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Please fax or mail completed form to: Mitsubishi Caterpillar Forklift America Inc. Attn: Technical Publications 2011 W. Sam Houston Parkway N. Houston, Texas 77043-2421 Fax: 713-365-1616

Mitsubishi Caterpillar Forklift Europe B.V. Attn: Service Engineering P.O. Box 30171 1303 AC, Almere, The Netherlands Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd. Attn: Service Engineering No. 2 Tuas Avenue 20 Singapore 638818 Republic of Singapore Fax: 65-861-9277

Service Manual TR3000 CONTROL 2FBC15 2FBC18 2FBC20 2FBC25 2FBC25E 2FBC30

A2BC1-60001-79999 A2BC1-60001-79999 A2BC2-60001-79999 A2BC2-60001-79999 A2BC3-60001-79999 A2BC3-60001-79999

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Table of Contents Mitsubishi Forklift Truck Important Safety Information . . . . . . . . . . . . . . . . . . .1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Component Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Current Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Transistor Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Transistor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Head Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Control Panel Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Contactors Tip Clearance (Gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Drive and Pump Motor Shunt Field Resistances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Systems Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Location of Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Symbol Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Programmable Setup Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Accessing Programmable Setup Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Operational Circuit Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Run-Time Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Chat Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Accelerator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Power Transistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

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Testing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Accessing Stored Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Troubleshooting Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Control And Power System Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Systems Operation and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 Conductor And Switch Continuity Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Driver Board Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Traction Motor Current Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 Actuation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 Capacitor Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139 Hydraulic Pump Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 Testing Transistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 Electrical System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163

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A Accelerator Adjustment . . . . . . . . . . . . . . . . . . . . . . 163 Continuity Test . . . . . . . . . . . . . . . . . . . . 128 Control Diagnostic . . . . . . . . . . . . . . . . . . 30

B Battery BDI Adjustment Charts . . . . . . . . . . . . . 169 Cell Voltage Test . . . . . . . . . . . . . . . . . . . 49 Hydrometer Test . . . . . . . . . . . . . . . . . . . 49 Load Test . . . . . . . . . . . . . . . . . . . . . . . . . 49 Maintenance . . . . . . . . . . . . . . . . . . . . . . 49 Brakes Parking Brake Switch Adjustment . . . . 164 Plugging Circuit . . . . . . . . . . . . . . . . . . . . 39 Regen Circuit . . . . . . . . . . . . . . . . . . . . . . 37 Test and Adjust Electric Brakes . . . . . . 167 Bypass Circuit Circuit with Shunt Field Activated . . . . . 45 Circuit Without Shunt Field Activated . . 46

C Chat Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . 54 Circuits Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 DC/DC Converter . . . . . . . . . . . . . . . . . . 31 Drive Control . . . . . . . . . . . . . . . . . . . . . . 32 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . 41 Drive Power . . . . . . . . . . . . . . . . . . . . . . . 33 Failure Protection Circuit . . . . . . . . . . . . . 44 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Hydraulic Circuits . . . . . . . . . . . . . . . . .138 Plugging Circuit . . . . . . . . . . . . . . . . . . . . 39

Power Transistors . . . . . . . . . . . . . . . . . . 34 Regenerative Braking . . . . . . . . . . . . . . . 37 Thermal Protection Circuits . . . . . . . . . . 44 Contactors Continuity Test . . . . . . . . . . . . . . . . . . . . 131 General Information . . . . . . . . . . . . . . . . . 30 Pump Contactor Operation Circuit . . . . 155 Continuity Tests Accelerator Control . . . . . . . . . . . . . . . .130 Contactors . . . . . . . . . . . . . . . . . . . . . . . 131 DC/DC Converter . . . . . . . . . . . . . . . . .133 Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Head Capacitor . . . . . . . . . . . . . . . . . . . 130 Vehicle Monitoring System . . . . . . . . . . 133 Control Panel Component Location . . . . . . . . . . . . . . . 10 Electrical Testing . . . . . . . . . . . . . . . . . . 162 Specifications . . . . . . . . . . . . . . . . . . . . . . 5 Thermal Protection Circuit . . . . . . . . . . . 44 Control System Checks . . . . . . . . . . . . . . . . 51

D DC/DC Converter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Continuity Test . . . . . . . . . . . . . . . . . . . . 133 Diagnostics Built-In Diagnostic Operation . . . . . . . . . 52 Chat Mode . . . . . . . . . . . . . . . . . . . . . . . . 30 Run-Time Diagnostic Functions . . . . . . . 52 Run-Time Diagnostics . . . . . . . . . . . . . . . 26 Self-Diagnostics . . . . . . . . . . . . . . . . . . . 53 Stored Fault Codes . . . . . . . . . . . . . . . . . 47 Drive Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Current Limit . . . . . . . . . . . . . . . . . . . . . .43 Drive Control Circuit . . . . . . . . . . . . . . . . 32

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Lift Power . . . . . . . . . . . . . . . . . . . . . . .149 Power Steering Idle . . . . . . . . . . . . . . . . 141 Power Steering In Use . . . . . . . . . . . . . 146 Pump Contactor . . . . . . . . . . . . . . . . . . 155 Pump Motor . . . . . . . . . . . . . . . . . . . . . 140 Pump Power Transistor Turn-Off . . . . . 158 Pump Shunt Field . . . . . . . . . . . . . . . . . 145 Pump Shunt Field Circuit . . . . . . . . . . . 145 Tilt and Auxiliary Control . . . . . . . . . . . . 156

Drive Power Circuit . . . . . . . . . . . . . . . . . 33 Electrical Testing . . . . . . . . . . . . . . . . . .162 Thermal Protection Circuit . . . . . . . . . . . 44 Driver Board Tests Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Drive Driver Board . . . . . . . . . . . . . . . . . 134 Pump Driver Board . . . . . . . . . . . . . . . . 134

E Electrical System Adjustments . . . . . . . . . . 163 Method A (Mechanical) . . . . . . . . . . . . . 163 Method B (Electrical) . . . . . . . . . . . . . . . 163 Electrical Tests and Adjustments Accelerator Group . . . . . . . . . . . . . . . . . 163 Current Limit Test and Adjust . . . . . . . . 166 Electric Braking . . . . . . . . . . . . . . . . . . .167 Harness Wiring Circuit Guide . . . . . . . . 171 Logic Board Layout . . . . . . . . . . . . . . . . 168 Park Brake Switch . . . . . . . . . . . . . . . . . 164 Resistor R312 . . . . . . . . . . . . . . . . . . . . 162 Transistor Replacement . . . . . . . . . . . . 161 Transistors . . . . . . . . . . . . . . . . . . . . . . . 160

L Lift Control Additional Information . . . . . . . . . . . . . . 157 Lift Control Circuit . . . . . . . . . . . . . . . . . 148 Lift Power Circuit . . . . . . . . . . . . . . . . . .149 Logics Circuit Elements . . . . . . . . . . . . . . . . . . . 23 Component Tests . . . . . . . . . . . . . . . . . 126 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 126 Test Board Layout . . . . . . . . . . . . . . . . .168 Voltage Check . . . . . . . . . . . . . . . . . . . . 127 Voltage Test Chart . . . . . . . . . . . . . . . . . 128

General Information . . . . . . . . . . . . . . . . . . . 14 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operational Circuit Elements . . . . . . . . . . . . 23

