Measurement of Logic Card Voltage

! WARNING
To prevent accidental movement of the vehicle,
place jack stands under the vehicle to lift the front
wheels off the ground. Do not move the jack
stands close to the front wheels.

1. Place jack stands under the vehicle to lift the front

wheels off the ground.
2. Turn the key switch off.
3. Disconnect the battery plug.
4. Remove the rear cover from the counterweight.
5. Using an IC clip, connect the positive (+) test lead of
the multimeter to the intended one on the logic card
side pins that are associated with the harness side
connectors CN1, CN2, CN14 and CN15. The logic
card side pins are covered with insulation coating, so
remove the coating from the pin to which the IC clip is
going to be connected.
6. Set the multimeter to the 100-VDC range.
7. Reconnect the battery plug.
8. Turn the key switch on. Connect the negative (-) test
lead of the multimeter to the NEG terminal (terminal
portion of the NEG bus bar, for example) of the
controller. Measure the standby voltage.
9. Then operate a control (a switch for example) to
measure the activation voltage.

NOTE

Be careful not to short-circuit pins.

For the normal voltage value, refer to the logic card

voltage chart on the next page.

1-29
CONTROLLER

Logic card measured voltage chart

Stand-by Activated
No. Name Note
voltage voltage
CN1-1, 2, 3, 4 V POW (FROM KEY) Vbatt* Vbatt* 0 V: Key OFF, Vbatt*: Key ON
CN1-5 REVERSE SW 14.5 to 15.5 V 0 V
CN1-6 TRACTION MOTOR 14.5 to 15.5 V 0 V
THERMAL SW
CN1-7 ACCEL IDLE SW 14.5 to 15.5 V 0V
CN1-8 PARK BRAKE SW 14.5 to 15.5 V 0V
CN1-9 SEAT SW 14.5 to 15.5 V 0V
CN1-10 BRAKE FLUID SW 14.5 to 15.5 V 0V
CN1-11 SPEED LIMIT SW 14.5 to 15.5 V 0V
CN1-12 FORWARD SW 14.5 to 15.5 V 0V
CN1-13 SERVICE BRAKE SW 14.5 to 15.5 V 0V
CN1-14, 15, GND 0V 0V
16, 17
CN1-18 5 V (ACCEL) 5V 5V
CN1-19 ACCEL ANGLE 1V 1 to 4 V
CN1-20 GND (ACCEL) 0V 0V
CN1-21 DISPLAY GND 0V 0V
CN1-22 DISPLAY TXD 0 to 12 V 0 to 12 V
CN1-23 DISPLAY RXD 0 to 12 V 0 to 12 V
CN1-24 BRAKE IDLE SW 14.5 to 15.5 V 0V
CN1-25, 26 OPEN
CN2-27, 28 OPEN
CN2-29 MAIN FUSE VOLTAGE Vbatt* Vbatt* 0 V to Vbatt*: Key OFF
Vbatt*: Line contactor ON
CN2-30 POS VOLTAGE Vbatt* Vbatt*
CN2-31 +VE Vbatt* Vbatt* 0 V: Key OFF, Vbatt*: Line contactor ON
CN2-32 STEERING CONTACTOR Vbatt* 0V
CN2-33 LINE CONTACTOR Vbatt* 0V
CN2-34 CHARGE RESISTOR + Vbatt* Vbatt* 0 V to Vbatt*: Key OFF
Vbatt*: Line contactor ON
CN2-35 CHARGE RESISTOR – 0V 0V
CN2-36 SET SW 14.5 to 15.5 V 0V
CN2-37 DIAG SW 14.5 to 15.5 V 0V
CN2-38 GND 0V 0V
CN2-39 15 V (SPEED SENSOR) 14.5 to 15.5 V 14.5 to 15.5 V
CN2-40 TRACTION MOTOR 0 to 5 V 0 to 5 V
REV A +
CN2-41 TRACTION MOTOR 0 to 5 V 0 to 5 V
REV B +
CN2-42 GND 0V 0V
Vbatt* = battery voltage

