CAT EP10-15 KRT PAC Controller 2 Manual

TROUBLESHOOTING FOR CONTROL CIRCUITS
General Information ............................................................................... 2 – 1

Before replacing devices ....................................................................... 2 – 1
Connection of the service tool ............................................................... 2 – 1
How to clean harness connectors and system components .................. 2 – 2
Troubleshooting ...................................................................................... 2– 3
E0 Traction Motor, Overheating ................................................. 2– 3
E2 Pump Motor, Overheating ...................................................... 2– 6
E5 Traction Inverter, Overheating .............................................. 2– 9
2
E7 Pump Inverter, Overheating .................................................. 2 – 12
Brake Oil, Low Level ................................................................ 2 – 15
14 Traction Motor Current Sensor Fault .................................. 2 – 17
15 Traction Motor, Over-current ................................................. 2 – 19
16 Traction Motor, Stall Timer ..................................................... 2 – 22
34 Pump Motor Current Sensor Fault ...................................... 2 – 25
35 Pump Motor Over-current ...................................................... 2 – 27
40 Line Contactor Fault ................................................................ 2 – 30
45 Traction Motor Open ............................................................... 2 – 33
47 Pump Motor Open .................................................................... 2 – 36
51 Accelerator Sensor Fault ........................................................ 2 – 39
52 Traction Motor Pulse Input Fault .......................................... 2 – 42
57 Pump Motor Pulse Input Fault .............................................. 2 – 45
60 Display Communication Fault ............................................... 2 – 48
61 Logic Card Initialize Failure ................................................... 2 – 51
62 Logics Fault ............................................................................... 2 – 52
63 Traction Inverter Fault ............................................................. 2 – 53
65 Pump Inverter Fault ................................................................. 2 – 56
72 Contactor Coil Fault ................................................................ 2 – 59
74 Hydraulic Lock Solenoid Fault .............................................. 2 – 61
76 PDS Buzzer Fault ..................................................................... 2 – 63
78 Battery Voltage Too Low ........................................................ 2 – 65
79 Battery Voltage Too High ........................................................ 2 – 67
83 Lift Stroke Sensor Fault .......................................................... 2 – 69
E Direction Lever or Accelerator, Faulty Setting .............. 2 – 71
(E) Seat Switch, Faulty Setting For Traction ........................ 2 – 73
(L) Seat Switch, Faulty Setting For Hydraulic ...................... 2 – 75
H1 Lift Lever, Faulty Setting ...................................................... 2 – 77
H2 Tilt Lever, Faulty Setting ...................................................... 2 – 79
H3 Attachment 1 Lever, Faulty Setting .................................. 2 – 81
H4 Attachment 2 Lever, Faulty Setting .................................. 2 – 83
Lo Battery Consumption Too Much ....................................... 2 – 85
(Lo) Battery Consumption Much ............................................... 2 – 87
Lift down, Inhibited ............................................................... 2 – 89
All Operations except Lift down, Inhibited ..................... 2 – 91
PDS Buzzer Does Not Sound ............................................. 2 – 93
Electrical System Diagram ................................................................... 2 – 97
Electrical System Schematic ............................................................... 2 – 99
Location of Major Components .......................................................... 2 – 101
General Information
! WARNING
Block the wheels to prevent the truck from unexpected moving.
Before replacing devices

Do not replace devices casually even if replacement is required as a result of troubleshooting. Be sure to check the
following items before replacing devices (logic unit, logic card, power supply card, inverters, inverter DSP cards,
display unit).
• Loose battery connectors
• Abnormal wire harness connections
• Loose connectors
• Broken, bent or loose connector pins
• Dirty connectors
If connectors are dirty, remove the connector and clean connectors.
See “How to clean harness connectors and system components” on page 2-2.
• Ensure that the main harness is not short-circuited to the truck body by using the following procedures.
Disconnect battery plug and discharge the inverters before

working on electrical system.
Disconnect connector CN4 of logic unit. Check continuity between

CN4-13(4) and truck body (logic unit installation bolts, etc.).
No continuity Continuity
Normal Repair or replace harness.
• Perform “Inspection before replacing controllers” described in the Removal and Installation of the controller.
If any of these items (above items) is a source of the trouble, the device will be damaged even if it is replaced with a
new one. Be sure to check the above items and replace carefully.
Connection of the service tool

1. Turn off the truck power. Logic unit
2. Remove the floor plate. Service tool connector
(under the floor plates)
3. Find the connector to the service tool.
4. Remove the cover and connect the PC as shown.
5. Turn on the truck power.
6. Start the service tool software.(GSE)
212051
2-1
How to clean harness connectors and system

components
1. Open-circuits are often caused by dirty harness
connectors and components. Dust, together with greasy
matter, forms grime which, in time, penetrates electrical
connections, resulting in loose metal-to-metal contact in
the worst case, electrical separation of surfaces in
contact. For this reason, it is essential that the
connectors and components be cleaned at each periodic
inspection and at when servicing the truck. Instead of a
commonly used solvent, use electronic parts cleaner (in
the manner illustrated on the right).
Electronic parts cleaner
Electronic parts
Three Bond 29D
cleaner 211223
NOTE
The cleaner liquid is volatile (Evaporates by itself). All
that is required is to thoroughly wash off the grime
with the spray.
No need to wipe off the sprayed liquid.
2. After checking the connector for continuity, wash it as

shown. Then, uncouple the connector and spray contact
surface activator onto contact surfaces.
Install and remove the connector several times to wet
the surfaces thoroughly with the activator liquid. Electronic parts
After coupling up the connector, check to be sure that it cleaner
is in locked state.
Contact surface
Three Bond 2501S (aerosol)
activator
NOTE
Do not spray too much liquid into the connector.
Cleaner liquid reacts differently with some resins
(plastic materials).
Contact surface
activator
205047
2-2
Troubleshooting
Problem: Traction Motor, Overheating (E0)

(1) Situation
Display: "E0". Poor pulling power and acceleration.
Normal pump motor and power steering operations.
(2) Possible cause

Overheating of traction motor, faulty traction motor or thermal sensor, faulty or open harness wiring, faulty DSP card of
traction inverter, abnormal power supply of logic unit, brake or parking brake drag, abnormality in rear axle.
(3) How the error code is triggered

Motor temperature is out of range at -25 °C to 145 °C (-13 °F to 293 °F).
It becomes normal when motor temperature is in the range of -20 °C to 70 °C (-4 °F to 158 °F).
(4) Checks
Let truck cool for 15 minutes.
Display: "E0". Display: No "E0".
(5) Traction motor becomes normal.
If problem recurs
(6) Disconnect battery plug. Disengage service brake
and parking brake, and check their drag.
No drag Drag
(7) Adjust brake.
(8) Lift rear wheel. Turn off power, rotate rear wheel.
Confirm rotation load.
Normal Abnormal
(9) Check if truck is operated on steep

upgrade or to pull large cargo load.
Normal
(10) Discharge the inverters. See page 1-60.
(11) Replace traction motor. (12) Replace traction

See Chassis & Mast. motor or rear axle.
Notice : Before See Chassis & Mast.
replacing motor, be Notice : Before
sure to check it. If replacing motor, be
motor is normal, sure to check it. If
perform trouble- motor is normal,
shooting again from perform trouble-
the first step. shooting again
from the first step.
2-3
(13) Disconnect battery plug. Wait until traction motor

temperature becomes close to room temperature.
(15) Disconnect connector CN14 of traction motor thermal

sensor. Measure resistance between CN14(124) and (125)
at motor side.
581 at 20 °C(68 °F)
(Min. 555 , Max. 607 )
For resistance at temperature
other than 20 °C(68 °F), see table
on page 2-5. Out of range
Thermal
(16) Disconnect connector CN6 of traction inverter. (17) Replace traction motor. See Chassis & Mast.
Check continuity between CN6-1 and CN14(125). Notice : Before replacing motor, be sure to check it.
Check continuity between CN6-2 and CN14(124). If motor is normal, perform troubleshooting
Continuity No continuity again from the first step.
14V Power
supply
(18) Disconnect connector CN4 of logic unit.
Check continuity between CN4-3 and CN6-17(252).
Continuity No continuity
CAN
Check continuity between CN3-5(211) and CN6-3(224).
(20) Connect connector CN4, then turn on power again. (21) Repair or replace harness.
(22) Measure voltage between CN6-17(252) and

CN6-20(255). Confirm value is 14V 2V.
Normal Abnormal
(23) Disconnect battery plug, then discharge the inverters. See page 1-60.
(24) Replace power supply card of logic unit.