H Harness Wiring Circuit Guide . . . . . . . . . . .171 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . 138 Actuation Circuit . . . . . . . . . . . . . . . . . . 138 Capacitor Charging Circuit . . . . . . . . . . 139 Flyback Circuit . . . . . . . . . . . . . . . . . . . . 147 Lift Control . . . . . . . . . . . . . . . . . . . . . . . 148

P Power Steering Power Steering Idle . . . . . . . . . . . . . . . . 141 Power Steering In Use . . . . . . . . . . . . .146 Power System Checks . . . . . . . . . . . . . . . . . 51 Programmable Setup Options General Information . . . . . . . . . . . . . . . . . 15 Setup Option 1 . . . . . . . . . . . . . . . . . . . . 21 Setup Options Other Than Option 1 . . . .22

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R Rapid Tune-Up . . . . . . . . . . . . . . . . . . . . . . 165

S Safety Information . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stored Fault Codes . . . . . . . . . . . . . . . . . . . . 47 Symbol Library . . . . . . . . . . . . . . . . . . . . . . . 11 Systems Operation and Test Equipment Continuity Tests Head Capacitor . . . . . . . . . . . . . . . . 130

T Test Equipment . . . . . . . . . . . . . . . . . . . . . . 125 Testing and Adjusting . . . . . . . . . . . . . . . . . . 47 Thermal Protection Circuits . . . . . . . . . . . . . 44 Tilt/Auxiliary Control Tilt/Auxiliary Circuit . . . . . . . . . . . . . . . . 156 TR3000 Control Panel . . . . . . . . . . . . . . . . .13 Transistors Electrical Tests . . . . . . . . . . . . . . . . . . . . 160 Power Transistor Circuit . . . . . . . . . . . . . 34 Replacement . . . . . . . . . . . . . . . . . . . . . 161 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 48 Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . 54 Preparation Tests . . . . . . . . . . . . . . . . . . . . . 49

V Vehicle Monitoring System Display Unit Circuit Test . . . . . . . . . . . . . . . . . . . . . . . 133 General Information . . . . . . . . . . . . . . . . . 24

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Mitsubishi Forklift Truck Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.

Mitsubishi Caterpillar Forklift America Inc. (MCFA) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all-inclusive. If a tool, procedure, work method or operating technique not specifically recommended by Mitsubishi Caterpillar Forklift America Inc. (MCFA) is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Mitsubishi forklift truck dealers have the most current information available.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING” as shown below.

! WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explaining the hazard, can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

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Specifications Component Measurements Component

Meter Scale

Meter Positive (+) Test Lead

Meter Negative (-) Test Lead

Desired Indication

All

Diode

Anode

Cathode

0.3 to 0.9 Volts

All

Diode

Cathode

Anode

Diodes (voltage indication)

Resistors (resistance indication) R312

200 ohms

36/48

34.20—37.80 ohms

72/80

71.25—78.75 ohms

Head Capacitor (resistance indication) Head Capacitor

20 K ohms

Positive side of capacitor (+)

Negative side of capacitor (-)

0 then change to above 10 K ohms

Contactor Coils (resistance indication) Directional (Forward)

200 ohms

32.31—39.49 ohms1

Directional (Reverse)

200 ohms

32.31—39.49 ohms1

Line

200 ohms

32.31—39.49 ohms1

Bypass

200 ohms

32.31—39.49 ohms1

Pump

200 ohms

32.31—39.49 ohms1

Regen

200 ohms

32.31—39.49 ohms1

Measured Resistance with room temperature coil (75°F) and terminals disconnected (coil isolated)

Current Measurements Model

Current Limit (amps) 36/48V 72/80V

Regnen Braking Current (amps) 36/48V 72/80V

2FBC15/18

380 - 420 A

—

2FBC20/25/25E

475 - 525 A

400 - 450 A

285 - 315A

190 - 210A

2FBC30

500 - 550 A

425 - 475 A

285 - 315A

190 - 210A

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Transistor Measurements

Head Capacitor

Multimeter Setting

(+) Test Lead

(–) Test Lead

927566 Results

974222 Results

Resistance

Emitter

Base

45 to 135Ω 60 to 180Ω

Diode

Base

Collector

.3 to.9V

Diode

Collector

Base

Diode

Emitter

Collector

.3 to.9V

Diode

Collector

Emitter

Transistor Connections

2. Spring washer 8T2229 concave side down. 3. Bus bar assembly 925789. 4. Lockwasher 8C3398. 5. Head capacitor terminal. 1

NOTE: Proper torque and assembly of capacitor hardware is critical. Avoid disassembly unless capacitor has to be replaced. 1. Tighten capacitor terminal screw to a torque of 5± 0.5N•m (50 ±5 lb in).

2 4

5 C30610P1

3 C30706P1

1. Emitter 2. Base 3. Collector

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Control Panel Thermal Switch Contacts open at . . . . . . . 81 to 89° C (178 to192° F) Contacts close at . . . . . . . 69 to 77° C (156 to 171°F)

Drive and Pump Motor Shunt Field Resistances Model

Contactors Tip Clearance (Gap) Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .no adjustment

2FBC15/18

Directional (Forward and Reverse) . . . . . .3.05mm ± 7% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(0.120” ± 7%) Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . .no adjustment Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .no adjustment Regen . . . . . . . . . . . . . . . . . . . . . . . . . . . .no adjustment

Fuses Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 A Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 A Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .675 A Shunt Field Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 A

2FBC20-30

Drive Motor Shunt Field Pump Motor Shunt Field Resistances (ohms) Resistances (ohms) 9” Diameter GE Motor 36/48 V 72/80 V

7” Diameter GE Motor 36/48 V 72/80 V

11.0913.55 Ω

8.5510.45Ω

27.9934.21 Ω

23.7629.04Ω

11” Diameter GE Motor 36/48 V 72/80 V

9” Diameter GE Motor 36/48 V 72/80 V

3.784.62Ω

29.1635.64Ω

33.0740.43Ω

11.5214.08Ω

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Control Panel 7

Torques R - 5 ± 1N•m V - 7.5 ± 2N•m T - 12 ± 2N•m

4 14 11 12 15 97C54-11300

NOTE: Apply a small amount of 5P8937 Thermal Joint Compound on the surface of the transistor, diode or thermal switch that contacts the heat sink. 1. Tighten the bolts that fasten the bus bar and cable to the heatsink (R) to a torque of 4 to 6 N•m (35 to 55 lb in) 2. Tighten the bolts that hold the positive heat sink to the control panel (T) to a torque of 10 to 14 N•m (90 to 125 lb in.) 3. Tighten the bolts that fasten the bus bars to the power transistors to a torque of 4 to 6 N•m (35 to 55 lb in)

8. Tighten bolt that holds the bar to the negative heat sink to the control panel to a torque of 4 to 6 N•m (35 to 55 lb in) 9. Tighten bolt to a torque of 4 to 6 N•m (35 to 55 lb in) 10. Tighten bolts that hold the negative heatsink to the control panel (V) to a torque of 5.5 to 9.5 N•m (40 to 84 lb in) 11. Tighten diode 4 pump (D4P) to torque of 13N•m (116 lb in) 12. Tighten diode 4 drive (D4D) to a torque of 36 N•m (320 lb in)

4. Tighten head capacitor terminal bolts to a torque of 4.5 to 5.5 N•m (40 to 50 lb in)

13. Tighten the bolt that holds the shunt (R) to a torque of 4 to 6 N•m (35 to 55 lb in)

5. Tighten bolts that fasten power transistors to the positive heat sink (R) to a torque of 4 to 6 N•m (35 to 55 lb in)

14. Tighten diode 5 drive (D5D) to a torque of 36 N•m (320 lb in)

6. Apply 9S3263 Thread Lock on the threads of all screws that are used to fasten components on the control panel.

15. Use a backup wrench to hold bolts and tighten the nuts that fasten the cables or bus bars to the contactors to a torque of 8 N•m (71 lb in)

7. Tighten screws at power transistor base connections to a torque of 1.3 to 1.7 N•m (11.5 to 15 lb in) 5

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Systems Operation Glossary Accelerator A device that converts mechanical movement into a digital voltage pattern to the logics for variable drive motor speed. Activate A word used with a component or circuit. To change from the normal condition to the “activated” condition because of an application of force or electricity. Ammeter An electric meter used to measure current flow in amperes.