1-30
 CONTROLLER

Logic card measured voltage chart

Stand-by Activated
No. Name Note
voltage voltage
CN14-1 15 V 14.5 to 15.5 V 14.5 to 15.5 V
CN14-2 PUMP MOTOR REV A + 0V 0 to 5 V
CN14-3 PUMP MOTOR REV B + 0V 0 to 5 V
CN14-4 GND 0V 0V
CN14-5 AUTO LIGHT RELAY Vbatt* 0 to 5 V
CN14-6 AUTO LIGHT 15 V 14.5 to 15.5 V 14.5 to 15.5 V
CN14-7 AUTO LIGHT SENSOR 0 to 5 V 13 to 15.5 V
CN14-8 LIFT LIMIT SW1 14.5 to 15.5 V 0V
CN14-9 LIFT LIMIT SW2 14.5 to 15.5 V 0V
CN14-10 LIFT LIMIT SW3 14.5 to 15.5 V 0V
CN14-11 PUMP MOTOR 14.5 to 15.5 V 0V
THERMAL SW
CN14-12 STEERING SW 14.5 to 15.5 V 0V
CN14-13 LIFT SW1 14.5 to 15.5 V 0V
CN14-14 LIFT SW2 14.5 to 15.5 V 0V
CN14-15 TILT SW 14.5 to 15.5 V 0V
CN14-16 ATTACH 1 SW 14.5 to 15.5 V 0V
CN14-17 ATTACH 2 SW 14.5 to 15.5 V 0V
CN14-18 ATTACH 3 SW 14.5 to 15.5 V 0V
CN14-19, 20 GND 0V 0V
CN14-21 5 V (JOYSTICK) 5V 5V
CN14-22 LIFT JOYSTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN14-23 TILT JOYSTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN14-24 ATTACH 1 JOYSTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN14-25 ATTACH 2 JOYSTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN14-26 ATTACH 3 JOYSTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN15-27 12 V (EMERGENCY) 9 to 15 V 9 to 15 V
CN15-28, 29 OPEN
CN15-30 GND 0V 0V
CN15-31 OPEN
CN15-32 VALVE POW (11 to 13 V) (11 to 13 V) Open: Emergency ON
CN15-33 LIFT VALVE A 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-34 LIFT VALVE B 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-35 LIFT VALVE COM 11 to 13 V 11 to 13 V
CN15-36 LIFT VALVE COM 11 to 13 V 11 to 13 V
CN15-37 TILT VALVE A 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-38 TILT VALVE B 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-39 ATTACH 1 VALVE A 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-40 ATTACH 1 VALVE B 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-41 ATTACH 1 VALVE COM 11 to 13 V 11 to 13 V
CN15-42 ATTACH 2 VALVE COM 11 to 13 V 11 to 13 V
CN15-43 ATTACH 2 VALVE A 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-44 ATTACH 2 VALVE B 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-45 (ATTACH 3 VALVE A) 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-46 (ATTACH 3 VALVE B) 11 to 13 V 0 to 15 V Open: Emergency ON
CN15-47 (ATTACH 3 VALVE COM) 9 to 15 V 11 to 13 V
CN15-48 OPEN
Vbatt* = battery voltage

1-31
CONTROLLER

Checking Contactor Coil

! WARNING

Disconnect the battery plug before working on

the controller.

1. Disconnect the lead wire of coil.

2. Set the multimeter to the 200 ohm range.
3. Measure coil resistance.
(It must be 118 to 145 ohm.) Coil resistance 118 to 145 ohm

• If the measured value deviates from the above range,

replace the contactor assembly.
4. With the lead wire of contactor coil connected, set the
multimeter to the 200-VDC range.
5. Connect the negative (–) test lead of the multimeter to
the negative-side coil terminal (small terminal) and the
positive (+) test lead of the multimeter to the positive-
side coil terminal (large terminal).
6. Connect the battery, and operate the control device that
activates the contactor.
7. The multimeter should indicate a value between 23.4
and 52 volts after the contactor operates. If the
contactor is found to be normal during the coil
resistance test, but the measured voltage is not within
the 23.4 to 52 DC volt range, replace the logic card.

Checking Contactor Tip

1. Visually inspect the contactor tips for melting,
adhesion, heat seizure and pitting corrosion.
2. To check for interference, press the tips and release
them.
3. Visually inspect the contactor assembly. Make sure
there is no foreign material that could interfere with
contactor movement.
4. Measure the gap at the contactor tips using a thickness
208284
gauge.
(It must be 3.15 ± 0.12 mm.)
• If you find any troubles, replace or correct the Gap 3.15 ± 0.12 mm
(Contactor tip) (0.124 ± 0.005 in.)
contactor.

1-32
 CONTROLLER

Checking Current Sensor of Controller

1. Turn the key switch off.
2. Disconnect the battery plug. ! WARNING

3. Disconnect the current sensor connector. To prevent the vehicle from moving suddenly,
lift the front wheels off the ground by placing
Location Connector name jack stands under the vehicle. Do not
Traction U phase J7 approach the front wheels during testing.

Traction V phase J8 7. Turn the key switch off and disconnect the battery
Pump U phase J5 plug. Connect the current sensor connector.