See page 1-67.
(25) Replace DSP card of traction inverter. See page 1-63.
2-4
Logic
CN3 CN6 Traction inverter
BG 0 to 5V V
CAN 5 WP 211 0 to 5V
224
L
3 Inside Inside Line contactor
6 212 229 4 of of
O cover case
257 14
O Fuse
15
5 WG 12V WG
254 16 P
RP 14V RP
Power 3 17
252
RL 8V RL N Battery (-)
4 253 18 DSP IMS
B GND B card
6 255 20 card U IU
5V * 1 Y 1
Power supply card GND G V IV
CN4 2
12V R Flat
5 cable W IW
0 to 5V W
6
0 to 5V G
7
GND B 19
Traction motor
DSP flat
cable 127 B 127 Speed
G sensor W TW
Inverter 146 146
case 145 W 145
IM V TV
U TU
126
R 126 Thermal
DSP card G 124 sensor
124
391 [-30 C(-22 F)] to
125
Y 125 1407 [160 C(320 F)]
CN14
*1: With connector disconnected
AMBIENT RESISTANCE
TEMPERATURE
( C) ( F) MIN. TYP. MAX.
-30 -22 370 391 411
-10 14 437 460 483
0 32 474 498 522
10 50 514 538 563
30 86 599 626 652
50 122 694 722 750
70 158 797 826 855
90 194 910 940 970
110 230 1029 1062 1096
130 266 1152 1194 1235
150 302 1282 1334 1385
212052
2-5
Problem: Pump Motor, Overheating (E2)

(1) Situation
Display: "E2". Lifting speed slower than normal. Normal traction motor and power steering operations.
(2) Possible cause

Overheating of pump motor, faulty pump motor or thermal sensor, faulty or open harness wiring, faulty DSP card of
pump inverter, abnormal power supply of logic unit, abnormal oil pressure of gear pump or hydraulic lines.

Motor temperature is out of range of -25 °C to 135 °C (-13 °F to 275 °F).
It becomes normal when motor temperature is in range of -20 °C to 70 °C (-4 °F to 158 °F).
(4) Checks
(5) Pump motor becomes normal.

If problem reoccurs
(6) Check if truck is operated to lift large cargo load.
Normal
(8) Check oil pressure of gear pump and hydraulic lines.

Normal Abnormal
(9) Replace pump motor. (10) Repair or replace gear

See Chassis & Mast. pump or piping.
Notice : Before replacing See Chassis & Mast.
motor, be sure to check it.
If motor is normal,
perform troubleshooting
again from the first step.
(11) Disconnect battery plug. Wait until pump motor

(13) Disconnect connector CN15 of pump motor thermal

sensor. Measure resistance between CN15(129) and (130).
581 at 20 °C(68 °F)
(Min. 555 , Max. 607 )
For resistance at temperature
other than 20 °C(68 °F), see table
on page 2-8. Out of range
Thermal
(14) Disconnect connector CN5 of pump motor inverter. (15) Replace pump motor. See Chassis & Mast.
Check continuity between CN5-1 and CN15(130). Notice : Before replacing motor, be sure to check it.
Check continuity between CN5-2 and CN15(129). If motor is normal, perform troubleshooting
Continuity No continuity again from the first step.
2-6
14V Power
supply
CAN

Normal Abnormal

See page 1-67.
(23) Replace DSP card of pump inverter. See page 1-63.
2-7
Logic
CN3 CN5 Pump inverter
BG 0 to 5V 224 V 3
CAN 5 WP 211
0 to 5V 229 L 4
Inside Inside Line contactor
6 212 of of
O cover case
270 14
O Fuse
15
5 WG 254 12V 259 RY 16 P
RP 14V 260 RGy 17
Power 3 RL
252
8V 261 R 18 DSP N Battery (-)
4 253 IMS
B GND 262 B 20 card card
6 255 U IU
5V* 1 Y 1
2 Flat
CN4 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
CN15 Pump motor

DSP flat
G 148 sensor W PW
Inverter 148
case 147 W 147 IM V PV
U PU
R
131 131 Thermal
DSP card G sensor
129 129
130
Y 130 391 [-30 C(-22 F)] to
1407 [160 C(320 F)]
AMBIENT RESISTANCE
TEMPERATURE
( C) ( F) MIN. TYP. MAX.
-30 -22 370 391 411
-10 14 437 460 483
0 32 474 498 522
10 50 514 538 563
30 86 599 626 652
50 122 694 722 750
70 158 797 826 855
90 194 910 940 970
110 230 1029 1062 1096
130 266 1152 1194 1235
150 302 1282 1334 1385
212053
2-8
Problem: Traction Inverter, Overheating (E5)
(1) Situation
Display: "E5". Poor pulling power and acceleration.
Normal pump motor and power steering operations.
(2) Possible cause

Overheating of traction inverter, faulty traction inverter thermal sensor, open harness wiring, faulty DSP card of traction
inverter, abnormal power supply of logic unit, faulty temperature of traction inverter.

Controller temperature is out of range at -25 °C to 100 °C (-13 °F to 212 °F).
Capacitor temperature is out of range at -25 °C to 110 °C (-13 °F to 230 °F).
It becomes normal when temperature is in the range of -20 °C to 70 °C (-4 °F to 158 °F)
(4) Checks
(5) Traction inverter becomes normal.
If problem recurs
(6) Check if truck is operated on steep upgrade or to pull
large cargo load.
Normal
Check thermal paste applied on inverter mounting
surface. Thermal paste film should be thin and even.
Normal Abnormal
(8) Replace traction inverter. (9) Clean mounting surface,

See page 1-61. apply thermal paste,
then reinstall inverter.
See page 1-61.
(10) Disconnect battery plug. Wait until inverter

Thermal
(12) Remove DSP card cover of traction inverter, then check
harness looseness or wire breakage. See page 1-63.
Normal Abnormal
14V Power supply
(13) Disconnect connector CN6 of traction inverter. (14) Secure harness if loose.
Disconnect connector CN4 of logic unit. Replace inverter if wire breaks. See page 1-61.
2-9
CAN
(18) Measure voltage between CN6-17(252) and CN6-20(255).

Confirm value is 14V 2V.
Normal Abnormal
(20) Replace power supply card of logic unit. See page 1-67.
(21) Replace DSP card of traction inverter. See page 1-63.
If fault remains
(22) Disconnect battery plug, then discharge the inverters.
See page 1-60.
(23) Replace traction inverter. (DSP card is normal.)

See page 1-61.
2-10
Logic
BG 0 to 5V V
224
L
6 212 229 4 of of
O cover case
257 14
O Fuse
15
5 WG 12V WG
254 16 P
RP 14V RP
Power 3 RL 17
252
8V RL N Battery (-)
4 253 18 DSP IMS
B GND B card
6 255 20 card U IU
5V * 1 Y 1
2
CN4 12V R Flat
5 cable W IW
0 to 5V W
6
0 to 5V G
7
GND B
19
Traction motor
DSP flat
G 146 sensor W TW
Inverter 146
case 145 W 145
IM V TV
U TU
126
R 126 Thermal
DSP card G sensor
124 124 391 [-30 C(-22 F)] to
125
Y 125 1407 [160 C(320 F)]
CN14
212054
2-11
Problem: Pump Inverter, Overheating (E7)

(1) Situation
Display: "E7". Lifting speed slower than normal. Normal traction motor and power steering operations.
(2) Possible cause

Overheating of pump inverter, faulty pump inverter thermal sensor, open harness wiring, faulty DSP card of pump
inverter, abnormal power supply of logic unit, faulty temperature of pump inverter.

Controller temperature is out of range at -25 °C to 100 °C (-13 °F to 212 °F).
Capacitor temperature is out of range at -25 °C to 110 °C (-13 °F to 230 °F).
It becomes normal when temperature is in the range of -20 °C to 70 °C (-4 °F to 158 °F).
(4) Checks
(5) Pump inverter becomes normal.
If problem reoccurs
(6) Check if truck is operated to lift large cargo load.

Normal
Check thermal paste applied on inverter mounting
surface. Thermal paste film should be thin and even.
Normal Abnormal
(8) Replace pump inverter. (9) Clean mounting surface,

See page 1-61. apply thermal paste, then
reinstall inverter.
See page 1-61.
(10) Disconnect battery plug. Wait until inverter temperature

becomes close to room temperature.
Thermal
(12) Remove DSP card cover of pump inverter, then check
harness looseness or wire breakage. See page 1-63.
Normal Abnormal
14V Power supply
(13) Disconnect connector CN5 of pump inverter. (14) Secure harness if loose.
Disconnect connector CN4 of logic unit. Replace inverter if wire breaks. See page 1-61.
2-12
CAN

Normal Abnormal

See page 1-67.
(21) Replace DSP card of pump inverter. See page 1-63.
If fault remains

See page 1-60.
(23) Replace pump inverter. (DSP card is normal.)

See page 1-61.
2-13
Logic
BG 0 to 5V 224 V 3
CAN 5 WP 211
0 to 5V L Inside Inside
Line contactor
6 212 229 4 of of
O cover case
270 14
O Fuse
15
5 WG 254 12V 259 RY 16 P
RP 14V 260 RGy 17
Power 3 RL
252
4 253 IMS
6 255 U IU
5V* 1 Y 1
2 Flat
CN4 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
CN15 Pump motor

DSP flat
G 148 sensor W PW
Inverter 148
U PU
R
131 131 Thermal
DSP card G sensor
129 129
130
Y 130 391 [-30 C(-22 F)] to
1407 [160 C(320 F)]
212055
2-14
Problem: Brake Oil, Low Level

(1) Situation
Lower brake oil indicator ON. Normal truck operation.
(2) Possible cause

Insufficient brake oil, faulty brake oil level sensor, shorted wiring, faulty logic unit.

Sensor signal is close or short.
(4) Checks
Check oil level in brake oil reservoir tank.
Normal Abnormal
(5) Add brake oil. See Chassis & Mast.

