Error Message & Troubleshooting

1.Display is not powered on.

2.Transistor-Travel, Transistor-Hydraulic
3.Fail Bus System
 1.Display is not powered on.

In case that you turn on the key switch,

but the display is not powered on and
you can’t operate the truck !

What do you check?

How do you check?
 EPS controller & harness check ！
Check the lighting condition of LED1(CPU) in the EPS controller. Display ×
Operation ×
LED1(CPU) ×
Cont.Power ○
In case that the LED1 is not blinking when you turn on the key switch,
check the voltage between CN2-1 pin (control power supply) and
K1 line (GND) in the EPS controller.

LED1(CPU)

EPS controller
 EPS controller & harness check ！
Display ×

• In case that the voltage is applied 48V, Operation ×

LED1(CPU) ×
replace the EPS controller. Cont.Power ○

• In case that the voltage is not applied 48V, Display ×

check the continuity from battery positive line Operation ×
LED1(CPU) ×
to CN2-1 pin and Cont.Power ×
from K1 line to battery negative line.
EPS controller & harness check ！
EPS controller

Red line ： from battery positive line to CN2-1pin in the EPS controller
Blue line ： from K1 line in the EPS controller to battery negative line
EPS controller & harness check ！

Blue line ： from K1 line in the EPS controller to battery negative line
2.Transistor-Travel, Transistor-Hydraulic

B11

B11 ： Transistor U-TRAVEL C21 ： Transistor U-HYD.

B12 ： Transistor V-TRAVEL C22 ： Transistor V-HYD.
B13 ： Transistor W-TRAVEL C23 ： Transistor W-HYD.

What do you check?

How do you check?
 Item to be checked
• Transistor (IGBT) continuity check
• IGBT board check
• MPU board check
• Electrolytic capacitor check
• EPS controller (electrolytic capacitor) check

When the transistor error occurs, there is a high possibility that

the above items are damaged.
Certainly, check them at the same time.
 IGBT continuity check ！

・ Use the continuity check mode of a digital tester.

IGBT module
・ If the circuit is conducting at any one test point
(No,1 to 6), replace the IGBT module.
 IGBT board check ！
IGBT board
　

Check the transformers(6pcs.)

　 　 　 　 　 　 　 　 R18,R20 for power supply by appearance.
IGBT gate resistors W phase for HYD.
R33,R34 V phase for HYD. R40,R41 U phase for HYD.

R8,R9 R13,R16 R27,R28 U phase for TRV.

W phase for TRV. V phase for TRV.
 IGBT board check ！
Check the resistance value of all gate resistors.

Over 5Ω resistance is damaged !

FET1

Back side of the IGBT board

Check the continuity between 　　　
　　　　　　　 gate and drain in the
FET1.
Conducting circuit is damaged !
 MPU board check ！
FET2

Check the T1 in appearance.

Transformer for power supply (T1)

Check the continuity between gate

and drain in the FET2.

Conducting circuit is damaged !

 Electrolytic capacitor
& EPS controller check ！
Check the electrolytic capacitors (9pcs.) in the main controller by appearance.

In case that any one capacitor is damaged, replace the all capacitors
(9pcs.).

Check the electrolytic capacitor in the EPS controller by appearance.

EPS controller Electrolytic capacitor

3.Fail Bus System

G68

G68 ： FAIL BUS SYSTEM

What do you check?

How do you check?
 3.Fail Bus System
The communication is failure between EPS controller
and MPU board.

MPU board

EPS controller
 Item to be checked
• Travel, Hydraulic and EPS operation are available?
• MPU board check
• Sensor check
• EPS controller check
• Wire harness check
Trv.Operation ×
When travel and hydraulic operation are not available, Hyd.Operation ×

there is a high possibility that the electrical short-circuit is

affecting the MPU board.
Don’t apply the voltage to the MPU board continuously.
(Turn off the key switch frequently even in the troubleshooting.)
 MPU board & sensor check ！
• In case that travel and hydraulic operation are not available,
check the lighting condition of LED P15 and P6 in the MPU
board
when you turn on the key switch.
Trv.Operation ×
• In case that the LED P15 is lighting, check the voltage
between CN7-5 pin (power supply for speed sensor) and Hyd.Operation ×
CN7-11 pin (GND) in the MPU board. LED(P15) ○

• In case that the voltage is not applied 5V, confirm that the
Trv.Operation ×
error message
is cleared by disconnecting the each sensor connector one by Hyd.Operation ×
one. LED(P15) ○
(Speed sensor, Accelerator, Foot brake and Hydraulic lever) Sensor Power ×
Supply

• Replace the defective sensor.

 MPU board & sensor check ！
MPU board

P15

LED

P6

・ CN7-5pin (power supply for speed

sensor)
<photo ： yellow adapter>
・ CN7-11pin (GND)
<photo ： black adapter> 　　
 MPU board & wire harness check ！
• In case that travel and hydraulic operation are not available,
Trv.Operation ×
check the lighting condition of LED P15 and P6 in the MPU board when you
turn on the key switch Hyd.Operation ×

• In case that the LED P15 is not lighting, check the voltage
between CN5-10 pin (control power supply) and CN1-7 pin (GND) in the M Trv.Operation ×
PU board Hyd.Operation ×
LED(P15) ×
• In case that the voltage is applied 48V, replace the MPU board.

Trv.Operation ×
Hyd.Operation ×
LED(P15) ×
Ctrl.Power ○
• In case that the voltage is not applied 48V, check the voltage
from power supply relay to the CN5-10 pin and check the electroactuation of
the power supply relay Trv.Operation ×
Hyd.Operation ×
LED(P15) ×
Ctrl Power ×
MPU board & wire harness
check ！
MPU board

EPS controller
 EPS controller check ！
• In case that travel and hydraulic operation a Trv.Operation ○
re available, but power steering operation is Hyd.Operation ○
not available, replace the EPS controller EPS ×

• In case that travel,hydraulic and EPS operat Trv.Operation ○

ion are available, check the connection of C Hyd.Operation ○
PU for travel and CPU for hyd. by setting th EPS ○
e rotary switch on the EPS controller to “7”
EPS controller check ！
Set the rotary switch “0” to “7”

CPU for travel

Select “TR” and confirm that

the value of voltage, ampere
and degree Celsius are shown.

Not showing are the

breaking of wire !
(Traction lines )
EPS controller check ！
Set the rotary switch “0” to “7”

CPU for hyd.

Select “HY” and confirm that

the value of voltage, ampere
and degree Celsius are shown.

Not showing are the

breaking of wire !
(Hydraulic lines )
 Wire harness check ！
MPU board

Red lines ：
Traction lines
EPS controller Blue lines ：
Hydraulic lines

In case of not showing both TR and HY,

Return to CONTENT
firstly, check the power supply and GND line ! ( Green lines )