WODEL FB: 7 TCM CORPORATIONCONTENTS Page 1. Characteristic explanation 1 2. The Motor Controller for Forklift Trucks 2 + Control for AC(IM) Motor and DC(Series) Motor + AC Controller System for the standard counter balance model and DC Controller System (Sample) 3. Control Circuit 7 . . . 13 4. Main electric parts and the checking Procedure 5. Troubleshooting 34 5.1 How to use “ Troubleshooting Guide ” 5.2 Check before Troubleshooting 5.3 Troubleshooting according to LED Error code 5.4. Troubleshooting according to Trouble phenomenon « . 47 6. Switch Setting on CPU Board A 48 7. Level Setting on VTM Board 7.1 Initial Setting Level at TCM Shiga Plant 7.2 How to change the setting level 7.3 Level Setting by VTM Board 51 8. Wiring and Circuit DiagramBr ‘ a All Innovations made for \80parators’ ComfortThe Motor Controller for Forklift Trucks Type of Merit Demerit DC|series There is along history anda lot of the {Forward and Backward change by actual samples. Easy control contactor with discontinuity (DC chopper). Characteristic of Series Wearing parts are required Motor with low speed and high torque. (Contactor and Brush). Limited rotating speed because of the brush and commutator. Impossible regeneration at low rotating level. Sbust independent control for Armature and Field Magnet, The stable output controls by the weaker Field Magnet. Forward and Backward contactor are not required Continuous Regeneration until the low rotating speed. Regular maintenance for brush is required. Limited rotating speed because of brush and commutetor. Too much switching time when the direction lever is shifted to F from R lor R from P Maintenance Free. Continuous 4 operation (Original rotating direction travel,2back| rotating direction travel, power and torque, @regeneration) are available according to the vector control. Regenerative torque control at wide speed ranges. Stable output, economical output operation, high rotating epeod 1M: INDUCTION MOTOR Small, Light, Solid, Cheap PM : PERMANENT MAGNETIC ‘MOTOR Gyachronous) Small, Light, High efficiency *Common Demerit for IM & PM A little complicated controller, Outbreak loss, Cooling “Typical Demerit for PM Cost (Magnet and Assembling Additional fan for cooling is required, Exact Magnetic pole search device is required Voltage up at stopping free run, Efficiency drop on the stable output range.Control for ACUM) Motor | The aim value of speed and/or torque on PWM signal is generated according to the AC Motor (IM: 3-phase induction motor) comparison with the calculated 3-phase are decided according to the setting of the alternating current(the frequency and the meter panel or signals from cancellation, amplitude) and the chopping wave of a direction and brake. carrier(10KHz). PWM inverter wave pattern [rears ARIAT | — ve TT = —Wrhase —agpne FoR AIM VALE FM — PHM CV) — PHU) — PH HU) —— PH V-H)) — PHM (U-V)) [ioceumation fos ax aaron The necessary electric currents for the magnetic flux and the torque are based on the decided aim value. The frequency and the amplitude for 3 phase alternating current which are applied to the AC-motor, are calculated according to the order and reverse coordinate transformation based on the feedback signal from the speed sensor, the electric current sensor and so on. (PWM Pulse-Width Modulation) The pulse width control We are switching the 6 pes of main circuit transistors according to the PWM signal, and then the necessary 3 phase alternating current is supplied to AC motor.Control for DC(Series) Motor | The aim voltage (The chopping current passing — oo rate[Duty Factor]) applied to DC Motor (Series) We are switching a main circuit transistor is decided by the signals from Meter panel according to the chopping signal, and then the setting, Accelerator, Direction, Brake and s0 