Capacitor Device used to store electrical energy for short periods of time. Cathode The negative (-) side of a diode. Circuit A way for current to go from the positive (+) side of an electrical power source to the negative (-) side of an electrical power source. This can be through wires and electrical components. Coil A component made from many circles or turns of wire used to concentrate a magnetic field. Collector A terminal of a transistor through which main current flows (see Transistor).

Ampere (or Amp) The unit of measurement of current flow. The amount of current that one volt can push through a resistance of one ohm.

Commutator An armature component used to transfer current from the brushes to the armature windings.

Analog to Digital Converter A device that converts an analog voltage into a pattern of digital HIGH and LOW voltage signals.

Compound Motor A motor which has a field winding in series with the armature and a shunt field winding in parallel with the series winding and armature.

Anode The positive (+) side of a diode. Armature The rotating portion of an electric motor or generator. Base The terminal of a transistor through which control current flows (see Transistor). Battery Two or more cells connected together for a supply of electric current. BDI (Battery Discharge Indicator) An electrically controlled display showing the operator the state of battery charge.

Compound/Series Motor Similar to a compound motor, except the parallel shunt field windings are controlled on and off to vary speed and torque. Conduct To allow the flow of current. Conductor A material that provides a path for current flow. Connector Part of a wire assembly or harness that connects with another wire assembly or harness. Used for ease of assembly and disassembly.

Brush A conductor, normally a block of carbon, that makes sliding contact between the stationary and moving part of the motor or generator.

Contactor Assembly An electrical component consisting of an electromagnetic coil and a set of heavy contact tips. Control current passes through the coil, building a magnetic field which closes or opens the contact tips.

Bus Bar A heavy electrical conductor to which other smaller wires are connected.

Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly.

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Contact Tips or Contacts The portion of a switch, relay or contactor where the circuit can be opened or closed.

Drain Terminal of a MOSFET through which main current flows (see MOSFET).

Continuity Having the ability to allow current flow.

Electrical Braking Electrically trying to rotate the drive motor opposite to the direction of truck movement.

Control Circuits The wires and components carrying low current used to signal the logics unit, turn on main components, or support auxiliary circuits (indicated by thin lines on a schematic). Counter Electromotive An opposing voltage set up by a collapsing or increasing magnetic field within a Force (CEMF) coil. Current The movement or flow of electricity through a conductor. A circuit must be complete for current to flow. Current Limit The maximum allowable armature current of a stalled drive motor during pulsing. Current Sensor A hall-effect sensor in the drive motor circuit that produces an increasing voltage output as the drive motor current increases. Current Shunt A precision low-value resistor connected in series with the armature of a motor. The logics uses the measured voltage drop across the shunt to control maximum current allowed in selected power circuits. Deactivate To change from the activated condition back to the normal (deactivated) condition. It can be caused by the application of force, the removal of force, or the removal of electricity. Digital Signal A signal in which the elements may be either of two distinct values. For example high voltage, low volt age. Diode A semiconductor device that allows current to flow in one direction, from the anode to the cathode. Display An electrical device that converts voltage inputs to a visual output.

Electromagnet A coil of wire, most often wound on an iron core, which produces a strong magnetic field when current is sent through the coil. Electromotive Force (EMF) The force that causes an electric current to flow in a circuit. This force is measured in volts. Emitter A terminal of a transistor through which low control current and main current flow (see Transistor). Ferrite Bead A small bead located on the base connection of the power transistors to reduce high frequency oscillation at the power transistor. Field Windings The stationary coils that produce a magnetic field in motors and generators. Filter An electrical device or component for restriction or suppression of undesired voltage spikes. Fuse A component in an electrical circuit that will open the circuit if too much current goes through it. Gate Terminal of a MOSFET where voltage is applied to control the device (see MOSFET). Grounded A wire or wires that are in contact with the metal chassis of the vehicle (ground). Can be caused by a loss of insulation from the wire, or by connecting the wire to the vehicle. Harness An assembly made of two or more wires that are held together. Heat Sink A mounting frame used for semiconductor cooling. Hour Meter An electrically activated device used to record the amount of usage a truck receives.

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Indicator A lamp or LED that gives an indication of some vehicle condition when it turns on or flashes. Input A voltage change at the incoming connection of a component. Insulator A material that has a very large resistance so that it will not let current flow through it. LED Light Emitting Diode - a diode that emits light (lights) when current flows in the forward direction. Linear Output Hall Effect Transducer (LOHET) A device that converts an increasing magnetic field to an increasing linear output voltage Logics or Logic Unit The main printed circuit board containing a micro processor and circuits to condition the voltage signals that go into or come out of the logics. It electronically monitors and controls the truck’s functions.

Normal Condition Words used with a switch or relay. Their normal condition is their condition when they are not controlled by the application of force, temperature, pressure, or electricity. Normally Closed (N.C.) A switch or relay whose contacts are closed in the normal condition. Normally Open (N.O.) A switch or relay whose contacts are open in the normal condition. OFF-Time The amount of time current does not flow through a transistor. Ohm The unit of measurement of resistance. The amount of resistance that will let one volt push only one ampere of current through it. ON-Time The amount of time current flows through a transistor.

Magnetic Field The area around a magnet where magnetic forces can be detected.

Open Circuit Wiring or components of a circuit that have no continuity.

Microprocessor A small computer chip preprogrammed to control the various electrical functions on a forklift truck.

Optical Switch An electronic device made up of an infrared light signal generator and photosensitive signal receiver that changes a digital voltage when the light pattern is conducting or blocked.

MOSFET A semiconductor component used in electrical lift trucks as an electronic switch. A MOSFET most often has three terminals: a Gate (G) a Source (S) and a Drain (D). The main current flows between the drain and the source. The main current flow is controlled by a voltage applied between the gate and the source.

Output The current flow from a component which is initiated from a voltage change at the component’s input. Source Terminal of a MOSFET through which the main current flows (See MOSFET).

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Terminal An electrical connection point on an electrical component. Thermal Switch A switch that activates at a set temperature. Transistor A semiconductor component used in electric lift trucks as an electronic switch. A transistor most often has three terminals, a base (B), a collector (C), and an emitter (E). The main current flow is between the collector and emitter. This main current flow is controlled by a much smaller current flow between the base and emitter. Turn ON When an electrical component conducts current. Varistor A component terminated across the horn connections to eliminate voltage spikes when the horn is activated.

