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Troubleshooting For Control Circuits
Troubleshooting For Control Circuits
NOTE
For your reference, most pages are provided with
schematics of pertinent electrical circuits.
Before conducting troubleshooting, read the procedures
carefully and also refer to the Electrical Schematics in
the “Group 2 Vehicle Electrical Components”.
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display does not work.
Possible Cause:
(2) Faulty wiring, display unit defect.
Checks:
(3) Disconnect battery plug. Check continuity between wire 203-R (red) of display connector CN4 and controller
connector CNC.
(4) Between 202-B (black) of display connector CN4 and CNC.
• No continuity
Correct or replace wiring.
• Continuity
Replace display.
209046
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TROUBLESHOOTING FOR CONTROL CIRCUITS
209047
4-2
TROUBLESHOOTING FOR CONTROL CIRCUITS
209048
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TROUBLESHOOTING FOR CONTROL CIRCUITS
4-4
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Worn brush indicator ON.
Possible Cause:
(2) Worn drive motor or pump motor brush, short circuit, display unit defect.
Checks:
(3) Disconnect battery plug. Disconnect drive motor brush wear indicator connector.
Reconnect battery plug, and close key switch. Check to see if indicator turns OFF.
• Indicator OFF
Inspect brushes and replace, if necessary.
• Indicator ON
(4) Disconnect battery plug. Check continuity between wire 126-W (white) of drive motor sensor connector and
NEG. (For protect diode, current can through only from CNB-7 to sensor’s connector.) Check continuity between
wire 127-O (orange) of drive motor sensor connector and NEG.
• No continuity or shorted
Correct or replace wiring.
• Continuity
209049
4-5
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Low brake oil indicator ON.
Normal vehicle operation.
Possible Cause:
(2) Insufficient brake oil, open wiring, display unit defect.
Checks:
(3) Check oil level in bare oil reservoir tank
• Oil level lower than LOW mark
Add brake oil.
• Oil level higher than LOW mark
(4) Disconnect battery plug. Disconnect level sensor connector CN10, and check continuity.
• Continuity
Replace level sensor.
• No continuity
(5) With connector CN10 and CN19 disconnected, check continuity between harness connector CN10 socket wire
140-L (blue) and CN19 and between 139-O (orange) and controller.
• No continuity
Correct or replace wiring.
• Continuity
Replace traction logic card.
Brake oil level sensor: Normally OFF
(Low oil level: ON)
209050
4-6
TROUBLESHOOTING FOR CONTROL CIRCUITS
208291
4-7
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL060” or “AL032”.
Inhibit drive and hydraulic operation. Line contactor OFF.
Possible Cause:
(2) Wire break in transistor, traction CS current sensor failure, logic card defect.
Checks:
(3) Disconnect battery plug.
Inspect armature wiring for wire breakage and shorting.
• Broken or shorted
Correct or replace faulty components.
• No broken and no shorted
(4) Replace logic card.
• Unacceptable
Replace controller.
4-8
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL060” or “AL032”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Short circuit in traction transistor, drive card failure, traction CS current sensor failure, logic card fault.
Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.
4-9
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL060” or “AL032”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Wire break in traction transistor, drive card failure, traction CS current sensor failure, faulty wiring, logic card
fault.
Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.
4-10
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL053” or “AL049”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Wire break in traction transistor, faulty wire connection, drive card defect, traction CS current sensor failure,
logic card defect.
Checks:
(3) Disconnect battery plug.
Check state of wiring.
• Unacceptable
Repair wiring.
• Acceptable
(4) Replace logic card.
• Unacceptable
Replace controller.
4-11
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL069”.
Inhibit drive and hydraulic operation. Normal power steering operation.
Possible cause:
(2) Short circuit in transistor, faulty wire connection, drive card defect, traction current sensor failure, logic card
defect.
Checks:
(3) Disconnect battery plug.
Inspect armature wiring for breakage and shorting.