Without service tool

See page 1-60.
(7) Disconnect connectors CN2 and CN3 of logic unit and

CN11 of sensor.
Check short circuit between CN2-38(139) and CN3-23(140)
at harness side.
No shorted Shorted
(8) Check continuity of brake oil level sensor connector

(9) Repair or replace harness.
coupled to CN11.
No continuity Continuity
(10) Replace brake oil level sensor.
If fault remains
(11) Replace logic card of logic unit. See page 1-66.
2-15
Logic Logic
CN2 CN3
38 23
0V/12V GND
O L
139 140
CN11
CN11
139
140
Main harness
Brake fluid
sensor
212056
2-16
Problem: Traction Motor Current Sensor Fault (14)

(1) Situation
Display: "14". All truck operations except "lift down" inhibited. This fault occurs only when turning on power.
Line contactor HOLD.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty DSP card of traction inverter,
faulty traction inverter, faulty main harness, faulty logic unit.

When turning on power, current sensor voltage is out of range of -120 A to 120 A.
(4) Checks
Disconnect battery plug, then discharge the inverters. See page 1-60.
(5) Disconnect connector CN6 of traction inverter and remove

DSP cover. Check DSP flat cable for looseness or wire
breakage.
Normal Abnormal
8V Power
supply
(6) Disconnect connector CN4 of logic unit. (7) Secure DSP flat cable if loose.
Check continuity between CN4-4 and CN6-18(253). Replace inverter if wire breaks. See page 1-61.
CAN
(9) Connect connector CN4 to logic unit, then turn on power (10) Repair or replace harness.
again.

Normal Abnormal
(13) Replace DSP card of traction inverter. See page 1-63. (14) Replace power supply card of logic unit.
See page 1-67.
If fault remains
(15) Discharge the inverters, then replace traction inverter.

(DSP card is normal.)
See page 1-61.
2-17
Logic
BG 0 to 5V V
224
L
6 212 229 4 of of
O cover case
257 14
O Fuse
15
5 WG 12V WG
254 16 P
RP 14V RP
Power 3 RL 17
252
8V RL N Battery (-)
4 253 18 DSP IMS
B GND B card
6 255 20 card U IU
5V * 1 Y 1
2
CN4 12V R Flat
5 cable W IW
0 to 5V W
6
0 to 5V G
7
GND B
19
Traction motor
DSP flat
G 146 sensor W TW
Inverter 146
case 145 W 145
IM V TV
U TU
126
R 126 Thermal
DSP card G sensor
124 124 391 [-30 C(-22 F)] to
125
Y 125 1407 [160 C(320 F)]
CN14
212054
2-18
Problem: Traction Motor, Over-current (15)
(1) Situation
Display: "15". All truck operations except "lift down" inhibited. Line contactor HOLD.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty DSP card of traction inverter, faulty
traction inverter, faulty traction motor, faulty contact or wire breakage of traction motor speed sensor harness, faulty
main harness, faulty logic unit.

Motor current is more than 881 Amps (Moment). Motor current is more than 740 Amps (Fixed time 1).
Motor current is more than 606 Amps (Fixed time 2).
(4) Checks
(5) Check traction motor and terminal for burning and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections (7) Replace traction motor.
(U, V, W phases) for traction inverter and motor. Notice : Before replacing motor, be sure to check it.
Normal Abnormal If motor is normal, perform troubleshooting
(8) Disconnect connector CN6 of traction inverter and (9) Secure cable if loose or connect cable correctly.
remove DSP cover. Check DSP flat cable for looseness or
wire breakage.
Normal Abnormal
(10) Confirm connection of traction motor speed sensor (11) Secure DSP flat cable if loose.
connector CN14. Replace inverter if wire breaks. See page 1-61.
Normal Abnormal
Sensor
(12) Disconnect connectors CN6 and CN14. (13) Connect connector securely.
Check continuity between CN6-5 and CN14(126).
8V Power
supply
CAN
(16) Connect connector CN4 to logic unit, then turn on (17) Repair or replace harness.
power again.
2-19

Normal Abnormal
(20) Replace DSP card of traction inverter. (21) Replace power supply card of logic unit.
See page 1-63. See page 1-67.
If fault remains
(DSP card is normal.) See page 1-61.
If fault remains
(23) Discharge the inverters, then reinstall traction inverter
and replace traction motor.
Notice : Before replacing motor, be sure to check it.
If motor is normal, perform troubleshooting
2-20
Logic
BG 0 to 5V V
224
L
6 212 229 4 of of
O cover case
257 14
O Fuse
15
5 WG 12V WG
254 16 P
RP 14V RP
Power 3 RL 17
252
8V RL N Battery (-)
4 253 18 DSP IMS
B GND B card
6 255 20 card U IU
5V * 1 Y 1
2
CN4 12V R Flat
5 cable W IW
0 to 5V W
6
0 to 5V G
7
GND B
19
Traction motor
DSP flat
G 146 sensor W TW
Inverter 146
case 145 W 145
IM V TV
U TU
126
R 126 Thermal
DSP card G sensor
124 124 391 [-30 C(-22 F)] to
125
Y 125 1407 [160 C(320 F)]
CN14
212054
2-21
Problem: Traction Motor, Stall Timer (16)

(1) Situation
Display:"16". All truck operations except "lift down" inhibited. Line contactor HOLD.
(2) Possible cause

Stall current flowed more than set time (#20) in traction motor, faulty traction inverter current sensor, shorted harness
wiring, faulty DSP card of traction inverter, faulty logic unit, faulty traction motor speed sensor.

Stall timer set time (set by Setup Option #20) is measured while stalling.
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
No error, problem recurs Error code 14
(5) Confirm stall timer set time of Setup Option #20. (6) See troubleshooting for code "14". See page 2-17.
Maximum value set Larger value can be set
(7) Check to see if truck is operated with heavy cargo load or (8) Change set time. See page 1-26.
on steps when motor stalls.
Normal steeps Heavy load Notice: The more stall occurs, the more overheating
occurs. Operate truck under normal condition.
(9) Check speed sensor of traction motor.

See troubleshooting for code "52". See page 2-42.
(10) Disconnect battery plug, then discharge the invertes.

See page 1-60. (11) Operate under normal condition.
(12) Disconnect connector CN6 of traction inverter and

remove DSP cover, then check DSP flat cable for
looseness or wire breakage. See page 1-63.
Normal Abnormal
12V Power
supply
(13) Disconnect connector CN4 of logic unit. (14) Secure harness if loose. Replace traction inverter if
Check continuity between CN4-5 and CN6-16(254). wire breaks. See page 1-61.
CAN
power again.
2-22

Normal Abnormal
See page 1-67.
2-23
Logic
BG 0 to 5V V
224
L
6 212 229 4 of of
O cover case
257 14
O Fuse
15
5 WG 12V WG
254 16 P
RP 14V RP
Power 3 RL 17
252
8V RL N Battery (-)
4 253 18 DSP IMS
B GND B card
6 255 20 card U IU
5V * 1 Y 1
2
CN4 12V R Flat
5 cable W IW
0 to 5V W
6
0 to 5V G
7
GND B
19
Traction motor
DSP flat
G 146 sensor W TW
Inverter 146
case 145 W 145
IM V TV
U TU
126
R 126 Thermal
DSP card G sensor
124 124 391 [-30 C(-22 F)] to
125
Y 125 1407 [160 C(320 F)]
CN14
212054
2-24
Problem: Pump Motor Current Sensor Fault (34)

(1) Situation
Display: "34". All truck operations except "lift down" inhibited. This fault occurs only when turning on power.
Line contactor OPEN.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter,
faulty pump inverter, faulty main harness, faulty logic unit.

When turning on power, current sensor voltage is out of range of -120 A to 120 A.
(4) Checks
(5) Disconnect connector CN5 of pump inverter and remove

breakage.
Normal Abnormal
8V Power
supply
Check continuity between CN4-4(253) and CN5-18(261). Replace pump inverter if wire breaks. See page 1-61.
CAN
power again.

Normal Abnormal
(13) Replace DSP card of pump inverter. See page 1-63. (14) Replace power supply card of logic unit.
See page 1-67.
If fault remains
(15) Discharge the inverters, then replace pump inverter.
2-25
Logic
BG 0 to 5V 224 V 3
CAN 5 WP 211
Line contactor
6 212 229 4 of of
O cover case
270 14
O Fuse
15
5 WG 254 12V 259 RY 16 P
RP 14V 260 RGy 17
Power 3 RL
252
4 253 IMS
6 255 U IU
5V* 1 Y 1
2 Flat
CN4 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
CN15 Pump motor

DSP flat
G 148 sensor W PW
Inverter 148
U PU
R
131 131 Thermal
DSP card G sensor
129 129
130
Y 130 391 [-30 C(-22 F)] to
1407 [160 C(320 F)]
212055
2-26
Problem: Pump Motor Over-current (35)

(1) Situation
Display: "35". All truck operations except "lift down" inhibited. Line contactor OPEN.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter, faulty pump
inverter, faulty pump motor, faulty contact or wire breakage of pump motor speed sensor harness, faulty main
harness, faulty logic unit.