Pump V phase J6 8. Place jack stands under the vehicle to lift the front
wheels off the ground. Engage the parking brake.
4. Set the multimeter to the 20-VDC range. Connect 9. Set the multimeter to the 20-VDC range. Connect
the positive (+) test lead of the multimeter to a the positive (+) test lead of the multimeter to a
point on the No. 4 pin circuit (for example, the point on the No. 2 pin circuit of the current sensor.
logic card side pin of the CN3 connector associated
with the No. 4 pin). Connect the negative (–) test Location Pin No Standard
lead of the multimeter to the NEG terminal. condition
Traction U phase J7-2BrY 2 to 3 V
Location Pin No Standard
condition Traction V phase J8-2BrY 2 to 3 V
Traction U phase J7-4GR 14 to 16 V Pump U phase J5-2BrY 2 to 3 V
Traction V phase J8-4GR 14 to 16 V Pump V phase J6-2BrY 2 to 3 V
Pump U phase J5-4GR 14 to 16 V
10. Connect the battery plug and turn the key switch
Pump V phase J6-4GR 14 to 16 V ON.

5. Connect the battery plug and turn the key switch • If values measured in the above step deviate
ON. from the specified ranges, replace the current
sensor.
• If values measured in the above step deviate
from the specified ranges, replace the logic card. 11. Shift the direction lever to forward. Gradually
depress the accelerator pedal (with front wheels
6. Then connect the positive (+) test lead of the raised) and read the voltage change.
multimeter to a point on the No. 2 pin circuit.
Location Pin No Standard
Location Pin No Standard condition
condition
Traction U phase J7-2BrY 0.5 to 4.5 V
Traction U phase J7-2BrY 4 to 6 V (unstable)
Traction V phase J8-2BrY 4 to 6 V 0.5 to 4.5 V
Traction V phase J8-2BrY (unstable)
Pump U phase J5-2BrY 4 to 6 V
• If values measured in this step deviate from the
Pump V phase J6-2BrY 4 to 6 V
specified ranges, replace the current sensor.
• If values measured in this step deviate from the
specified ranges, replace the logic card.

1-33
CONTROLLER

12. Shift the lift lever to forward (lowering) and read

the voltage change.

Location Pin No Standard

condition

Traction U phase J5-2BrY 0.5 to 4.5 V

(unstable)

Traction V phase J6-2BrY 0.5 to 4.5 V

(unstable)

• If values measured in this step deviate from the

specified ranges, replace the current sensor.

1-34
 CONTROLLER

Checking MOS-FET Module

! WARNING
Disconnect the battery plug before working on the
controller.

1. Turn the key switch off. + of

multimeter – of multimeter Standard multimeter
indication
2. Disconnect the battery plug.
3. Remove all high-tension cables (except NEG) from the TU truck OL
traction controller. TV truck OL
4. Remove the logic card with bracket and bus bars (POS,
TW truck OL
NEG).
PU truck OL
5. Set the multimeter to the 20 k ohm range. Measure the
resistance between each of the terminals shown in the PV truck OL
table on the right and the truck body. If the multimeter
PW truck OL
reading does not conform to the indication in the table,
replace the MOS-FET module.
• If you find any troubles, replace the MOS-FET
module.
Unit Test
1. Turn the key switch off.
P terminal N terminal
2. Disconnect the battery plug.
3. Remove the MOS-FET module from the controller.
4. Set the multimeter to the 20 k ohm range. Measure
resistance between each terminal. XXXXXX
F terminal
• If you find any troubles, replace the MOS-FET
Heat sink
module.
5 3 1
6 4 2
Standard multimeter CN1
+ of multimeter – of multimeter indication
CN1-1 (+15 V) N terminal 10.0 to 10.4 k ohm 211683

CN1-1 (+15 V) CN1-3 1.48 to 1.54 k ohm

CN1-1 (+15 V) CN1-4 1.48 to 1.54 k ohm
CN1-2 N terminal OL
P terminal Heat sink OL
N terminal Heat sink OL
F terminal Heat sink OL

1-35
CONTROLLER

5. Short-circuit P terminal and N terminal. Set the Unit: mm (in.) 10 (0.39)

multimeter to the 20 k ohm range. Measure resistance
between each terminal.