• Broken or shorting
Correct or replace faulty components.
• No broken and No shorting
(4) Replace logic card.
• Unacceptable
Replace controller.
4-12
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL072”.
Inhibit drive and hydraulic operation. Normal power steering operation.
Possible Cause:
(2) Stall current flowed more than set time in drive motor. Faulty current sensor, faulty logic card.
Checks:
(3) Check to see if vehicle is operated on steep upgrade or to pull large cargo load when motor stalls.
• Operated under heavy load
Do not operate vehicle for more than set time under a condition that causes the motor to stall.
• Operated under normal condition
(4) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.
4-13
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL058”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Drive motor field circuit defect, faulty drive card, faulty logic card.
Checks:
(3) Disconnect battery plug.
Inspect field wiring for wire breakage and shorting.
• Broken or shorted wire
Correct or replace faulty components.
• No broken and no shorted wire
(4) Replace logic card.
• Unacceptable
Replace controller.
4-14
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL015”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Drive card failure, faulty wiring, logic card fault.
Checks:
(3) Disconnect battery plug.
Inspect field wiring for open or short circuit.
• Open or short circuit
Repair or replace faulty components.
• No open or short circuit
Replace logic card.
• Unacceptable
Replace controller.
4-15
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL057”.
Inhibit drive and hydraulic operation. Normal power steering operation.
Possible Cause:
(2) Traction current sensor failure, faulty wiring, fault in logic card.
Checks:
(3) Disconnect battery plug.
Inspect field wiring for wire breakage and short.
• Broken or shorting
Correct or replace faulty components.
• No broken and no shorted wire
(4) Replace logic card.
• Unacceptable
Replace controller.
4-16
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL028”.
Inhibit vehicle operation.
Possible Cause:
(2) Wire break in pump transistor, faulty wire connection, drive card defect, pump current sensor failure, logic card
defect.
Checks:
(3) Disconnect battery plug.
Inspect pump wiring for wire breakage and shorting.
• Broken or shorted
Correct or replace faulty components.
• No broken and no shorted
(4) Replace logic card.
• Unacceptable
Replace controller.
4-17
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL028”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Short circuit in pump transistor, drive card defect, pump current sensor failure, logic card defects.
Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.
4-18
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL028”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Wire break in pump transistor, faulty wire connection, drive card defect, pump current sensor failure, logic card
defect.
Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.
4-19
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL056” or “AL052”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Wire break in pump transistor, faulty wire connection, drive card defect, pump current sensor failure, logic card
defect.
Checks:
(3) Disconnect battery plug.
Check state of wiring.
• Unacceptable
Repair wiring.
• Acceptable
(4) Replace logic card.
• Unacceptable
Replace controller.
4-20
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL035”.
Inhibit vehicle operation.
Possible Cause:
(2) Short circuit in pump transistor, faulty wire connection, drive card defect, pump current sensor failure, logic card
defect.
Checks:
(3) Disconnect battery plug.
Inspect pump wiring for breakage and shorting.
• Broken or shorting
Correct or replace faulty components.
• No broken and no shorting
(4) Replace logic card.
• Unacceptable
Replace controller.
4-21
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL037”, “AL07”, “AL075”, “AL076”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Faulty line contactor, faulty wire connection, logic card defect.
Checks:
(3) Disconnect battery plug. Check line contactor tip for wire breakage and shorting (melting). Check line contactor
tip move freely.
• Broken or shorted wire
Replace contactor.
• No Broken or shorted wire
(4) Check resistance of contactor coil.
• Lower than 15 ohm, over 32 ohm
Replace contactor coil.
• 15 to 32 ohm
(5) Check continuity between CNA-8 and line contactor coil red. Disconnect controller connector CNA.
• No continuity
Replace or correct contactor wiring.
• Continuity
(6) Check continuity between CNA-9 and line contactor coil black.
• No continuity
Correct or replace contactor wiring.
• Continuity
Replace traction logic card.