Motor current is more than 881 Amps (Moment). Motor current is more than 740 Amps (Fixed time 1).
Motor current is more than 606 Amps (Fixed time 2).
(4) Checks
(5) Check pump motor and terminal for burning and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections (7) Replace pump motor.
(U, V, W phases) for pump inverter and motor. Notice : Before replacing motor, be sure to check it.
Normal Abnormal If motor is normal, perform troubleshooting
(8) Disconnect connector CN5 of pump inverter and remove (9) Secure cable if loose or connect cable correctly.
breakage.
Normal Abnormal
(10) Confirm connection of pump motor speed sensor (11) Secure DSP flat cable if loose.
connector CN15. Replace pump inverter if wire breaks. See page 1-61.
Normal Abnormal
Sensor
(12) Disconnect connectors CN5 and CN15. (13) Connect connector securely.
8V Power
supply
2-27
CAN
power again.

Normal Abnormal
(20) Replace DSP card of pump inverter. See page 1-63. (21) Replace power supply card of logic unit. See page
1-67.
If fault remains

If fault remains
(23) Discharge the inverters, then reinstall pump inverter

and replace pump motor.
2-28
Logic
BG 0 to 5V 224 V 3
CAN 5 WP 211
Line contactor
6 212 229 4 of of
O cover case
270 14
O Fuse
15
5 WG 254 12V 259 RY 16 P
RP 14V 260 RGy 17
Power 3 RL
252
4 253 IMS
6 255 U IU
5V* 1 Y 1
2 Flat
CN4 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
CN15 Pump motor

DSP flat
G 148 sensor W PW
Inverter 148
U PU
R
131 131 Thermal
DSP card G sensor
129 129
130
Y 130 391 [-30 C(-22 F)] to
1407 [160 C(320 F)]
212055
2-29
Problem: Line Contactor Fault (40)

(1) Situation
(2) Possible cause

Faulty line contactor, faulty main harness, faulty logic unit, faulty traction inverter, faulty pump inverter.

Inverter voltage data is checked when contactor is closed (400 mS).
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
Error code 40 Error code 63 or 65
(5) Block wheels, then confirm line contactor operation in (6) See troubleshooting for code "63" or "65".
output check function. See page 1-43 or 1-53. See page 2-53 or 2-56.
Not operated Operated
With service tool
(7) Check DC voltage of pump and traction inverters (8) Disconnect battery plug, then discharge the
with Input Monitor. These values should be same as inverters. See page 1-60.
battery voltage.
Traction inverter value Pump inverter value
abnormal abnormal
(11) Replace traction inverter.
See page 1-61.
(9) Disconnect battery (10) Disconnect battery
plug, then discharge plug, then discharge If fault remains
the inverters. the inverters.
See page 1-60. See page 1-60. (14) Disconnect battery plug, then discharge
the inverters. See page 1-60.
(12) Replace traction (13) Replace pump inverter.

inverter. See page 1-61. See page 1-61. (15) Replace pump inverter. See page 1-61.

See page 1-60.
(17) Check to see if line contactor tip moves smoothly.

Check line contactor tip for melting.
Normal Abnormal
(18) Measure resistance of contactor coil.

[27 at -30 C(-22 F) to 41 at 80 C(176 F)]
Within range Out of range
2-30
(19) Disconnect connectors CN1 and CN4 of logic unit. (20) Replace line contactor. See Chassis & Mast.
Check continuity between CN1-64(247) and contactor
coil minus (-) (247).
Check continuity between CN1-63(325) and contactor
coil puls (+) (249).
(21) Discharge the inverters, then replace logic card of (22) Repair or replace harness.
logic unit. See page 1-66.
2-31
Logic
CN3
CN6
5 BG V
211 224 3 Traction
CAN L P
6 212 WP 229 4 inverter
CN5
V
224 3 Pump
L P
229 4 inverter
Contactor panel assy

Pump fuse
Line contactor
+ - Traction fuse
Logic
CN1
249
GB
63 325
G
64 247
212057
2-32
Problem: Traction Motor Open (45)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of traction motor cable, faulty traction motor, faulty contact or wire breakage of traction
inverter connector, faulty contact of DSP flat cable in traction inverter, wire breakage of main harness, faulty power
supply card of logic unit, faulty DSP card of traction inverter, faulty traction inverter, when restarting after motor shorted.

Motor voltage is abnormal when power is turned on.
Current does not flow when torque instruction is requested.
(4) Checks
(5) Check traction inverter and motor for cable looseness

and improper contact.
Normal Abnormal
(6) Disconnect traction motor cables from inverter. (7) Secure cable if loose.
Measure resistance of motor cables (U, V and W phases).
Less than 1 1 or more
(8) Check connector CN6 of traction inverter for looseness. (9) Measure resistance between terminals of both cable
Normal Abnormal ends (between U and U, V and V, and W and W).
(11) Connect connector securely.

(12) Replace traction motor. (13) Replace motor cables.
Notice : Before
(10) Disconnect connector CN6 of traction inverter and replacing motor, be
remove DSP cover. sure to check it.
Check DSP flat cable for looseness or wire breakage. If motor is normal,
Normal Abnormal again from the first step.
12V Power
supply
Check continuity between CN4-5 and CN6-16(254). Replace inverter if wire breaks. See page 1-61.
2-33
CAN
power again.

Normal Abnormal
See page 1-67.
If fault remains

2-34
Logic
BG 0 to 5V V
224
L
6 212 229 4 of of
O cover case
257 14
O Fuse
15
5 WG 12V WG
254 16 P
RP 14V RP
Power 3 RL 17
252
8V RL N Battery (-)
4 253 18 DSP IMS
B GND B card
6 255 20 card U IU
5V * 1 Y 1
2
CN4 12V R Flat
5 cable W IW
0 to 5V W
6
0 to 5V G
7
GND B
19
Traction motor
DSP flat
G 146 sensor W TW
Inverter 146
case 145 W 145
IM V TV
U TU
126
R 126 Thermal
DSP card G sensor
124 124 391 [-30 C(-22 F)] to
125
Y 125 1407 [160 C(320 F)]
CN14
212054
2-35
Problem: Pump Motor Open (47)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of pump motor cable, faulty pump motor, faulty contact or wire breakage of pump
inverter connector, faulty contact of DSP flat cable in pump inverter, wire breakage of main harness, faulty power
supply card of logic unit, faulty DSP card of pump inverter, faulty pump inverter, when restarting after motor shorted.

Motor voltage is abnormal when power is turned on.
Current does not flow when rotational speed instruction is requested.
(4) Checks
(5) Check pump inverter and motor for cable looseness and
improper contact.
Normal Abnormal
(6) Disconnect pump motor cables from inverter. (7) Secure cable if loose.
Measure resistance of motor cables (U, V and W phases).
(8) Check connector CN5 of pump inverter for looseness. (9) Measure resistance between terminals of both cable
ends (between U and U, V and V, and W and W).
Normal Abnormal
(11) Connect connector securely.

(12) Replace pump motor. (13) Replace motor cables.
Notice : Before
(10) Disconnect connector CN5 of pump inverter and replacing motor, be
remove DSP cover. sure to check it.
Check DSP flat cable for looseness or wire breakage. If motor is normal,
Normal Abnormal again from the first step.
12V Power
supply
Check continuity between CN4-5(254) and CN5-16(259). Replace inverter if wire breaks. See page 1-61.
2-36
CAN
power again.

Normal Abnormal
(21) Replace DSP card of pump inverter. See page 1-63. (22) Replace power supply card of logic unit.
See page 1-67.
If fault remains

2-37
Logic
BG 0 to 5V 224 V 3
CAN 5 WP 211
Line contactor
6 212 229 4 of of
O cover case
270 14
O Fuse
15
5 WG 254 12V 259 RY 16 P
RP 14V 260 RGy 17
Power 3 RL
252
4 253 IMS
6 255 U IU
5V* 1 Y 1
2 Flat
CN4 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
CN15 Pump motor

DSP flat
G 148 sensor W PW
Inverter 148
U PU
R
131 131 Thermal
DSP card G sensor
129 129
130
Y 130 391 [-30 C(-22 F)] to
1407 [160 C(320 F)]
212055
2-38
Problem: Accelerator Sensor Fault (51)

(1) Situation
(2) Possible cause

Improper accelerator pedal linkage, faulty accelerator sensor, faulty main harness, faulty logic unit.

Accelerator sensor voltage is out of range of 0.2 V to 4.8 V.
Sensor voltage is 1.61 V or more when accelerator switch is opened.
Sensor voltage is 0.27 V or less when accelerator switch is closed.
(4) Checks
Raise rear wheel until they clear floor.
Without service tool With service tool
(5) Disconnect battery plug. (6) Check accelerator sensor voltage with Input Monitor
and confirm value is in range of 0.2V to 4.8V.
Check relation between sensor voltage and accelerator
switch operation.
0.27V or less: OFF
(7) Check link length of accelerator pedal. 1.61V or more: ON
Normal Abnormal
Abnormal signal Interrupted
(8) Adjust accelerator pedal (9) Disconnect battery plug. (10) Adjust accelerator
linkage. pedal linkage.
(12) Disconnect connectors CN2 and CN3 of logic unit.