Volt The unit of measurement of electromotive force. One volt is the force needed to make one ampere of current flow through one ohm of resistance in a circuit. Watt The unit of measurement of power. The amount of power used when one volt pushes one ampere of current through a resistance of one ohm. The result of amperes (current) multiplied by volts (volt age) is watts (power). Wire A conductor used to provide a path for current to flow to and from electrical components. Wiring Diagram A drawing using visual representation of compo nents the way they actually look. It is used to show the locations of components and the connections between them. Zener Diode A special diode used to regulate voltage or as an overvoltage (too high a voltage) protector.

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Location of Control Panel Components TR3000 Control Panel 1.

Logic unit (logics)

Head capacitors

Line fuse

Battery negative connection

Line contactor

Battery positive connection

Lift contactor

Bypass contactor

Forward contactor

10. Reverse contactor

CP Components

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Symbol Library 1

8 9 10

12 13 14 15

27 Schematic Symbols (1) Power Transistor (2) Zener Diode (3) Ferrite Bead (4) NPN Transistor (5) PNP Transistor (6) Thermal Switch (7) Switch (8) Battery (9) Resistor (10) Diode (11) Normally closed contacts (12) Normally open contacts (13) Armature (14) Male contact of a connector (pin) (15) Female contact of a connector (socket) (16) Wire Connection (17) No wire connection (18) Contactor Coil (19) Current Shunt (20) Field Windings (21) Capacitor (22) Varistor of Wires (23) Fuse (24) Switch (25) N-Channel MOSFET (26) P-Channel MOSFET (27) Twisted Pair (28) Hall Effect Current Sensor (29)Thermistor

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Components Behind Logic Unit (1) 1)Pump driver board 13)P5 Main wiring harness connector 14)Auxiliary fuse holder 15) Key fuse 16)Accessory fuse 17) Resistor R312 18)T2P transistor 19) Drive Driver Board 20) T1P(Transistor one pump) 21) T1D (Transistor one drive) 22)Thermal Switch 23)T2D(Transistor two drive ) 24)Negative heatsink

Control Panel and Driver Board with Regen / 10300V2

Control Panel and Driver Boards Plug Only / 10200V2

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TR3000 Control Panel 1)PS main wiring harness connector 2)Head capacitors 3)Line Fuse 4) Battery negative connection 5)Line contactor 6)Battery positive connection 7)Pump Contactor 8)Traction Bypass Contactor 9)Forward contactor 10)Reverse contactor

Control Panel Cover off with Regen / 10300V3

Control Panel Cover off Plug Only / 10200V3

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General Information When the term 2FBC is used, it refers to the 2FBC family of forklift trucks, which includes the 2FBC15, 2FBC18, 2FBC20, 2FBC25, 2FBC25E, and 2FBC30 models. The TR3000 panel is the control center of the 2FBC family of forklift trucks. The Logic Unit (logics) is the decision-making part of the control system. The logics provides a self-contained Battery Discharge Indicator (BDI) with lift interrupt and built-in diagnostics capability. The logics monitors the battery state of charge and the diagnostics. It also displays related information to the operator on the liquid crystal display (LCD) panel located on the steer console. Four jumper connectors located on the logic card are used to select the appropriate battery voltage: J1=36V

J2=48V

J3=72V

J4=80V

If the wrong voltage is selected by the jumper position, the forklift truck will not operate, and the display will show a fault code (68 or 69). See the topic, On-Board “Run Time” Diagnostics later in this section of the manual.

C0000

If the jumper is lost, the default voltage is 36V for the logic card.

The TR3000 control system operates the drive motor and the hydraulic pump motor systems on the 2FBC family of forklift trucks. The steering system is activated when the truck is powered up and the line contactor closes. The truck uses a combined power steering/hydraulic system where the hydraulic fluid power for steering is provided by a hydraulic motor, pump, and priority valve. The speed of the hydraulic motor is controlled by voltage inputs to and outputs from the logics. Inputs are generated by a pressure switch (steering) and valve control switches (lift 1, lift 2, auxiliary 1 and auxiliary 2). Outputs pulse hydraulic pump power transistors and the pump shunt field, and they control the pump contactor coil. The power transistors pulse in order to control the speed of the hydraulic pump motor. To provide full speed, the logics activates the pump contactor, stops pulsing the power transistors, and turns off the pump shunt field. A failure protection circuit is also included to protect against malfunctions of the power circuit. The speed and direction of the drive motor is controlled by voltage inputs to and outputs from the logics. Inputs to the logics are generated by the accelerator control and direction switch. Outputs from the logics control contactor coils, drive transistor pulsing, and drive shunt field. The drive circuit pulses transistors to provide travel speed control up to 90% of full speed. Above that, the bypass contactor closes and the drive shunt field turns off to provide full speed. The drive circuit includes a failure protection circuit that detects malfunctions of the drive power circuit, a regenerative braking circuit (standard on 2FBC20 - 30 models), or a plugging circuit (standard on 2FBC16 - 18 models), and a current limit circuit to prevent excessively high currents during transistor pulsing. Thermal protection circuits are used on the hydraulic pump motor, the drive motor, and the control panel to prevent permanent damage caused by overheating.

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Programmable Setup Options Thirty one programmable setup options are available on the 2FBC family of electric forklift trucks equipped with TR3000 control system. These options can be set by the user so that truck performance best matches the operating conditions under which the truck will be used. The thirty options are divided into three groups: Group 1: Setup options 1 - 9 Group 2: Setup options 10 - 27 Group 3: Setup options 28 - 35 The following chart shows a list of all thirty-one options in their three groups. Minimum settings, maximum settings, and the factory defaults are given in the chart. For more information on using the Programmable Setup Options, see the following topics in this section of the manual. • Functional Descriptions of Programmable Setup Options • Accessing Programmable Setup Options • Programming Setup Option 1 • Programming Setup Options (Other than Option 1) • Activating Default Settings.

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PROGRAMMABLE SETUP OPTIONS FIRST GROUP Settings Option No.

Min.

Max.

Default

Description

Truck Mode Option

Lift 1 Speed (Pump Motor Speed)

Lift 2 Speed (Pump Motor Speed)

Tilt Speed

Aux 1 Speed

Aux 2 Speed

Top Drive Speed

Variable Acceleration

0 = Disable

.1 = for sales demo only

Service Reminder Interrupt

100.0, 150.0, 200.0, 250.0, 300.0, 350.0, 400.0, 450.0, 500.0

SECOND GROUP 10

Auxiliary Input for Lift and Drive Speed

Auxiliary Travel Speed Limit

Pulsing Stall Timer

Park Brake Duty Cycle Limit

BWI Operation

80% Bypass Option

BDI Reset Value

Dead Battery Lift Lockout

Dead Battery Travel Speed with Disable

Variable Regen on Accelerator (Regen only)

Regen Function on Accelerator or Brake (Regen only)

Regen Enable for 1T 2FBC 36/48V Trucks

Service Brake Duty Cycle Limit

Chat Timer

French BDI Option (nonactive)

Pump and Drive Pulsing Frequency

Regen Adjustment for Brake Regen

Pump Transistor Upgrade

EE Option

Tire Size Adjustment

0 C 0.0

31-34

Blank

*35

1.5

Bypass Stall Timer

THIRD GROUP

C 1.5 C 2.0

C 2.5

C 3.0

Truck Size and Type

* Any setting above 3 seconds may cause severe damage to traction motor. Contact Service Engineering before changing. 16

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Functional Descriptions of Programmable Setup Options NOTE: The three numbers separated by “/ ” following “Settings” indicate the minimum value/maximum value/factory default value. These are the same values given in the Programmable Setup Options table on the preceding page of this manual.