on. necessary direct current is supplied to DC motor. The aim voltage jattery souse (Chopper (Chopping current passing rate) $ — _ rent] "Tho im voltage ia Decided | copie res pine TO sisoet sie (Duty Fear! L ! rfyea Lay Ami Carrier Signal (Chopping wave, 400Hz) The chopping signal is produced according to the comparison between the decided chopping current passing rate [Duty Factor] and the chopping wave (400Hz) of carrier. ‘The voltage applied to DC MotorAC Controller System for the standard counter balance model | S\9—o~o- (P) Fl {D F2 MP Hs Ss [Oo _33 Power Module x3 Le, oe wean aeeeeee MPS Battery TMbUE - oo -EMpWh 4 ; sy) : i t AC Motor DC Motor ieee 1 i Mot i 1 for driving |C] for Loading DC Motor iCSDU eo] spvy | Speed Condenser Board Sensor wv) Gate Drive: Driving(6), Loading(1) EPS) @) (a) @) t—+_+ | | Ly Power, Gate Drive Board <> 32 bit CPU boardDC Controller System (Sample) | DC Motor for Driving! DC Motor Battery a) DC Motor for Loading Gate Drive : Driving(1), Loading(1), EPS) et 3 16 bit CPU Board - Power, Gate Drive Board3. Control Cireuit 3.1 Power Source, Driving Controller Cirewit Guidance outroller 1 When keys turned on, 489 Supplies to the term inal-Lpand Souree the result Inverter functions Accelerator potentiometer eotroller 4.51 is supplied fromC2-), and the ~ voltage of hanged according to the angle of the accelerator pedal 7 Accel released deceterane peteatin bot Gp] ort 0 5Speed control Sy iteh stem functions with (1) Speed Limit Sys the indicated tortoise m ark on the Coa teeller meter panel by this cm iteh Se 2) The voltage on terminal 3 Speed Node Switch is located upper Q etstze Fisch (Switeh iv closed) £ Sea is located bottom Switch is opened 1. Wode Sw iteb (SIP IE) (1) Operator ean from 3 modes (Super, Power and Beonemy) by pushing this switch to change the lifting and traveling speed. The indicator of this modes is on the meter panel (3) The voltag ty tere nel ED The switch re iN isena is opened) During pushing the ewatek OV (Se jtoh is elozed)Cirewit Guidance Controller 5. RB Relay ler recognizes that the (1) Controle re brake pedalic depresced when this relay is eloved (2) When brake pedal is depr | the voltage on terminal (1) chang from SY to OV §. Parking Switeh cseuatlea (1) Parking lamp lights and safety vary ayotem functions te avoid starting --75-- when parking let thie awitek is closed (1) Phe voltage on term inal@ip Parking lever pulled OV (Sw iteh is eloved) Parking lever released is pulled and SY (Switch is opened) TPR Leve x Sep Ga |) Controller detects thar PER Lever 7 Pe. is shifted to F or R by these line = Band 54 (a) The voltage on term inol@D and Lever pocition Neatral F R apps Ps Te Po Porward, ROR (Backward 8. Back Buszer relay (1) This is the coil for the relay to function Back Buster tt (2) The voltage on term inal@2p) become OV and the telay functions when FER lereric chatted to 8Cirewit Guidance Controller Speed Senserd Speed Sencar B 9. Forwarding Chime relay(0 PT) (1) This is the coil for the relay to function Forwarding Chime (2) The voltage on term inal becomes OV and the relay functions when PER lever ie hitted 10. Speed sensor for Drive M otor (1) Thic cencor detects the rotating speed for Drive Motor (2) Alternating voltage created when Drive M otor rotates Therw eo seuser fut 11. Thermo censor for Drive M oter Drive Nato (1) This sensor detects the tem perature on Drive Motor (2) The mark @@p on the meter panelis flached on and off, and then Motor's output current is lim ited, when the t detects peteies more than 155% 3.2 Loading System Cirewit Guidance Loading Controller 1. Lift Potention eter {the potentiom eter from the terminal (1) Power Source LV is supp (2)Signal of Potentiom eter The voltage on the term inal@-1D banged by the angle of lift lever te follows Lever position (V) Porward atral Backward : Lees | Lee a1V6 aap than | than vy viv faa | tA!Cirewit Guidance Covtroller 2. Tilt ATPL, ATT? Switek (1) 5V is supplied from (2) Pump Motor rotates when one of the lever is pushed or pulled and ed one of the switch Therms sviteh fo pump wohr 3. Thermo ewiteh for pump motor (1) This ewiteh detects the (OPT) lem peralureyd pam pm olur (2) The mark (C) on the meter panels flsebed on and off, and current ie then Motor’s output lim ited, when the ecnaor detects more than 1200 4.Broe sor for Pump Moter (1) This censor detects the wearing condition of brush for Pump Motor (2) Thin ewiteh iz closed when the brush weare t.Asthe result term inal eceives 48V and the mark KOM on the meter panel is flashed on and of 3.3 Power Steering System Cirevit Controller Guidance 1. P8 Torque Seneo (1) Power Source 4.51 is supplied from the term inal (2) Input Voltage a) The current paseing rate[D uty Factorlon BPS Motor is controlled the inpat volta according t torque sensor ) The term inal voltag@2-) Straight travel 2.39 Turn to left ‘Turn to right + increase voltage » decrease voltage1 FB-7 Check Point (For Driving) ‘CNGonnectorNO [wire color “wire No, Key Switch | Parking Lever Forward SwitcH Accelerator Terminal name Notes + = + = ON Release ON __|At full depress| 29 [ 220 | uBie7 | 1186 [Accel POT Power source 45 45, 45 45 28 [ 220 | ty93 | 1186 [Accel POT.Power signal o 0 0 25 1-6 _[Nterminall P150 [= |[S/C switch [Turtle Marked : OV With no turtle mark : 5V 1-9 _[Nterminall _RI51 = _|S/P7E switch [Switch Release : 5V Push : OV 1-7_[Nterminall_wiid | — _|RB relay Brake free : 54V Depress - OV 1-19_[Nterminall 015 = [Parking switch ° 5 5 5 1-21 _[Nterminall wis4 | — |R switch 5 5 Lever R:0 1-8_[Nterminall_ werss | — _|F switch 5 5 Lever F:0 1-13 [Nterminall_RWi1 | — Inverter power source 48 48 48 1-24 _[Nterminall RWI = [inverter power source B 4&8 48 2-22 _[Nterminall WL95 | — |Back buzzer coil 48 48 24 | 23 | RW31_ | RB32_|[Drive motor rev. sensor A 0 0 0-56 AC tie [11-5 | Gwas | G829_ [Drive motor rev. sensor B 0 o 0-66 AC ti-4 [11-3 [ Wie | WRi7 [Drive motor thermo sensor 34 31 3a 3a ‘Changing by thermo 27 _[ 218 | wie2 | 1160 [PS torque censor power sourcd| Straight: 46V. End of right side: 46V. End of left side: 4.6V 26 | 218 | Gt61 | L160 _|PS torque sensor signal ~End of right side:3.4V. End of left side: 1.1V 42 _[Nterminall R147 | — [PS motor + Straight: 48V. End of right side: 48V. End of left side:48V 41 _[Nterminall B146 = _ [PS motor — Straight: 48V/. End of right side: 48V. End of left side:48V bu DV, = = [Drive motor cable 0 0 0410 21~23 AC Dv Dw = = [Drive motor cable 0 0 0.270 21~23 AC Dw bu = = [Drive motor cable 0 o 0.230 21~23 AC 5-3 [Nterminall RB = |esou 15 15 15 15 55 [Nterminall RB = Jespw (+) 15 15 15 15 514 _[Nterminal] Gy = |esou © 0 0 0 0 5-15 _|Nterminal] Gy =__[espu (0) 0 0 0 0 5-16 _[Nterminal] Gy =__|esow © 0 0 0 0 5-17_[Nterminall Gy = _[espw ©) 0 0 0. oO 5-4 [Nterminall 0 =_|espu (our) 7.05 7.05 6.85—7.05 7.05 5-6 _[NterminallP —__|esow (our) 7.02 7.02 7.13-7.02 7.02 |-~zZ- FB-7 Check Point (For Pump Loading) EN(connectorINO [wire color “wire No, Lever position Terminal name Notes + = + = Atneutral | Atreverse At front, 211 [221 | GRi8a | WR188 [Lift POT meter power source 46 46 46 2-10 [221 [roa [ wrige [Lift POT meter signal under 1.1 [over 3tunder 43] under 1.1 1-18 _|Nterminall_YR20 = Tit switch 5 0 0 1-4 [Nterminall _YG2i —_JATTI switch’ 5 0 0 1-5 _[Nterminall YL22 = __JATT? switch 5 0 0 1-22_|Nterminall LWi75 | — [Pump motor thermo sensor 0 o 0 Option PA _|Nterminall — = [PA terminal 4B 48-0 43 PB__|Nterminall —— = _|PF terminal 48 48 48 5-7_|Nterminal] RB = |osp (+) 15 15 15 5-18_[Nterminall Gy —__[esP_©) 0 0 0 5-19 [Nterminall Gy = __|esP_(0) 0 0 0 8-8 [Nterminall _W —__|esP (out) 7.05 