Disconnect connector CN16 of accelerator sensor.
(13) Check continuity between CN3-20 and CN16(142).

(Sensor voltage)

(Switch)

Check continuity between CN3-23(140) and CN16(143).
2-39
Without With service tool

service tool
(17) Replace accelerator pedal. (18) Connect connectors CN2 and CN3. Turn on power and
check voltage between CN16(141) and CN16(143).
5V Not 5 V
If fault remains
(19) Disconnect battery plug. (20) Turn off power. Short-circuit CN16(141) and
CN16(142). Turn on power and check accelerator
voltage with Input Monitor.
5V Not 5 V
(21) Reinstall accelerator pedal, then replace logic card (22) Turn off power. Open CN16(141) and CN16(142).
of logic unit. See page 1-66. Short-circuit CN16(142) and CN16(143). Turn on
power and check accelerator voltage with Input
Monitor.
0V Not 0 V
(23) Replace accelerator (24) Disconnect battery

pedal. plug.
(25) Replace logic card

of logic unit.
See page 1-66.
2-40
CN16
143 144 142 141

Logic
CN2
Main harness
L 12V/0V
Accel switch 42 144
Accelerator
Logic CN16
CN3 L
RW 5V RW
24 141
Accel angle 20 G 0.27 to 1.61V G
142
L GND B
23 140
212058
2-41
Problem: Traction Motor Pulse Input Fault (52)

(1) Situation
(2) Possible cause

Faulty contact of traction inverter connector, faulty connection of traction motor connector and cable, faulty 12V input
voltage of traction inverter, faulty contact or wire breakage of traction motor speed sensor harness, faulty DSP card of
traction inverter, faulty traction motor speed sensor.

Motor rotation speed is more than 5800 rpm.
(4) Checks
(5) Check to see if traction motor cables (U, V and W-phases)

are connected to traction inverter properly.
Normal Abnormal
(6) Check to see if connector CN6 of traction inverter is (7) Connect cables properly.
fastened securely.
Normal Abnormal
(8) Check to see if connector CN14 of traction motor speed (9) Fasten connector securely.
sensor is fastened securely.
Normal Abnormal
Sensor
(10) Disconnect connectors CN6 and CN14. (11) Fasten connector securely.
14V Power
supply
CAN
power again.
2-42

Normal Abnormal
(18) Replace DSP card of traction inverter. See page 1-63. (19) Replace power supply card of logic unit. See page
1-67.
If fault remains
(20) Discharge the inverters, then replace traction motor.

2-43
Logic
BG 0 to 5V V
224
L
6 212 229 4 of of
O cover case
257 14
O Fuse
15
5 WG 12V WG
254 16 P
RP 14V RP
Power 3 RL 17
252
8V RL N Battery (-)
4 253 18 DSP IMS
B GND B card
6 255 20 card U IU
5V * 1 Y 1
2
CN4 12V R Flat
5 cable W IW
0 to 5V W
6
0 to 5V G
7
GND B
19
Traction motor
DSP flat
G 146 sensor W TW
Inverter 146
case 145 W 145
IM V TV
U TU
126
R 126 Thermal
DSP card G sensor
124 124 391 [-30 C(-22 F)] to
125
Y 125 1407 [160 C(320 F)]
CN14
212054
2-44
Problem: Pump Motor Pulse Input Fault (57)

(1) Situation
(2) Possible cause

Faulty contact of pump inverter connector, faulty connection of pump motor connector and cable, faulty 12V input
voltage of pump inverter, faulty contact or wire breakage of pump motor speed sensor harness, faulty DSP card of
pump inverter, faulty pump motor speed sensor.

Motor rotation speed is more than 4000 rpm. Motor rotation speed is zero while current flows to motor.
Motor rotates in reverse.
(4) Checks
(5) Check to see if pump motor cables (U, V and W-phases)

are connected to pump inverter properly.
Normal Abnormal
(6) Check to see if connector CN5 of pump inverter is (7) Connect cables properly.
fastened securely.
Normal Abnormal
(8) Check to see if connector CN15 of pump motor speed (9) Fasten connector securely.
sensor is fastened securely.
Normal Abnormal
Sensor
(10) Disconnect connectors CN5 and CN15. (11) Fasten connector securely.
14V Power
supply
CAN
power again.
2-45

Normal Abnormal
(18) Replace DSP card of pump inverter. See page 1-63. (19) Replace power supply card of logic unit. See page
1-67.
If fault remains
(20) Discharge the inverters, then replace pump motor.

2-46
Logic
BG 0 to 5V 224 V 3
CAN 5 WP 211
Line contactor
6 212 229 4 of of
O cover case
270 14
O Fuse
15
5 WG 254 12V 259 RY 16 P
RP 14V 260 RGy 17
Power 3 RL
252
4 253 IMS
6 255 U IU
5V* 1 Y 1
2 Flat
CN4 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
CN15 Pump motor

DSP flat
G 148 sensor W PW
Inverter 148
U PU
R
131 131 Thermal
DSP card G sensor
129 129
130
Y 130 391 [-30 C(-22 F)] to
1407 [160 C(320 F)]
212055
2-47
Problem: Display Communication Fault (60)

(1) Situation
Display: "60". Normal truck operation.
(2) Possible cause

Faulty main harness, faulty display unit, faulty logic unit.

CAN communication is impossible.
(4) Checks
CAN
Disconnect connector CN17 of display unit.
Check continuity between CN17-2(151) and POS (Line contactor).
Check continuity between CN17-1(152) and NEG (Traction inverter).
(6) Measure resistance of CAN between CN17-3(149) and (7) Repair or replace harness.
CN17-4(150).
Out of range 60 5%
(8) Disconnect connector CN5 of pump inverter. (9) Replace display unit.
Measure resistance of CAN between CN17-3(149) and
CN17-4(150).
120 5% Out of range
2-48
If fault remains
(11) Connect connector (12) Disconnect battery plug, then discharge the
CN5 of pump inverter. inverters. See page 1-60.
Disconnect connector
CN6 of traction inverter.
Perform CAN check
of Traction Inverter (13) Reinstall the display unit.
Fault (63). Replace logic card of logic unit. See page 1-66.
(10) Perform CAN check of Pump Inverter Fault (65).
2-49
Line contactor Fuse holder

CN18
G Fuse CN18 CN21
2
R Fuse 4
3 3 13 2
13
20 3
13
G
Main harness Main harness
Key switch
CN21
G
13
R Display
4
Disconnect CN17
switch
R
151 2 Battery+
B B 1 GND
1 152
Power supply card

Traction CN4
N
inverter
R 13
25
R
25 14
BW 15
23
POS NEG BY
22 16
+ -
Battery
Logic Display
CN17 CN3 CN17
152 151 BG G
5 211 149 3 CAN H
WP L 4
149 150 6 212 150 CAN L
Main harness
212059
2-50
Problem: Logic Card Initialize Failure (61)

(1) Situation
Display: "61". All truck operations inhibited. Line contactor OPEN.
(2) Possible cause

Setup Option Group 3 data not set, Setup Option Group 1 and 2 default data not set, faulty Setup Option data,
faulty logic unit.

Setup Option data is in abnormal setting range.
(4) Checks
Set Setup Option Group 3 data. See page 1-36 to 1-38.
(5) Set Setup Option default data. See page 1-27.
(6) Turn on power.
If fault remains
(7) With service tool, set Setup Option Group 3 data.
(8) With service tool, set Setup Option default data.
If fault remains
(9) Disconnect battery plug.
(12) With service tool, set Setup Option default data.
2-51
Problem: Logics Fault (62)
(1) Situation
Display: "62". All truck operations inhibited. Line contactor OPEN.
(2) Possible cause

Faulty EEPROM data, faulty logic unit.

ROM SUM value of logic card is different from check data. EEPROM SUM value of logic card is different from check
data. RAM of logic card is faulty.
(4) Checks
Set Setup Option Group 3 data. See pages 1-36 to 1-38.
(5) Set Setup Option default data. See page 1-27.
(6) Turn on power.

Error code "61"
If fault remains "62"
(7) Disconnect battery plug, then discharge the inverters. (8) See troubleshooting for code "61". See page 2-51.
See page 1-60.

Set Setup Option default data.
2-52
Problem: Traction Inverter Fault (63)
(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty DSP card of traction inverter, faulty traction
inverter, faulty main harness, faulty logic unit.

Traction inverter is connected as pump inverter (CN6-9 is connected to GND).
ROM SUM value of taction inverter is different from check data.
RAM of traction inverter is faulty. Communication with traction inverter is impossible.
(4) Checks
(5) Disconnect connector CN6 of traction inverter and

remove DSP cover. Check DSP flat cable for looseness
or wire breakage.
Normal Abnormal
8V Power
supply
(6) Disconnect connector CN4 of logic unit. (7) Refasten flat cable or replace inverter. See page 1-61.
CAN From another troubleshooting flow chart

(9) Measure resistance of CAN with connectors CN6 and

CN3 disconnected.
Resistance between CN3-5(211) and CN3-6(212)

120 5% Other than 120 5%
(10) Connect connector

CN6 of traction
inverter.
Disconnect connector
CN5 of pump inverter.
Perform CAN check
of pump inverter
Fault(65).
2-53
(11) Measure resistance of CAN for traction inverter DSP card.