• Unacceptable
Replace controller.
209051
4-22
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL032” or “AL049”.
Inhibit drive and hydraulic operation.
Possible Cause:
(2) Open circuit in drive motor, traction current sensor failure, traction logic card fault.
Checks:
(3) Disconnect battery plug.
Disconnect controller terminals (A, B). Measure resistance between A and B.
• Open
Replace motor or motor wiring.
• Acceptable
(4) Replace logic card.
• Unacceptable
Replace controller.
209052
4-23
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL028” or “AL052”.
Inhibit vehicle operation.
Possible Cause:
(2) Open circuit in pump motor, pump current sensor failure, logic card fault.
Checks:
(3) Disconnect battery plug.
Disconnect controller terminals (A1, D2). Measure resistance between A1 and D2.
• Open
Replace motor or motor wiring.
• Acceptable
(4) Replace logic card.
• Unacceptable
Replace controller.
209053
4-24
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL078”, “AL086”, “AL087”.
Inhibit drive and hydraulic operation.
Possible Cause:
(2) Accelerator sensor defect, faulty wiring, logic card fault.
Checks:
(3) Disconnect battery plug. Check continuity between accelerator socket and traction logic card.
CN7-141R ↔ CNA-12
CN7-142G ↔ CNA-14
CN7-143B ↔ CNA-13
CN7-144L ↔ CNA-6
• No continuity
Correct or replace wiring.
• Continuity
(4) Reconnect battery plug and connectors. Check voltage of CNA-14 without pressing accelerator pedal and while
pressing accelerator pedal fully. And check continuity between accelerator 143 and 144 without pressing
accelerator pedal and while pressing accelerator pedal fully.
• Acceptable
Replace Drive logic card.
• Unacceptable
(5) Check accelerator return adjustment and interference.
• Properly adjusted
Replace accelerator.
• Conduction
Adjust accelerator linkage.
209054
4-25
TROUBLESHOOTING FOR CONTROL CIRCUITS
Possible Cause:
(2) Key switch turned on while forward / reverse lever was left either in forward or reverse position. Key switch
turned on while tilt lever, Attachment 1 lever or Attachment 2 lever was in ON position or accelerator pedal was
depressed. Faulty forward / reverse lever switch, tilt lever switch, Attachment 1 lever switch and Attachment 2
lever switch; logic card defect.
Checks:
(3) Move forward / reverse, tilt, Attachment 1 and / or Attachment 2 levers to neutral. Select direction of movement
again and depress accelerator pedal.
• Normal vehicle operation
Correct starting procedure requires all of forward / reverse, tilt, Attachment 1 and Attachment 2 levers be in
neutral position and accelerator pedal be released when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty component.
• Faulty component not located
Replace logic card.
209055
209056
4-26
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL082” or “AL083”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Key switch turned on while lift lever was in ON position. Faulty lift lever potentiometer. Faulty logic card.
Checks:
(3) Set lift lever to OFF, then ON again.
• Normal hydraulic system operation
Proper starting procedure requires that lift lever be in neutral position when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty components.
• Faulty component not located
Replace logic card.
209057
4-27
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL079”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Key switch turned on while tilt lever was in ON position. Faulty tilt lever switch. Faulty logic card
Checks:
(3) Set tilt lever to OFF, then ON again.
• Normal hydraulic system operation
Proper starting procedure requires that tilt lever be in neutral positron when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty components.
• Faulty component not located
Replace logic card.
209058
4-28
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL079”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Key switch turned on while Attachment 1 lever was in ON position. Faulty Attachment 1 lever switch, faulty
logic card.
Checks:
(3) Set Attachment 1 lever to OFF, then ON again.
• Normal hydraulic system operation
Proper starting procedure requires that Attachment 1 lever be in OFF position when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty components.
• Faulty component not located
Replace logic card.
209059
4-29
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL079”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Key switch turned on while Attachment 2 lever was in ON position. Faulty Attachment 2 lever switch, faulty
logic card.