7.057.566 7.054. Major electric parts and checking procedure Paris arrangement drawing N81F41152 Terminal point mp Pump loading controller ype PS Transistor wD Power module Diode for charging & commutation Drive controller Condenser board N terminal = 45 =CPU Board J Ne CNGCNA © ENIO up ® news psw2 N61F30851 CPU Board is a head for control. ‘The set up for each model 1,2 and 3 ton, it can be done by combining change over switches(DSW2) on the CPU Board. However even if the switch position is changed to the different model, it is not interchangeable. Because there is the other adjustment on each CPU Board. Driving System ‘The aim values for the speed or torque on Driving AC motor is decided according to the signals from the moter panel setting, accelerator, direction and brake. The necessary electric currents for the magnetic flux and the torque are based on the decided aim values. The applied frequency and amplitude for 3-phase alternating current on AC motor are calculated by vector control method together with the feedback signals from speed sensor, current sensor and so on. Loading System The aim voltage (The chopping current passing rate [Duty Factor]) applied to Loading DC Motor is decided by the feedback signals from the meter panel setting, accelerator, direction, brake and so on. The chopping signal is produced according to the comparison between the decided chopping current passing rate [Duty Factor] and the chopping wave of carricr, <1t> <2t> <3t> Dsw2 pDsw2 pswa ON ‘ON ‘ON 1234 T2354 1234 Parts No. Type Model NG1FS0861 = 3 It BP—Type NGIF30851 = 4 2t N61F30861 = 5 at — 14 —Inspection Order Caution Visually check for there is not any harmful flaw, deformation or extreme discoloration, specially pay attention not any contact fault at a part of connector due to corrosion. Do not carelessly touch the printed circuit board with bare hand, otherwise, IC parts may be broken by static electricity. Handle it with care to hold its edge. Be sure to put the printed circuit board in an anti-static bag when carrying or storing it in order to prevent it from damage by physical shock. Power Supply Board Do] ome exuey lewar o NG1F30841 Power supply board supplies the power for CPU board, PET power module drive circuit and each sensor. Parts No. ‘Type ‘Model BP—Type N61F30847=7 All Inspection Order Caution Visually check for there is not any harmful flaw, deformation or extreme discoloration, specially pay attention not any contact fault at a part of connector due Wo corrosion, Do not carelessly touch the printed circuit board with bare hand, otherwise, IC parts may be broken by static electricity. Handle it with care to hold its edge. Be sure to put the printed circuit board in an anti-static bag when carrying or storing it in order to prevent it from damage by physical shock. — 15 -FET Power Module(1/2) [Litrato sensonicroseo) SID2OUT) siwx(oun) FOR THERMO.SENSOR FONCTION FET power module consists of the half-bridge that multiplied FET elements in parallel are connected in series each at upper side and lower side. FET congregation connected in parallel for the upper side is called as “Hi-Side FET’. Another FET congregation connected in parallel for the lower side is called as “Lo-Side FET”. Each FET function which can flow the current to source(S) from Drain(D) in applying 10 volts between Gate(G) and Source(S). U phase power module (TMDU) and Loading power module (TMP) provides the thermo-sensor. So the thermo-sensor detecis the increasing emperature on each power module always. Sign ‘Type Model TMDU N51F 45956 = 222 TMDV/W N5IF45481 = 222 qt TMP N51F 45951 216 TMDU N51F 46529 = 224 TMDV/W N51F46528 = 224 a TMP N51F45956 = 216 TMDU N51F46529 = 124 TMDV/W N51F 46528 = 124 3t TMP N51F45956 = 114(1) Visually check for there is not any harmful