First Group Option 1 - Truck Mode • Settings: 1/5/1 This option is used to preset the value of seven other options. This allows the user to set the truck up for one of five various modes of operation: standard Factory, Hi-Performance, Economy, Long-Travel, or Dock. Option 1 is a convenient way to program truck performance without having to program many options individually. It is nevertheless possible to modify the preset values of the options that make up the chosen application. See the topic, “Programming Setup Options - Option 1” later in this section. Option 2 - Lift 1 Speed • Settings: 0/10/5 This option, and options 3, 4, 5, and 6 (see below), allow the user to select the preferred pump motor speed for the Lift 1 speed control. The chart below shows the range of possible speeds that can be programmed. Pump Speed

Armature Duty Cycle

Shunt Field Duty Pump Cycle Contactor

100%

Off

100

Off

100

Off

100

Off

100

Off

100

Off

100

Off

100

Off

100

Option 3 - Lift 2 Speed • Settings: 0/10/8 This option performs the same function as option 2, except that it sets up the Lift 2 control.

Option 4 - Tilt Speed • Settings: 2/7/3 This option performs the same function as option 2, except that it sets up the tilt control. Option 5 - Aux 1 Speed • Settings: 0/10/3 This option performs the same function as option 2, except that it sets up the Aux 1 control. Option 6 - Aux 2 Speed • Settings: 0/10/0 This option performs the same function as option 2, except that it sets up the Aux 2 control. Option 7 - Top Speed Option • Settings: 5/20/16 (5-20 KPH) This option can be used to control the top speed of the truck. This option will NOT apply the brakes if the speed limit is exceeded (i.e. going down a hill). Also, you must be careful not to set the speed limit to a value that would keep the truck out of bypass unless this is absolutely necessary. Without bypass the panel will be more likely to overheat in an application. Option 8 - Variable Acceleration • Settings: 1/16/10 (SLOWEST/FASTEST) This option will allow the acceleration of the truck to be controlled. It is much like the rabbit/turtle switch that other forklift trucks offer. Option 9 - Service Reminder Interrupt (SRI) • Settings: • Increment Values: 0 = Disable 000.1 For sales use only. 100.0, 150.0, 200.0, 250.0, 300.0, 350.0, 400.0, 450.0, 500.0 This option allows you to do either of two things. You can merely have the Service Reminder action light come on when the selected time increment is reached; or, you can activate the light and also shut off the lift, tilt, and auxiliary functions and slow the truck to the dead battery travel speed (option 18). The increment values represent hundreds of hours. They appear on the display in two groups. The second group, which is indicated by an equal sign preceding the increment value, will shut off the lift, tilt, and aux functions and reduce travel speed. The SRI will be reset every time the DIAG/RUN/SETUP switch is toggled past this option. If you enter this option and do NOT wish to reset the SRI, simply turn off the key switch.

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Second Group Option 10 - Auxiliary Input For Lift And Drive Speed • Settings: 0/4/0 0 Disabled 1 Disable Lift On Low 2 Speed Limit On Low 3 Disable Lift On High 4 Speed Limit On High • This option is used in conjunction with the lift limit input P1-14. This input is internally pulled up on the logic to +15V. Option 11 - Auxiliary Travel Speed Limit • Settings: 1/20/10 This option is used in conjunction with option 10 when the speed limit portion of option 10 is used. Option 12 - Pulsing Stall Timer • Settings: 3/30/5 This option allows some adjustment (3 to 30 seconds) to the time it takes the truck to shut down when the drive motor current is too high for too long in transistor mode. This condition, called a drive stall timer failure, produces an error code 20 on the display. Option 12 helps prevent drive motor abuse. Option 13 - Park Brake Duty Cycle Limit • Settings: 0/15/3 This option controls the maximum drive duty cycle when the park brake is applied. It allows the drive system to operate much like a car when the park brake is applied. The truck will try to move, but be unable. This should help remind the operator that the park brake is applied. Option 14 - BWI Operation • Settings: 0/1/1 NO EFFECT/BWI AFFECTS TRUCK OPERATION This option determines what will happen if either the drive or pump motor brush wear indicator (BWI) is activated: • Pump BWI active - Lift Lockout • Drive BWI active - Truck is slowed to 1/2 of current maximum speed or 6 KPH, whichever is slower. Option 15 - 80% Bypass Option • Settings: 0/1/1 OFF/ON If enabled, this option will not allow the truck to enter bypass when the truck is in current limit. This option in conjunction with the drive pulsing stall timer (option 12) will help to reduce drive motor abuse in hard applications.

Option 16 - BDI Reset Value • Settings: 0/10/5 0-10 RESET VALUE This option sets the value above which we consider a battery to be recharged. If the truck enters a dead battery condition, it will remain in this state even if the key switch is cycled until a battery that equals or exceeds the BDI reset value is connected to the truck. Option 17 - Dead Battery Lift Lockout • Settings: 0/1/1 OFF/ON This option determines the action of the lift during a dead battery condition. Option 18 - Dead Battery Travel Speed With Disable • Settings: 0/20/10 1 - 20 KPH WITH 0 = DISABLE This option determines the maximum truck speed during a dead battery condition. Option 19 - Variable Regen On Accelerator • Settings: 0/1/0 OFF/ON When enabled, this option allows the accelerator to control the level of braking in regen. The option works only on trucks equipped with regen. It is influenced by the setting of option 20. (It will not work with settings EAB1 or EAB3 because they require the accelerator to be off.) Option 20 - Regen Function On Accelerator Or Brake • Settings: 0/3/3 0 DISABLED/EAB1/EAB2/EAB3 1 EAB1 - Service Brake is on; Accel must be off 2 EAB2 - Service Brake is on; Accel does not matter 3 EAB3 - Whenever accel is off This option allows the use of the Electrical Assisted Braking (EAB). The three modes are defined above. Only one mode can be enabled at a time. This option works only on trucks equipped with regen because the added braking load would overheat a truck equipped only with plugging. Option 21 - Regen Enable For 2FBC15/18 36/48V Truck • Settings: 0/1/0 DISABLED/YES This option allows a person to enable regen on a truck that did not previously have regen. After the necessary components have been added, this option is enabled. Option 22 - Service Brake Duty Cycle Limit • Settings: 0/15/3 ACCEL POS LIMIT This option controls the maximum drive duty cycle when the service brake is applied. This allows some drive while the service brake is on so that the truck can be two-footed. If the truck is being abused because of two-footing, option 22 can be

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used to prevent the situation. Option 23 - Chat Timer • Settings: 0/20/5 1-20 SECOND TIMER WITH 0=DISABLE This option controls the amount time required to enter chat mode. Option 24 - French BDI Option (nonactive) • Settings: 0/1/0 OFF/ON This option allows the use of a different BDI discharge curve for use with tubular plate batteries. These batteries have a flatter discharge curve than normal so the voltage at which they are considered dead is higher than the normal battery. See the topic, “Battery Discharge Indicator (BDI) Adjustment,” in the Testing and Adjusting section of this manual. Option 25 - Pump And Drive Pulsing Frequency • Settings: 0/1/0 NORMAL/DOUBLE FREQUENCY This option allows the 187.5 Hz transistor pulsing frequency used for drive and lift related pump operation to be changed to 375 Hz. For some people the 375 Hz pulsing may be more acceptable than 187.5 Hz pulsing. The 15 kHz used for pump steering functions is unaffected by this option and remains at 15 kHz. Option 26 - Regen Adjustment For Brake Regen • Settings: 3/10/5 50% TO 100% OF P3 POT IN 10% INCREMENTS This option allows the EAB regen to be adjusted independent of the level of regen set by pot P3. It is independent as long as the desired EAB regen level is lower than that set by P3. This allows the user to set the EAB regen softer than normal regen. Option 27 - Pump Transistor Upgrade • Settings: 0/2/0 DISABLED/2 200A/2 300A In an 2FBC16 OR 2FBC18, option 27 allows the user to upgrade the pump transistor to a higher capacity configuration. In a heavy application where the user is suffering too many pump transistor failures, this option along with the addition of bigger pump transistors improves reliability.