+ of multimeter – of multimeter Standard multimeter

indication
N terminal F terminal 1 M ohm or higher
P terminal F terminal 1 M ohm or higher

6. Set the multimeter to the 20 k ohm range. Measure

resistance for each FET.
0.75 (0.03)
NOTE
2.54 (0.1) 2.54 (0.1)
The terminals of each MOS-FET module are covered

(0.18)
with insulation coating. Remove the coating from the

4.5
1 2 3
terminals shown in the illustration below before
performing measurement. Apply insulation coating to
the terminals after measurement. 2

1 Gate
+ of
Location multimeter – of Standard multimeter 2 Drain
multimeter indication 1 3 Source

QL01 to Gate Source 10.0 to 10.4 k ohm

QL20 terminal terminal Exactly same for all
3 209560
QH01 to Gate Source 10.0 to 10.4 k ohm
QH20 terminal terminal Exactly same for all

D NEG
G S

Terminal

Terminal

S G
D POS 209567

1-36
 CONTROLLER

Regeneration Check
The AC motor uses a common circuit for current flow in
both loading and regeneration. The following procedure
will confirm the regeneration operation.
1. Place the clamp ammeter onto the cable connected to
the controller’s CNT terminal (use DC current range).
Clamp ammeter
This is positive direction as current flows from the setting direction
battery to the controller.
2. Run the truck forward. With the direction lever shifted
in F position, release the accelerator pedal. Then
perform a full-reverse operation.
3. The clamp ammeter should show a negative value. This
value becomes the regeneration current.

Energy is generated when a motor is rotated by an external

force. The regeneration power is produced when this
energy is greater than the one that is consumed by the
211684
controller and motor. This means that the regeneration
current is not measured if the speed or load changes
gradually.

1-37
CONTROLLER

AC Motor System Basics

1. Feature of AC motor
The PAC model forklift trucks covered by this manual The frequency and voltage can be controlled in a
use AC motors (three-phase induction motors) as the variety of methods including the “vector control
traction motor and pump motor. AC motors have the method” employed in the PAC model forklift trucks.
following advantages over DC motors: This method provides highly responsive control
(1) AC motors are simple in construction. Since they according to ever changing truck-operating conditions
do not have friction parts like brushes and through high-speed calculation on huge amount of data.
commutators, daily maintenance is significantly The vector control calculation is performed by one of
reduced. the CPUs on the logics card. (Fig. 2)

(2) AC motors are compatible with high-speed

operation.
U
(3) An AC motor of a certain size produces higher
power than a DC motor of the same size.
Controller V
IM
2. Speed control of induction motors
W
Speed control of DC motors depends on regulation of
the field and armature current amounts, while that of
AC motors basically depends on adjustment of the
frequency of the alternating current power supply. The V V
U V W
speed of an AC motor is determined by the frequency of
the power supply AC current and the load on the motor.
t t
In addition, the voltage and current to the motor must
be controlled properly so that the motor operates in its
Low-speed operation High-speed operation
optimum characteristic range. (Fig. 1) (low frequency)
209542

Fig. 1

Logics card Gate

driving MOS-FET modules
pulse

Accelerator Calculation for Vector control

F required output calculation IM
N
R

Current
Brake Truck speed Speed

209543

Fig. 2

1-38
 CONTROLLER

3. Inverter
Switch
The truck battery delivers DC current, so the current must
be converted into AC current to drive an AC motor. The VB VL Load
device that converts direct current into alternating current is
generally called an “inverter”. The processes involved in
T1 T2 T1 T2 T1
creating AC current from DC current are described below. VL = x VB
T1 + T2
(1) Changing DC voltage cyclically ON OFF ON
Average voltage VL
If the switch in a circuit like a one shown in Fig. 3 is
turned on for time T1 and then turned off for time T2
and this on-off operation is repeated many times, the Small duty ratio Large duty ratio
average of the voltage applied to the load is determined ON ON ON

by the ratio between T1 and T2. Varying the ratio,

therefore, results in varying voltage. The ratio between
OFF OFF
T1 and T2 is called “duty ratio”. By changing the duty 209544
ratio cyclically, it is possible to obtain cyclically
Fig. 3
changing DC voltage shown in Fig. 3.
(2) Converting DC power into AC power
Driving a three-phase AC motor using battery delivered
power requires creating three phase outputs (U, V, W)
of an identical waveform that differ in phase by 120°
using a circuit with six switches S1 to S6 that are S1 S3 S5
arranged as shown in Fig. 4. The outputs thus created U
V
forms a three-phase alternating current. Fig. 5 shows W
on-off condition of each switch (arm) and output S2 S4 S6
voltage variation.
Functioning as switches in the inverter of the AC motor
trucks are MOS-FET transistors. The MOS-FET
209545
transistors can switch at very high speeds, thus creating
smooth waveforms of alternating current. Fig. 4

S1 ON

Switching for U phase

S3 ON
S2 ON

Switching for V phase

S5 ON S4 ON

Switching for W phase

S6 ON
209546
Voltage between output wires
Fig. 5

1-39