TROUBLESHOOTING
TABLE OF CONTENTS
1. CONTROL CIRCUITS ....................................................................................................... 1
1.1 CONTROLLER POWER SUPPLY AND DRIVE SYSTEM ...............................................1
1.2 LOAD HANDLING SYSTEM .............................................................................................. 5
1.3 POWER STEERING SYSTEM ............................................................................................8
1.4 OTHERS ................................................................................................................................ 9
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING .................. 11
2.1 PART LOCATION DIAGRAM AND TERMINAL LOCATIONS ..................................... 11
2.2 PROCEDURE FOR CHECKING THE CONTROLLER ASSEMBLY SEPARATELY ....13
2.2.1 CONTROLLER ASSEMBLY ...................................................................................... 13
2.2.2 INVERTER UNIT ........................................................................................................ 16
2.2.3 EPS MOTOR CONTROLLER ....................................................................................18
2.2.4 HEAT-DISSIPATING SHEET ...................................................................................... 19
2.2.5 MC CONTACTOR .......................................................................................................20
2.2.6 FAST CHARGE RESISTANCE (RCH) ....................................................................... 20
2.2.7 FUSE (F1)..................................................................................................................... 21
2.2.8 ACCELERATOR PEDAL ............................................................................................ 21
2.2.9 MOTOR ROTATION SENSOR ................................................................................... 22
2.2.10 LIFT POTENTIOMETER ............................................................................................ 23
2.2.11 STEERING POTENTIOMETER ................................................................................. 24
2.2.12 LCD PANEL ................................................................................................................. 25
2.2.13 CM CONTACTOR .......................................................................................................26
2.2.14 CONTROL SWITCH PANEL ...................................................................................... 27
2.2.15 BATTERY CHARGER SWITCH PANEL ................................................................... 28
2.2.16 CHARGE RECTIFICATION DIODE .......................................................................... 29
2.2.17 CHECKING CHARGE TIMER ................................................................................... 30
2.2.18 MOTOR THERMO-SENSOR .....................................................................................31
2.2.19 F/R SWITCH ................................................................................................................ 32
2.2.20 CHECKING VOLTAGE ON THE LCD PANEL ......................................................... 33
3. TROUBLESHOOTING GUIDE....................................................................................35
3.1 HOW TO USE THIS GUIDE .............................................................................................. 35
3.2 CHECKING BEFORE TROUBLESHOOTING ................................................................. 36
3.3 ERROR CODE TABLE ....................................................................................................... 38
3.4 LCD PANEL SYSTEM ERRORS ....................................................................................... 48
3.5 TROUBLESHOOTING BY ERROR CODE ...................................................................... 49
3.6 TROUBLESHOOTING BY PROBLEM ............................................................................66
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