Third Group Option 28 - EE Option • Settings: 0/2/0 OFF/EE DRIVE ONLY/EE DRIVE&PUMP The EE option is used to slow down the pump and drive system, which results in cooler running motors. The EE option accomplishes this by always keeping the shunt field on when the motor is operating. Option 29 - Tire Wear Adjustment • Settings: 0/40/20 = NO ADJUSTMENT SMALLEST/LARGEST This option allows the speedometer to be adjusted based on the amount of tire wear. The speedometer calculations are based on a certain tire size. If we deviate from this tire size, the speedometer will not work. Option 30 - Truck Size and Type • Settings: SIZES SHOWN: O 0 0.0 C 1.6 C 1.8 C 2.0 C 2.5 C 3.0 This option is used to tell the logics the size and type of the truck. Special care should be applied here. The value of this option is used to configure the drive and pump operation for the truck and if set incorrectly could result in erratic truck operation. When the logics are received out of the parts system or initially put on a truck on the production line, option 30 is set to 0 0.0. If the truck is powered up in RUN mode without first setting this option to some value other than 0 0.0, the truck will shut down and an error code 65 will be displayed. Option 31 - 34 - Blank • Settings: 0 These options are intentionally left blank. Option 35 - Bypass Stall Timer • Settings: 1.5/20/1.5

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Accessing Programmable Setup Options You can access any of the three groups of setup options directly in order to make programming changes. To access the First Group (Options 1 - 9): 1. Place the DIAG/RUN/SETUP switch in SETUP. 2. Turn the key switch ON. The display will show the value of Option 1 (APP-[ ] 01, where [ ] = the selected application.). To access the Second Group (Options 10 - 27): 1. Place the DIAG/RUN/SETUP switch in SETUP. 2. Pull back on and hold the LIFT and TILT levers and turn the key switch ON. The display will show the value of Option 10. To access the Third Group (Options 28 - 35): 1. Place the DIAG/RUN/SETUP switch in SETUP. 2. Pull back on and hold the LIFT, TILT, and AUX 1 levers and turn the key switch ON. The display will show the value of Option 28.

Changing Programmable Setup Options 1. Set Park Brake. 2. Turn key off. 3. Open door (panel). 4. Remove Logic Cover. 5. Place DRS switch in Setup. 6. Plug in battery (if unplugged). 7. Turn on key. 8. Move the directional lever from neutral to forward or reverse and back to neutral. You have now increased or decreased the setting value. 9. Move the DRS switch back to Run (center). You will see triple bars on the display. Triple bars tell you that the value selected has been stored in memory. 10. Toggle DRS switch from Setup to Run and then back to Setup to change to another option. 11. Change value with Forward and Reverse lever.

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Programming Setup Option 1

Application A - Factory

Option 1 allows you to set the truck to one of five predefined modes of operation, according to how your truck is used. It changes the truck travel speed, acceleration rate, and hydraulic pump speeds. The modes (applications) are:

Application b - Hi-Performance Application C - Economy Application d - Long-Travel Application E - Dock The modes are defined by the values of options 2, 3, 4, 7, 8, 26, and 28. The following table gives the values for these options as they correspond to each mode.

OPTION 1 MODES / VALUES Truck Mode

Value of Option 2

APP-A (FACTORY)

APP-b (HI-PERF)

APP-C (ECONOMY)

APP-d (Long-travel)

APP-E (DOCK)

NOTES: 1. Option 28 (EE Mode) is controlled by Option 1 only if Option 28 is set to 0 or 1. If it is set to 2 by the user, Option 1 will not change this value, which represents a fully EE’d truck.

3. You can toggle past Option 1 without resetting it to the preset values, even if any of the values have been modified, by not changing the mode in the hour meter area.

2. If the option number is flashing when you first access the option, this means that one of the effected values has been changed from its preset value (the value in the table). Probably one of the values was modified to further customize operation of the truck.

Option 1 Applications

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Programming Setup Options (Other than Option 1) 1. Access the option you want to change, using the appropriate method described in the previous section, “Accessing Programmable Setup Options.” 2. Change the value: • To increase the value of the option, move the direction lever to FORWARD, then back to NEUTRAL. • To decrease the value of the option, move the direction lever to REVERSE, then back to NEUTRAL. 3. To move to the next option: • Move the DIAG/RUN/SETUP switch from SETUP to RUN, then back to SETUP. The option number displayed will increment to the next number. • New values are locked in each time you move the DIAG/RUN/SETUP switch from SETUP to RUN. After programming any option(s), test the forklift truck to be sure that its operation is correct.

Activating Default Settings Options 1 -27 can be set to their factory default values by the following procedure. NOTE: Options 28 - 35 do not reset to default values with this method. Each of these options must be reset individually. 1. Place the DIAG/RUN/SETUP switch in the SETUP position. 2. Place the direction lever in REVERSE. 3. Make sure the seat switch is OPEN (no operator on the seat). 4. Hold down the accelerator and turn ON the key switch. 5. Watch for flashing “donE” on the display. This indicates that Options 1-27 have been set to their factory default values. 6. Turn the key switch to OFF. 7. Return the DIAG/RUN/SETUP switch to the normal operation mode (RUN).

Programming the Clock 1. Turn key ON. 2. Push and hold down left orange button for approximately 5 seconds or until the minutes area of the clock starts to flash. Release button. 3. Push the right orange button to advance the minutes of the clock. 4. Press and release the left orange button. The hours section of the clock will start to flash. 5. Push the right orange button to advance the hours of the clock. 6. When finished setting the clock, press and release left orange button.

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Operational Circuit Elements Logic Unit The Logic Unit (logics) has one printed circuit board contained in a vertical sheet metal box on the control panel. Most of the circuitry on the board conditions voltage signals into and out of the microprocessor. Software in the microprocessor controls the logics outputs for power components in the pump system, traction system, contactor coils, and display. Access to the board is provided by two lock screws, which allow the cover to be removed.

Logic Board

A jumper should be installed on one of the jumper blocks according to truck battery voltage: J1 = 36 volts J2 = 48 volts J3 = 72 volts J4 = 80 volts

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Vehicle Monitoring System Display Unit

Battery Discharge Indicator

The vehicle monitoring system display unit is located in the steering console. It is a self-contained, solid-state instrument panel with a liquid crystal display (LCD) that has areas for showing: BDI; truck, drive motor, and pump motor hours; clock; truck speed; and fault codes. A separate action light strip below the LCD display uses seven international pictorial symbols to alert the operator of conditions that need attention. The display unit interacts with the logics and failure protection circuits. It functions as a BDI, and provides on-board diagnostic data on the operational condition of the truck during normal use (“Run-Time” diagnostics) as well diagnostics during troubleshooting (“Self” diagnostics). See the topic, “Built-in Diagnostic Operation” in the Troubleshooting section of this manual.