flaw, deformation or extreme discoloration, specially pay attention not any contact fault at a part of connector due to corrosion. (2) Check the resistance value with analog circuit tester on each terminal according to the following table after dismount the electric wire, bus bar, condenser board which are all parts connected to power module. (8) Judge the FET power module is OK or NG according to the checked resistance values. Inspection Order (with ANALOG circuit tester) WITH ANALOG CIRCUIT TESTER Cheek Tester Lead San a a Judgment Point a Black) | (Reference) OK NG pusips |_>i_| Sipz [Atewka AfewkQ | 09 andlor 0 sip2 [Di = =o Tess than SiD2_|__S2 Afewk® AtewkQ | 00 andlor oQ Sipesa 82 | sib2 2 =o Less than crsipe |Of | Stb2 [About aka [About 4keQ | 09 andor 9 Sip2 [| Gi_| About iak@ | About 12kQ | 00 andlor oO Gos @ S2__| About4k@ | About4kQ | 00 and/orooQ $2 G2_| About 19kQ | About 12kQ | 0@ andor oQ pia Di Gi_| About 20kQ | About 20k9 | 00 andlor 09 Gi Di mk er) Less than 0 Gasipa [Siz | G2 [About 26kQ | “About 20kO | 09 andlor og G_ | sip2 mm a) Less than 29 3The above standard value is just reference. It can be changed depends on the kind of tester, the condition of battery and so on. It is available to measure the gate terminal of any FET elements which are lined the same up to check gate (G1, G2). »Pay attention to the following points when you check. + Do not carelessly touch the gate terminal (G1, G2) and soldered part of the printed circuit board on FET module may be broken by static electricity. + Be sure to put the printed circuit board in an anti-static bag when carrying or storing it in order to prevent it from damage by physical shock. (Caution) When the power module fails and need to replace it, please replace the power supply board together as well. -1W7-FET Power Module(2/2) Cheek points (with DIGITAL circuit tester) 4 + (@00 (e00 |, (rer) Coe Board's Holes e Liste} © feom woe : ee 2 With DIGITAL circuit tester __NO. | Tester lead Black(~) | Tester lead Red(+) Conductivity 1 pd] eS | supe Di x 2 sip2 82 __ | fe} |_ 82 siD2 x 5 oi. | supe oO. | sip2 qi x_ 4 G2 82 fe} s2 Ga x 5 Di Gt x - aL | Di x 6 S12 _ @ x a2 7 sip2 x | (Caution) (1) Range of digital tester must be adjusted to Diode Check, (2) If you have Analog circ lester too, please use the Analog tester instead of Digital tester.It is better. 18 —Condenser Board Condenser board consists of many aluminum electrolytic condensers connected in parallel, and installed just above FET power module. Condenser board absorbs the surge voltage which is generated in FET power module and defend FET from the surge voltage. Mark Type “Applicable Model, CBD N61F30830=221 CBP N61F30831=215 " CBD N61F30813=230 = CaP. N61F30831=215 CBD N61F30813=150 CBP, N61F30831=114 & Inspection Order @)Visually check for scores, scratches, excessive discoloration. @Replace any defective condenser board with a new one.Contactor ETE Movable contact Pm Contact Cail ‘This contactor functions to conduct with a contact only when exciting coils both for driving and loading. Mark Type Applicable Model Mo MA25M 46V 1, 3 ton MP ‘ MD MA27M_ 46V 2ton MP MAZ5M 46V MPS CM2—A DC48v common Inspection order (1) Checking mechanical movement of contactors Inspection should be performed on each contactor removed from the truck. @Push the movable contact with hand to conduct, and check if it functions smoothly. Push further after contacts are clused lo check if the compression spring is properly compressed to press the contact. @Measure a resistance between a contact and a movable contact by means of the circuit tester with Min Q range. Standard Value : 0Q (2) Checking the contactor coil Remove the coil wiring connector. Set the tester to a resistance range of 100 Q and measure the resistance between terminal using the