Resistance between CN2-3 and CN2-4 of DSP card side connectors
120 5% Other than 120 5%
(12) Replace DSP card of

traction inverter.
(13) Connect connector CN6 of traction inverter.

Measure resistance of CAN with connector CN3 disconnected.

60 5% Other than 60 5%
Mode
(15) Check CN6-8 and CN6-9 that pin is not inserted in.
Normal Abnormal
power again.

Normal Abnormal
(20) Replace DSP card of traction inverter. (21) Replace power supply card of logic unit.
See page 1-63. See page 1-67.
2-54
Logic
BG 0 to 5V V
CAN 5 WP 211
0 to 5V
224 3 Inside Inside Line contactor
6 212 229
L 4 of of
O cover case
257 14
O Fuse
15
5 WG 12V WG
254 16 P
RP 14V RP
Power 3 RL 17
252
8V RL N Battery (-)
4 253 18 DSP IMS
B GND B card
6 255 20 card U
8
Power supply card V
9
CN4 Flat
cable W
DSP flat
cable
Inverter
case
DSP card
212060
2-55
Problem: Pump Inverter Fault (65)
(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter, faulty pump
inverter, faulty main harness, faulty logic unit.

Pump inverter is connected as traction inverter (CN5-9 is opened).
ROM SUM value of pump inverter is different from check data.
RAM of pump inverter is faulty. Communication with pump inverter is impossible.
(4) Checks
(5) Disconnect connector CN5 of pump inverter and remove

breakage.
Normal Abnormal
8V Power
supply
(6) Disconnect connector CN4 of logic unit. (7) Refasten flat cable or replace inverter. See page 1-61.
CAN From another troubleshooting flow chart

(9) Measure resistance of CAN with connectors CN5 and CN3 disconnected.

120 5% Other than 120 5%
(10) Connect connector CN5 of pump inverter.

Disconnect connector CN6 of traction inverter.
Perform CAN check of Traction Inverter Fault (63).
(11) Measure resistance of CAN for pump inverter DSP card.
Resistance between CN2-3 and CN2-4 of DSP card side connectors

120 5% Other than 120 5%
(12) Replace DSP card of pump inverter.
2-56
(13) Connect connector CN5 of pump inverter.

Measure resistance of CAN with connector CN3 disconnected.

60 5% Other than 60 5%
Mode
(15) Check continuity between CN4-6(255) and CN5-9(258).
(16) Check CN5-8 that pin is not inserted in.

Normal Abnormal
power again.

Normal Abnormal
(21) Replace DSP card of pump inverter. See page 1-63. (22) Replace power supply card of logic unit. See page 1-67.
2-57
Logic
BG 0 to 5V V 3
CAN 5 WP 211
0 to 5V
224
L Inside Inside Line contactor
6 212 229 4 of of
O cover case
270 14
O Fuse
15
5 WG 254 12V 259 RY 16 P
RP 14V 260 RGy 17
Power 3 RL
252
8V R 18 DSP N Battery (-)
4 253 261 IMS
B GND 262 B 20 card
card
6 255 U
mode 1 8
Power supply card mode 2 B V
9 Flat
CN4
cable W
258
DSP flat
cable
Inverter GND
case
DSP card
212061
2-58
Problem: Contactor Coil Fault (72)

(1) Situation
(2) Possible cause

Faulty line contactor, faulty main harness, faulty logic unit.

With short circuit detection signal of logic card.
(4) Checks
(5) Remove coil side terminals of line contactor.
(6) Check short circuit between coil terminal plus(+)(249) and minus(-) (247) of harness.
Not shorted Shorted
(8) Repair or replace main harness.
(7) Measure coil resistance.

[27 at -30 C(-22 F) to 41 at 80 C(176 F)]
Abnormal Normal
(9) Replace line contactor. See Chassis & Mast. (10) Replace logic card of logic unit. See page 1-66.
2-59
Logic
CN3
CN6
5 BG V
211 224 3 Traction
CAN L P
6 212 WP 229 4 inverter
CN5
V
224 3 Pump
L P
229 4 inverter
Contactor panel assy

Pump fuse
Line contactor
+ - Traction fuse
Logic
CN1
249
GB
63 325
G
64 247
212057
2-60
Problem: Hydraulic Lock Solenoid Fault (74)
(1) Situation
Display: "74". When lift lock valve defective, lift operation inhibited. When unload valve defective, all hydraulic
operations except "lift down" inhibied. Normal traction motor operation.
(2) Possible cause

Faulty unload valve, faulty lift lock valve, faulty main harness, faulty logic unit.
(3) How the error code is triggered.

(4) Checks
(5) Find faulty valve (unload valve or lift lock valve)

with Output Monitor.
(6) Disconnect battery plug, then discharge the inverters. (faulty unit only)
See page 1-60.

Unload valve Lift lock valve
(8) Disconnect connector CN1 of logic (14) Disconnect connector CN1 of logic
unit. Disconnect connector CN23 unit. Disconnect connector CN22
of unload valve. of lift lock valve.
(9) Check short circuit between CN23 (15) Check short circuit between
(317) and CN23(318). CN22(308) and CN22(309).
Not shorted Shorted Shorted Not shorted
(10) Check short circuit between (11) Repair or replace main harness. (16) Check short circuit between lift
unload valve side connectors. lock valve side connectors.
Measure coil resistance. Measure coil resistance.
[7.5Ω at -30 °C (-22 °F) to [7.5Ω at -30 °C (-22 °F) to
12.8Ω at 80 °C (176 °F)] 12.8Ω at 80 °C (176 °F)]
Abnormal Normal Normal Abnormal
(12) Replace unload valve. (13) Replace logic card of logic unit. (17) Replace lift lock valve.
See page 1-66.
2-61
Power supply card

CN4 CN23
CN23
R 25 4
G
V POW 13 318 Unload
B 318 317
317 valve
Main harness
Logic
CN1
CN22 CN22
B Y Lift
59 309
B B lock 309 308
60 308
valve
Main harness
212062
2-62
Problem: PDS Buzzer Fault (76)
(1) Situation
Display: "76". Normal truck operation.
(2) Possible cause

Faulty PDS buzzer, faulty main harness, faulty logic unit.

(4) Checks
(5) Disconnect connectors CN1, CN2 and CN4 of logic unit. Disconnect connector CN24 of PDS buzzer.
Disconnect connectors CN25 and CN26 in PDS relay.
(6) Check short circuit between CN26(311) and CN26(330).

Check short circuit between CN26(311) and CN25(326).
Not shorted Shorted
(7) Check short circuit between CN24(312) and CN24(314). (8) Repair or replace main harness.
Not shorted Shorted
(9) Replace logic card of (10) Replace PDS buzzer.

logic unit.
See page 1-66.
2-63
PDS Buzzer
CN24
312
Y
R
314
Power supply card PDS Relay

CN4 Relay1
CN25
R G
V POW 13 25 4 313
R
314
POS L
3 326
B
NEG 1 315
O
316
Logic
CN1 Relay2
CN26
W W
Buzzer 44 311 311
Y
312
Logic
L
CN2 328
GB
Parking brake 34 109
B
329
O
330
Logic Parking brake switch
CN3 GB
109 CN25 CN26 CN24
W W
GND 25 108 315 326 313 329 328 311 314
316 314 330 312 312
Main harness Main harness Main harness
212063C
2-64
Problem: Battery Voltage Too Low (78)
(1) Situation
(2) Possible cause

Faulty or discharged battery, low voltage battery, improper battery voltage adjustment setting (Setup Option #46),
faulty main harness, faulty logic unit.

Corrected battery voltage is too low. Battery voltage is corrected with #46 value.
24 V battery: less than 20 V
(4) Checks
Disconnect battery plug. Measure battery voltage with multimeter.
20V to 28 V Abnormal
(5) Set #46 of Setup Option Group 3. See pages 1-36 to 1-38. (6) Charge battery or replace with proper battery.
(7) Turn off power and turn on power again.
If fault remains

See page 1-60.
(9) Check continuity between CN3-19(269) and contactor

POS.
(10) Discharge the inverters, then replace logic card of

(11) Repair or replace main harness.
2-65
Line contactor
Logic
CN3
R R
19 269 3
Disconnect
switch
NEG
POS NEG
+ -
Battery
212064
2-66
Problem: Battery Voltage Too High (79)
(1) Situation
(2) Possible cause

Faulty or highly charged battery, high voltage battery, improper battery voltage adjustment setting (Setup Option #46),
faulty logic unit.

Corrected battery voltage is too high. Battery voltage is corrected with #46 value.
24 V battery: more than 30 V
(4) Checks
Disconnect battery plug. Measure battery voltage with multimeter.
20 V to 28 V Abnormal
(5) Set #46 of Setup Option Group 3. See pages 1-36 to 1-38. (6) Replace with proper battery.
(7) Turn off power and turn on power again.
If fault remains

See page 1-60.

POS.
(10) Discharge the inverters, then replace logic card of (11) Repair or replace main harness.
2-67
Line contactor
Logic
CN3
R R
19 269 3
Disconnect
switch
NEG
POS NEG
+ -
Battery
212064
2-68
Problem: Lift Stroke Sensor Fault (83)

(1) Situation
Display: "83". Pump motor operations inhibited.
(2) Possible cause

Faulty lift stroke sensor, faulty main harness, faulty logic unit, faulty lift lever.
From another troubleshooting flow chart
(3) How the error code is triggered.