1. Battery Discharge Indicator

3. Speed Fault Code Indicator (Run-Time and Self Diagnostics)

This liquid crystal display (LCD) uses bars and a battery symbol to indicate the level of battery discharge. When all ten bars appear, the battery is fully charged. As the battery discharges, bars disappear from the display one by one. When only one bar remains on the display, the battery is 70% discharged and the battery symbol will flash. At 80% discharge, the battery symbol is solid and no bars appear. The drive and lift (hydraulic) motors run at a slower speed. The operator should complete the current lift operation and travel to the battery replacement or charge area. Replacement of the discharged battery will reset the BDI, and normal operation will resume.

Hour Meter and Clock At start-up, the five LCD numbers and the three symbols above them indicate service hours for the truck, for the drive motor, and for the pump motor. Each symbol momentarily lights and its respective hours appear on the LCD display, in cycle. Periodic maintenance is based on the number of pump hours recorded. After start up and while the truck is operating, the LCD numbers display the time of day.

Speed / Fault Code Indicator

2. Hour Meter and Clock

4. Vehicle Monitoring System Action Lights

Display Unit 1. Battery Discharge Indicator 2. Hour Meter and Clock 3. Speed/Fault Code Indicator (Run-time and Self- Diagnostics). 4. Action Lights.

During normal operation, truck speed is indicated by the two LCD numbers in this area. Either miles per hour or kilometers per hour can be chosen for the display by pushing the left orange button. The numbers will change to a fault code if a run-time fault is detected. The “!” action light will flash on and off while the code is displayed.

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Action Lights These symbols glow red when specific problems are detected. The truck should be stopped and corrective action taken immediately.

Action Lights

1. Service Reminder - The wrench symbol lights when it is time for periodic maintenance. Maintenance intervals are programmable. See the topic, “Programmable Setup Options,” Option 9. 2. Brush Wear Indicator - The motor symbol lights if the drive or pump motor brushes need service. Truck operation can be slowed or stopped. See the topic, “Programmable Setup Options,” Option 14. 3. Over Temperature - The thermometer symbol glows if an overtemperature condition develops in either drive motor, pump motor, or the control panel. Reduced drive and/or lift performance can be programmed into the control system. See the topic, “Programmable Setup Options,” Options 10 and 11. 4. Battery Charge - The battery symbol flashes if the battery charge reaches the 70% discharged level. At 80% discharge, the symbol glows constantly (no flashing). Reduced drive and/or lift performance can be programmed. See the topic, “Programmable Setup Options,” Options 16, 17, 18. 5. Brake Fluid Level - The brake fluid symbol flashes if the brake fluid reaches a predetermined low level. 6. Park Brake - The park brake symbol flashes when the park brake is applied. 7. Fault Detection - At start-up and during truck operation, drive and pump circuits are monitored for failures.If a fault is detected, the truck shuts down and cannot be operated until the cause of the fault is repaired.The fault symbol will flash and a fault code number will appear in the Speed/Fault Code Indicator. 25

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Run-Time Diagnostics The TR3000 Control System controls and monitors all the electrical and hydraulic operations of the forklift truck. An important part of its job is to detect problems and signal the operator or maintenance person to take corrective action. Run-time diagnostics function during truck operation. During truck start-up or operation, if the logics detects a problem, a diagnostic code will appear in the Speed/Fault Code Indicator instead of vehicle speed. The “!” symbol flashes in the action light strip at the same time the code is displayed. The codes indicate an improper operating sequence or a defect in the truck electrical system. Run-time diagnostics cover the following areas of truck operation and protection: • Truck, drive motor, and pump motor hours • Service reminder hours • Motor brush wear • Stall protection • Overtemperature protection of the drive motor, pump motor, and the control panel. • Brake fluid level Listed below are all the possible Run-time error codes, the components involved and their location (if applicable), the cause of the error code, and the truck response to the problem. Also see the “Troubleshooting Problem List” and the troubleshooting flow charts in the Testing and Adjusting section of this manual. DISPLAY = 10 - Drive armature transistor emitter high when not expected Components Involved: T1D and/or T2D Location: Panel Cause: A code 10 results when the processor senses the drive armature transistor emitter being high when it should be low. This error is detected during the Close Line Contactor Routine (CLOSLC) and anytime the line contactor is in. Response: Truck shuts down and the error code is displayed.

DISPLAY = 11 - Drive armature transistor’s emitter low when not expected Components Involved: T1D and/or T2D Location: Panel Cause: A code 11 results when the processor senses the drive armature transistor emitter being low when it should be high. This error is detected during the Close Line Contactor Routine (CLOSLC). Response: Truck shuts down and the error code is displayed. DISPLAY = 15 - D6D anode low when not expected • REGEN-EQUIPPED PANELS Components Involved: D6D, Regen Contactor, Sense Wire Location: Panel Cause: A code 15 results when the processor senses the D6D anode low when it should be high. This error is detected during the first 50mS of regen. This check prevents a regen contactor that is welded shut from causing the truck to act unpredictably. It is also possible that this error is caused by a broken wire. Response: Truck shuts down and the error code is displayed. • PLUG-ONLY PANELS Components Involved: Sense Wire Location: Panel Cause: A code 15 results when the processor senses the D6D sense wire is low. Since this truck lacks regen, this sense wire is permanently connected +BAT. If this wire is sensed low it means that the wire is broken or the truck size and type have been set to indicate that the truck is equipped with regen when it really isn’t. This error is sense during the Close Line Contactor Routine (CLOSLC) and anytime the regen contactor is closed. Response: Truck shuts down and the error code is displayed.

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DISPLAY = 16 - D6D anode high when not expected REGEN-EQUIPPED PANELS Components Involved: D6D, Regen Contactor, Sense Wire Location: Panel Cause: A code 16 results when the processor senses the D6D anode high when it should be low. It can be caused when the truck type and size are set to indicate that it is a plug-only truck when it isn’t. It can also be caused by a bad regen contactor or logic. Response: Truck shuts down and the error code is displayed. PLUG-ONLY PANELS Components Involved: Sense Wire Location: Panel Cause: This error is not used on plug-only panels because the sense wire is permanently tied to +BAT and therefore should always be high. DISPLAY = 18 - Drive shunt field transistor’s drain is high when not expected Components Involved: T371 Location: Drive Driver Board Cause: A code 18 occurs when the processor senses the drive SF collector being high when it should be low. This error is detected during the Close Line Contactor Routine (CLOSLC). Response: Truck shuts down and the error code is displayed. DISPLAY = 19 - Drive shunt field transistor’s drain is low when not expected Components Involved: T371 Location: Drive Driver Board Cause: A code 19 occurs when the processor senses the drive SF collector being low when it should be high. This error is detected during the Close Line Contactor Routine (CLOSLC). Response: Truck shuts down and the error code is displayed.