Checks:
(3) Set Attachment 2 lever to OFF, then ON again.
• Normal hydraulic system operation
Proper starting procedure requires that Attachment 2 lever be in OFF position when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty components.
• Faulty component not located
Replace logic card.
209060
4-30
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL006”.
Normal vehicle operation. Inhibit vehicle operator line contactor OFF.
Possible Cause:
(2) Faulty display, faulty wiring, faulty logic card.
Checks:
(3) Disconnect battery plug. Check continuity between display CN4 and logic card CNC.
• No continuity
Correct or replace wiring.
• Continuity
(4) Inspect display.
• Unacceptable
Replace display.
• Acceptable
Replace logic card.
209046
4-31
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL013”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Faulty EEPROM on logic card.
Checks:
(3) Conduct initial adjustment of controller.
• Normal vehicle operation
Vehicle operates normally.
• No change
Replace logic card.
4-32
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL006”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Faulty logic card.
Checks:
(3) Replace logic card.
4-33
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL055”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Discharge battery, faulty battery, misuse of lower voltage battery, faulty logic card, faulty BD1 adjustment.
Checks:
(3) Measure the voltage.
For 24V truck > 15
• Unacceptable
Replace battery.
• Acceptable
(4) Conduct Set-up option.
• Normal vehicle operation
Vehicle operates normally.
• No change
Replace logic card.
208229
4-34
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL059”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Overcharge battery, faulty battery, misuse of higher voltage battery, faulty logic card, faulty BDI adjustment.
Checks:
(3) Measure the voltage.
For 24 V truck < 36
• Unacceptable
Replace battery.
• Acceptable
(4) Conduct Set-up option.
• Normal vehicle operation
Vehicle operates normally.
• No change
Replace logic card.
208229
4-35
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Battery low indicator “AL066”.
Poor traction power and acceleration. Lifting speed slower than normal.
Possible Cause:
(2) Much consumption with small capacity or poor battery.
Checks:
(3) Check battery voltage in case of both operating and non operating.
• Battery voltage lower than 23.6 V
Check the following:
Battery capacity
Power supply to pump motor
Large cargo load
• Battery voltage higher than 23.6 V
Replace logic card.
4-36
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL067”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Too much consumption with small capacity or poor battery.
Checks:
(3) Check battery voltage in case of both operating and non operating.
• Battery voltage lower than 15 V
Check the following:
Battery capacity
Power supply to pump motor
Large cargo load
• Battery voltage higher than 15 V
Replace logic card.
4-37
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL018”.
Normal vehicle operation
Possible Cause:
(2) Faulty wiring, power relay and / or logic card.
Checks:
(3) Disconnect battery plug, disconnect CNA from CN18, then check continuity between CNA’s terminals 8 and 15.
• Continuity present
Replace harness.
• No continuity
Check power relay coil resistance.
If resistance is 0 ohm, replace relay.
If resistance is 320 ohm, replace logic card.
209062
4-38
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL016”.
Inhibit vehicle operation. Line contactor OFF.
Possible Cause:
(2) Faulty logic card.
Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.
4-39
TROUBLESHOOTING FOR CONTROL CIRCUITS
Symptom:
(1) Display = “AL071”.
Poor traction power and acceleration. Normal pump motor and power steering operation.
Possible Cause:
(2) Faulty parking brake switch, unreleased parking brake, faulty foot brake switch, faulty wiring, faulty logic card.
Checks:
(3) Disconnect battery plug. Set parking brake. Check whether CNA’s terminals 7 and 10 are grounded.
• If grounded, there is no problem.
• If not grounded, release the parking brake and check again whether CNA’s terminals 7 and 10 are grounded.
• If grounded, check parking brake switch wiring; replace switch if necessary.
• If not grounded, replace foot brake switch.
• If above actions do not solve problem, replace logic card.
209063
4-40