Lift stroke sensor voltage is out of range of 0.1 V to 4.9 V.
(4) Checks
(5) Disconnect battery plug. (6) Check lift stroke sensor voltage with Input Monitor and
confirm value is in range of 0%(1.2V) to 100% (3.2V).

Disconnect connector CN20 of lift stroke sensor.

(Sensor voltage)
(11) Replace lift stroke sensor. (12) Repair or replace harness.
If fault remains
(14) Reinstall lift stroke sensor, then replace logic card

of logic unit. See page 1-66.
2-69
Logic
CN3 CN20 Lift stroke sensor
RW R
+5V 24 141 290 4
W V
GND 25 108 292 8
B
291 5
Logic
CN2
V
27 292
CN20
4 3 2 1
290 306 305 302
291 307 292

5 6 7 8
Main harness
212067
2-70
Problem: Direction Lever or Accelerator, Faulty Setting (E)
(1) Situation
Display: "E". Traction motor operation inhibited. Normal pump motor operation. Line contactor HOLD.
(2) Possible cause

Power turned on while depressing accelerator pedal, power turned on while operating direction lever, seat switch turned
off during running, faulty direction lever switch, faulty accelerator sensor, faulty main harness, faulty logic unit.

Detects following signal when turning on power, or when operator taking the seat.
Direction lever: F or R Accelerator sensor voltage: More than 0.27 V
(4) Checks
Shift direction lever to neutral, and release accelerator pedal.
If fault remains
(5) Turn off power. Shift direction lever to neutral, release
accelerator pedal, then turn on power again.

With service tool
(6) Check direction lever and accelerator sensor operations (7) Turn on power in diagnosis mode. Inspect direction
with Input Monitor. lever and accelerator sensor. See page 1-43 to 1-53.
(8) Turn off power. (faulty unit only)

Direction lever Accelerator sensor
(9) Disconnect connector CN10 of direction lever. (10) Refer to error code "51". See page 2-39.
Turn on power.
Normal Error code"E"
(11) Replace direction lever. (12) Disconnect connectors CN2 and CN3 of logic unit.
(13) Check short circuit between CN3-25(108) and

CN2-36(104), CN3-25(108) and CN2-37(103).
Not shorted Shorted
(14) Disconnect battery (15) Repair or replace main

plug. harness.
2-71
Logic Direction
CN2 CN10 lever
OL 103 0/12V OL
Forward 37 F
Br 0/12V Br
Reverse 36 104 R
GND 102 G
B2
L CN10
Accel switch 42 144
104 103
102
Main harness
Logic 0/12V
Accelerator
CN3
CN16
W L
GND 25 108
RW 5V RW
+5V 24 141
G 0 to 5V G
Accel angle 20 142
GND
GND 23 L 140 143
B
CN16
143 144 142 141
Main harness
212065
2-72
Problem: Seat Switch, Faulty Setting For Traction ((E))
(1) Situation
Display: "E" flickering. Traction motor operation inhibited. Normal pump motor operation. Line contactor HOLD
when turning on power.
(2) Possible cause

Operator not on seat, seat switch turned off during running, improper seat suspension adjustment, faulty seat switch,
faulty main harness, faulty logic unit.

Detects seat switch opening when turning on power or during running.
(4) Checks
If this fault occurred If this fault occurred when
during running turning on power
(5) Stop truck, then shift direction lever to neutral. Sit

properly in operator's seat and release accelerator pedal.
If fault remains Normal
Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again.
If fault remains
(7) Turn off power.
(8) Adjust seat suspension.

Faulty seat switch position

(10) Disconnect connector of seat switch, then short circuit

between wire color Y(111) and B(110).
Connect battery plug, then turn on power again.
(11) Disconnect battery plug, then discharge the inverters. (12) Replace seat switch.
See page 1-60.

Check continuity between plug connector, wire color B(110) and CN3-25(108).
Check continuity between plug connector, wire color Y(111) and CN2-33(111).
(14) Replace logic card of logic unit. See page 1-66. (15) Repair or replace main harness.
2-73
Logic
CN2
Y
111 33 Seat SW
G 32 Seat belt SW
113
Logic
Seat SW CN3
Y
B 110 W 25
108 GND
B 112
G
Seat belt
SW
212066
2-74
Problem: Seat Switch, Faulty Setting For Hydraulic ((L))
(1) Situation
Display: "L" flickering. All truck operations inhibited. Line contactor HOLD when turning on power.
(2) Possible cause

Operator not on seat, seat switch turned off during pump motor operation, improper seat suspension adjustment,
faulty seat switch, faulty main harness, faulty logic unit.

Detects seat switch opening when turning on power or during pump motor operation.
(4) Checks
If this fault occurred during If this fault occurred when
pump motor operation turning on power
(5) Sit on seat, then stop pump motor operation.

Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again.
If fault remains
(7) Turn off power.
(8) Adjust seat suspension.

Faulty seat switch position
(10) Disconnect connector of seat switch, then short circuit

between wire color Y(111) and B(110).
Connect battery plug, then turn on power again.
(11) Disconnect battery plug, then discharge the inverters. (12) Replace seat switch.
See page 1-60.

Check continuity between wire color B(110) and CN3-25(108).
Check continuity between wire color Y(111) and CN2-33(111).
2-75
Logic
CN2
Y
111 33 Seat SW
G 32 Seat belt SW
113
Logic
Seat SW CN3
Y
B 110 W 25
108 GND
B 112
G
Seat belt
SW
212066
2-76
Problem: Lift Lever, Faulty Setting (H1)
(1) Situation
Display: "H1". All truck operations inhibited. Line contactor HOLD when turning on power.
(2) Possible cause

Power turned on while operating lift lever, faulty lift stroke sensor, faulty main harness, faulty logic unit.

Detects lift lever operation when turning on power.
Detects lift lever operation when operator taking the seat.
(4) Checks

Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again
without lift operation.
If fault remains
(7) Refer to error code "83". See page 2-69.
2-77
Logic
CN3 CN20 Lift stroke sensor
RW R
+5V 24 141 290 4
W V
GND 25 108 292 8
B
291 5
Logic
CN2
V
27 292
CN20
4 3 2 1
290 306 305 302
291 307 292

5 6 7 8
Main harness
212067
2-78
Problem: Tilt Lever, Faulty Setting (H2)
(1) Situation
(2) Possible cause

Power turned on while operating tilt lever, faulty tilt switch, faulty main harness, faulty logic unit.

Detects tilt switch when turning on power.
Detects tilt switch when operator taking the seat.
(4) Checks

Fail-safe function
without tilt operation.
If fault remains
(7) Turn off power.
(8) Disconnect connector CN20 of switch. Sit on seat,

then turn on power again.
(9) Disconnect battery plug, then discharge the inverters. (10) Replace tilt switch.
See page 1-60.
(11) Check continuity between CN1-50 and CN20-2(305).

Check short circuit between CN20-2(305) and
CN20-1(302).
Continuity, Not shorted No continuity, Shorted
(12) Disconnect battery plug. (13) Repair or replace main harness.
2-79
Logic
CN1 CN20
L
Tilt 50 305 2 Tilt
G
Attach1 49 306 3 Attach1
R
GND 43 W 1
302
CN20
4 3 2 1
290 306 305 302
291 307 292
5 6 7 8
Main harness
212068
2-80
Problem: Attachment 1 Lever, Faulty Setting (H3)

(1) Situation
(2) Possible cause

Power turned on while operating attachment 1 lever, faulty attachment 1 switch, faulty main harness,
faulty logic unit.

Detects attachment 1 switch when turning on power.
Detects attachment 1 switch when operator taking the seat.
(4) Checks

Fail-safe function
without attachment 1 operation.
If fault remains
(7) Turn off power.

(9) Disconnect battery plug, then discharge the inverters. (10) Replace attachment 1 switch.
See page 1-60.

CN20-1(302).
2-81
Logic
CN1 CN20
L
Tilt 50 305 2 Tilt
G
R
GND 43 W 1
302
CN20
4 3 2 1
290 306 305 302
291 307 292
5 6 7 8
Main harness
212068
2-82
Problem: Attachment 2 Lever, Faulty Setting (H4)
(1) Situation
(2) Possible cause

Power turned on while operating attachment 2 lever, faulty attachment 2 switch, faulty main harness,
faulty logic unit.

Detects attachment 2 switch when turning on power.
Detects attachment 2 switch when operator taking the seat.
(4) Checks

Fail-safe function
without attachment 2 operation.
If fault remains
(7) Turn off power.

(9) Disconnect battery plug, then discharge the inverters. (10) Replace attachment 2 switch.
See page 1-60.

CN20-1(302).
2-83
Logic
CN1 CN20
L
Tilt 50 305 2 Tilt
G
R
GND 43 W 1
302
CN20
4 3 2 1
290 306 305 302
291 307 292
5 6 7 8
Main harness
212068
2-84
Problem: Battery Consumption Too Much (Lo)
(1) Situation
Display: "Lo". All truck operations except "lift down" inhibited.
Line contactor OPEN.
(2) Possible cause

Extremely consumed battery, faulty main harness, faulty logic unit.