tester. @Judge whether the coil is good or not using the measured value. Tudgment Ceniteast Good Defective MD 20~502 (typ, 302) ‘co 2 (broken coil) MP 20~50Q (typ, 302) 0 Q (broken coil) MPS 120~3809 (typ, 2662) £0. (broken coil) (3) Checking contactor contact point @Visually check the contactor contact points for roughness on the surface. @Replace any contactor with excessively rough or worn surface, with a new one. —~ 20 -Current Sensor Junction connector SiDeaeieeen) The current sensors detect the trave ig U-phase current, traveling W-phase current, And load handling current and generate a voltage in proportion to each electric ourrent. Mark Type Applicable Model CSDU/W, CSP__| S3CM7—80074MD common Inspection Order Visually check for there is not any harmful flaw, deformation or extreme Discoloration before check the current sensor as follows. Don’t touch VR of current sensor. (1) Checking the driving current sensor(CSDU,CSDW) Set the tester with current range and connect (-)side of tester to the terminal of cable. @Connect (+)side of tester to connector(GNS) and measure the (The list for current) _current of some point with Key switch ON. Seeeeatng ec Noel Measurement condition aes —| a8, [ow CNS-10: eNe-17_ | Geo | ov oN Otranes) | 7V(OA) oe lee ay wa oe of 9-180 aS pions | 7v¢oa) | Het ay Sea or V-1v (2) Checking the load handling sensor(CSP) @ Set the tester with current range and connect (-)negative pole of tester to the terminal of cable. @connect (+)positive pole of tester to connector{CNd) and measure a rent) _ ‘Me ourrent of some point with Key switch ON. Measure point Normal Pin No. Cable color | Value Measurement condition CN5-7 (Sues 15V ONS=18, ONS=19 Gym) ov CN5-8 Wowie) | 7V(0A) iti ti ane 08 0 eth Tost aMotor-side Rotation sensor unetion Connector ‘The magnetic induction sensor is generates alternating current per pitch of toothed of rotor attached to the side opposite the side to which the motor shaft is directly connected. Two magnetic induction sensor are used for the traveling motor. Inspection Order Disconnect the junction connector. @Measure the resistance between the sensor terminal with 100Qrange. (uudge whether the sensor is good or not using the measured values. Normal Value Approx. 620 (20°C)Fuse(F1, F2, F3) Ston When flowing over current in the main circuit or made a short-circuited, it is blown out to cut off the current to prevent spreading damaged of the circuit elements, the motor And cables. Model Mark Description it 2t a FI Driving Fuse | 48LF—275 | 4eLF—a25 | o6LF—276 F2_| Losdhanding Fuse | 4a1F—228 | 48LF—226 | 96LF—200 F3 PS Fuse 48LF—40 48LF—40 96LF—40 Inspection Order (1) Checking the driving fuse(F 1) @Set the tester with current range and connect (-)pole of tester to the terminal of cable. @connect (+)pole of tester to the terminal(A) and the terminal(B) of F1 and measure the voltage. (The list for voltage) ‘Measuring Point Voltage Tudgment ; Battery voltage OK Terminal(B) = NOWCHAREET Terminal(A) | Battery voltage OK (2) Checking the Load handling fuse(F2) set the tester with current range and connect (-)pole of tester to the terminal of cable. ‘@Connect (+)pole of tester to the terminaK(A) and the terminal(B) of F2 and measure the voltage. (The list for voltage) [7 Measuring Point Valinge Tadgment jaltery voltage OK Deen ov NOChangsy Terminal(B) Battery voltage ‘OK (3) Checking the PS fuse(F3) DSet the tester with current range and connect (~)pole of tester to the terminal of cable. (Connect (+)pole of tester to the terminal(A) and the terminaKB) of F3 and measure the voltage. (The list for voltage) [7 Measuring Point Voltage Judgment Battery voltage ‘OK Terminal(A) — NO ChangsY Tenminal(B) Battery vonage OK Caution Check up the cause of problem and measure appropriately, When the fuse had a defect.