Corrected battery voltage is less than 15V. Battery voltage is corrected with #46 value.
(4) Checks
Disconnect battery plug.
(5) Check battery voltage.

15V or more Less than 15V
(6) Set #46 of Setup Option Group 3. See pages 1-36 to 1-38. (7) Charge battery or replace with new battery.
If fault remains

POS.
2-85
Line contactor
Logic
CN3
R R
19 269 3
Disconnect
switch
NEG
POS NEG
+ -
Battery
212064
2-86
Problem: Battery Consumption Much ((Lo))

(1) Situation
Display: "Lo" flickering. Traction motor operation restricted to "ECONOMY" mode. Normal pump motor
and power steering operations.
(2) Possible cause

Consumed battery, improper battery voltage adjustment setting (Setup Option #46), faulty main harness,
faulty logic unit.

Corrected battery voltage is less than 16V. Battery voltage is corrected with #46 value.
(4) Checks
Disconnect battery plug.
(5) Check battery voltage.

16V or more Less than 16V
(6) Set #46 of Setup Option Group 3. See pages 1-36 to 1-38. (7) Charge battery or replace with new battery.
If fault remains

POS.
2-87
Line contactor
Logic
CN3
R R
19 269 3
Disconnect
switch
NEG
POS NEG
+ -
Battery
212064
2-88
Lift down, Inhibited
(1) Situation
No error code displayed. Lift down inhibited. Other operations available.
(2) Possible cause

Faulty lift lock valve, faulty main harness, faulty logic unit.
(3) Checks

Disconnect connector CN22 of lift lock valve.
(5) Check short circuit between lift lock valve side connectors. (6) Repair or replace main harness.
Measure coil resistance.
[7.5Ω at -30 °C (-22 °F) to 12.8Ω at 80 °C (176 °F)]
Normal Abnormal
(7) Replace logic card of logic unit. See page 1-66. (8) Replace lift lock valve.
If fault remains
(9) Reinstall logic card of logic unit.
(10) Check hydraulic system. See Chassis & Mast.
2-89
Power supply card

CN4 CN23
CN23
R 25 4
G
V POW 13 318 Unload
B 318 317
317 valve
Main harness
Logic
CN1
CN22 CN22
B Y Lift
59 309
B B lock 309 308
60 308
valve
Main harness
212062
2-90
All Operations except Lift down, Inhibited
(1) Situation
No error code displayed. All operations except lift down inhibited.
(2) Possible cause

Faulty unload valve, faulty main harness, faulty logic unit.
(3) Checks

Disconnect connector CN23 of unload valve.
(5) Check short circuit between unload valve side connectors. (6) Repair or replace main harness.
Measure coil resistance.
[7.5Ω at -30 °C (-22 °F) to 12.8Ω at 80 °C (176 °F)]
Normal Abnormal
(7) Replace logic card of logic unit. See page 1-66. (8) Replace unload valve.
If fault remains
(9) Reinstall logic card of logic unit.
(10) Check hydraulic system. See Chassis & Mast.
2-91
Power supply card

CN4 CN23
CN23
R 25 4
G
V POW 13 318 Unload
B 318 317
317 valve
Main harness
Logic
CN1
CN22 CN22
B Y Lift
59 309
B B lock 309 308
60 308
valve
Main harness
212062
2-92
PDS Buzzer Does Not Sound
(1) Situation
No error code displayed.
When power turned off, PDS buzzer does not sound with release of parking brake.
When power turned on, PDS buzzer does not sound with release of parking brake and leaving seat.
(2) Possible cause

Faulty PDS buzzer, faulty main harness, faulty logic unit, faulty PDS relay, faulty parking brake switch.
(3) Checks
(4) Disconnect connectors CN1, CN2, CN3 and CN4 of logic unit.
Disconnect connectors CN25 and CN26 of PDS relay.
Pull up disconnect switch.
Check continuity between battery (POS) and CN25(326).
Check continuity between CN24(314) and CN25(314).
(5) Measure resistance of PDS relay with connectors CN25 (6) Repair or replace main harness.
and CN26.
Measure resistance between CN25(315) and CN25(316).
Measure resistance between CN26(329) and CN26(330).
[867Ω at -30 °C (-22 °F) to 1355Ω at 80 °C (176 °F)]
Normal Abnormal
(7) Check continuity of PDS relay with connectors CN25 and

CN26.
(9) Release parking brake lever. (8) Replace faulty PDS relay.
2-93
(10) Pull parking brake lever. (11) Disconnect parking brake plug connector.
Check continuity between wire color GB(109) and CN26(328).
No continuity Continuity Check continuity between wire color W(108) and CN3-25(108).
(12) Replace PDS buzzer. (13) Check parking brake switch (14) Repair or replace main harness.
setting.
Normal Abnormal
If fault remains
(15) Reinstall PDS buzzer. Replace logic (17) Adjust parking brake switch
card of logic unit. See page 1-66. (16) Replace parking brake switch.
setting. See Chassis & Mast.
2-94
PDS Buzzer
CN24
312
Y
R
314
Power supply card PDS Relay

CN4 Relay1
CN25
R G
V POW 13 25 4 313
R
314
POS L
3 326
B
NEG 1 315
O
316
Logic
CN1 Relay2
CN26
W W
Buzzer 44 311 311
Y
312
Logic
L
CN2 328
GB
Parking brake 34 109
B
329
O
330
Logic Parking brake switch
CN3 GB
109 CN25 CN26 CN24
W W
GND 25 108 315 326 313 329 328 311 314
316 314 330 312 312
Main harness Main harness Main harness
212063C
2-95
3. Electrical System Diagram
2-97
4. Electrical System Schematic
2-99
5. Location of Major Components
Logic unit
Traction inverter
Contactor
Pump inverter
212444
2-101
Mitsubishi Caterpillar Forklift Europe B.V.
Hefbrugweg 77 1332 AM
Almere, The Netherlands
Copyright © 2007 by MCFA. All Rights Reserved.

99759-6H100 CATERPILLAR and CAT are registered trademarks of Caterpillar Inc. Printed in The Netherlands

CAT EP10-15 KRT PAC Controller 2 Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CAT EP10-15 KRT PAC Controller 2 Manual

Uploaded by

Copyright:

Available Formats

TROUBLESHOOTING FOR CONTROL CIRCUITS

General Information ............................................................................... 2 – 1

Before replacing devices

Disconnect battery plug and discharge the inverters before

Disconnect connector CN4 of logic unit. Check continuity between

Normal Repair or replace harness.

Connection of the service tool

How to clean harness connectors and system

2. After checking the connector for continuity, wash it as

Problem: Traction Motor, Overheating (E0)

(2) Possible cause

(3) How the error code is triggered

(5) Traction motor becomes normal.

(7) Adjust brake.

(9) Check if truck is operated on steep

(10) Discharge the inverters. See page 1-60.

(11) Replace traction motor. (12) Replace traction

(13) Disconnect battery plug. Wait until traction motor

(14) Discharge the inverters. See page 1-60.

(15) Disconnect connector CN14 of traction motor thermal

(22) Measure voltage between CN6-17(252) and

(24) Replace power supply card of logic unit.

(25) Replace DSP card of traction inverter. See page 1-63.

Problem: Pump Motor, Overheating (E2)

(2) Possible cause

(3) How the error code is triggered

(5) Pump motor becomes normal.

(8) Check oil pressure of gear pump and hydraulic lines.

(9) Replace pump motor. (10) Repair or replace gear

(11) Disconnect battery plug. Wait until pump motor

(12) Discharge the inverters. See page 1-60.

(13) Disconnect connector CN15 of pump motor thermal

(20) Measure voltage between CN5-17(260) and

(22) Replace power supply card of logic unit.

(23) Replace DSP card of pump inverter. See page 1-63.

CN15 Pump motor

*1: With connector disconnected

Problem: Traction Inverter, Overheating (E5)

(2) Possible cause

(3) How the error code is triggered

(5) Traction inverter becomes normal.

(8) Replace traction inverter. (9) Clean mounting surface,

(10) Disconnect battery plug. Wait until inverter

(11) Discharge the inverters. See page 1-60.

(18) Measure voltage between CN6-17(252) and CN6-20(255).

(21) Replace DSP card of traction inverter. See page 1-63.

(23) Replace traction inverter. (DSP card is normal.)

Problem: Pump Inverter, Overheating (E7)

(2) Possible cause

(3) How the error code is triggered

(5) Pump inverter becomes normal.

(6) Check if truck is operated to lift large cargo load.

(8) Replace pump inverter. (9) Clean mounting surface,

(10) Disconnect battery plug. Wait until inverter temperature

(11) Discharge the inverters. See page 1-60.

(18) Measure voltage between CN5-17(260) and CN5-20(262).

(20) Replace power supply card of logic unit.

(21) Replace DSP card of pump inverter. See page 1-63.

(22) Disconnect battery plug, then discharge the inverters.

(23) Replace pump inverter. (DSP card is normal.)

CN15 Pump motor

*1: With connector disconnected

Problem: Brake Oil, Low Level

(2) Possible cause