DISPLAY = 20 - Drive stall timer failure Components Involved: Location: Logics Panel Cause: A code 20 occurs when the processor senses that the drive motor has been drawing too much current for too long. The time before the failure occurs will be dependent on the level of current being drawn. The more the overload, the shorter the time before a failure. This error is detected anytime the drive motor is being driven. The stall timer failure timer can be set in setup mode. See the topic, “Programmable Setup Option,” option 12, in this section of the manual. Response: Truck shuts down and the error code is displayed. DISPLAY = 21 - Drive current sensor not operating Components Involved: E361 (Current Sensor) Location: Panel Cause: A code 21 occurs when the processor senses a zero reading that is outside of the allowed bounds. This is an indication that the sensor is not working correctly or has failed. This error is detected anytime the directional contactors are open and the truck is in neutral. Response: Truck shuts down and the error code is displayed. DISPLAY = 24 - Drive output overcurrent fault Cause: A code 24 occurs when the processor senses that the output driver(Q109) is going into a current limit situation. Response: Truck shuts down and the error code is displayed. DISPLAY = 25 - Accelerator fault low Cause: A code 25 occurs when the processor senses that the pulse width modulation (PWM) voltage from the accelerator is too low. This error is detected at all times. Response: Truck shuts down and the error code is displayed.

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DISPLAY = 26 - Accelerator fault high Cause: A code 26 occurs when the processor senses that the pulse width modulation (PWM) voltage from the accelerator is too high. This error is detected at all times. Response: Truck shuts down and the error code is displayed. DISPLAY = 29 - Speed sensor failure Cause: A code 29 occurs when the processor senses that the speed sensor is not working correctly. Response: Truck shuts down and the error code is displayed. DISPLAY = 30 - Pump armature transistor’s emitter is high when not expected Components Involved: T1P and/or T2P Location: Panel Cause: A code 30 occurs when the processor senses that the pump armature transistor emitter is high when it should be low. This error is detected during the Close Line Contactor Routine (CLOSLC) and any time the line contactor is in. Response: Truck shuts down and the error code is displayed. DISPLAY = 31 - Pump armature transistor’s emitter is low when not expected while driving B terminal Components Involved: T1P and/or T2P Location: Panel Cause: A code 31 occurs when the processor senses that the pump armature transistor emitter is low when it should be high while driving the B terminal of the transistor(s). This error is detected during the Close Line Contactor Routine (CLOSLC). Response: Truck shuts down and the error code is displayed. DISPLAY = 32 - Pump armature transistor’s emitter is low when not expected while driving b0 terminal Components Involved: T1P and/or T2P Location: Panel Cause: A code 32 occurs when the processor senses that the pump armature transistor emitter is low when it should be high while driving the B0 terminal of the transistor(s). This error is detected during the Close Line Contactor Routine (CLOSLC). Response: Truck shuts down and the error code is displayed.

DISPLAY = 33 - Combination of 31 and 32 Cause: A code 33 occurs when the processor senses that the pump armature transistor emitter is low when it should be high while testing the B and B0 terminals. This error is detected during the Close Line Contactor Routine (CLOSLC). Response: Truck shuts down and the error code is displayed. DISPLAY = 38 - Pump shunt field transistor’s drain is high when not expected Components Involved: T351 Location: Drive Driver Board Cause: A code 38 occurs when the processor detects the pump SF transistor collector high when it should be low. This error is detected during the Close Line Contactor Routine (CLOSLC). Response: Truck shuts down and the error code is displayed. DISPLAY = 39 - Pump shunt field transistor’s drain is low when not expected Components Involved: T351 Location: Drive Driver Board Cause: A code 39 occurs when the processor detects the pump SF transistor collector low when it should be high. This error is detected during the Close Line Contactor Routine (CLOSLC). Response: Truck shuts down and the error code is displayed. DISPLAY = 40 - Pump stall timer failure Cause: A code 40 occurs when the processor senses that the pump motor has been drawing too much current for too long. This error is detected any time the pump motor is being driven. Response: Truck shuts down and the error code is displayed. DISPLAY = 41 - Pump current shunt not operating Components Involved: Pump Shunt, Wires #29 and 119 Location: Panel Cause: A code 41 occurs when the processor senses that the pump shunt is not registering current when it should be. Response: Truck shuts down and the error code is displayed.

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DISPLAY = 44 - Pump output overcurrent fault Cause: A code 44 occurs when the processor senses that one or more of the output drivers (Q106 - Q108) are going into a current limit situation. Response: Truck shuts down and the error code is displayed. DISPLAY = 50 - Combination of 10 and 30 Cause: Combination of 10 and 30. Response: Truck shuts down and the error code is displayed. DISPLAY = 51 - Combination of 11, 31, and 32 Cause: Combination of 11 and 31. Response: Truck shuts down and the error code is displayed. DISPLAY = 60 - Serial communication fault Cause: A code 60 occurs when the serial communication system fails to communicate a message in a given amount of time between the logics and display. Response: Truck shuts down and the error code is displayed. DISPLAY = 61 - EEPROM error Cause: A code 61 occurs when the processor cannot program a location correctly, or when reading an EEPROM value and its complement, they don’t agree. Response: Truck shuts down and the error code is displayed. DISPLAY = 62 - Frame Fault positive voltage (nonactive) Cause: Connection between the forklift truck frame and a positive voltage source. Response: Truck shuts down and the error code is displayed.

DISPLAY = 63 - Frame Fault Negative voltage (nonactive) Cause: Connection between the forklift truck frame and a negative voltage source. Response: Truck shuts down and error code is displayed. DISPLAY = 65 - Truck size not initialized Cause: A code 65 occurs when the truck is powered up in RUN mode with option 30 (Truck size and type) equal to 0 0.0. Response: Truck shuts down and the error code is displayed. DISPLAY = 66 - Watchdog timer failure Components Involved: Logic Card Location: Panel Cause: A code 66 occurs when the logic senses that its watchdog timer is not functioning. Because this circuit monitors the processor proper operation it must always be functional. Response: Truck shuts down and the error code is displayed. DISPLAY = 67 - Battery volts too low Cause: A code 68 occurs when the processor senses that the battery volts are too low for the battery voltage chosen by the jumper. 24 > 36/48V BATTERY 60 > 72/80V BATTERY Response: Truck shuts down and the error code is displayed. DISPLAY = 69 - Battery volts too high Cause: A code 69 occurs when the processor senses that the battery volts are too high for the battery voltage chosen by the jumper. 36/48V BATTERY > 60 Response: Truck shuts down and the error code is displayed.

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Chat Mode If the seat switch is closed, key switch turned ON, and the direction lever is left in NEUTRAL with no other operator requests, the line contactor will deactivate after approximately five seconds. The forklift truck will remain in this condition until the operator activates the direction switch, accelerator pedal, or a control valve lever. The line contactor then reactivates, and the truck is ready for normal operation.

Contactors The control panel is equipped with 36/48 and 72/80 volt contactors. The logics will control the “effective voltage” supplied to the coils. When a contactor is first activated, full battery voltage is applied to the coil. After the contact tips have closed, the logics will pulse the coil to reduce the voltage across the coil to between 15 and 35 volts.

Accelerator Control The 2FBC15 family TR3000 accelerator uses a single wire to communicate pedal position to the logics. The accelerator uses a three-wire connector: Pin 1 - BAT- (Wire #1) Pin 2 - Switched Positive (Wire #4) Pin 3 - Signal Wire (Wire #8) The accelerator uses a pulse width modulated (PWM) signal to communicate the position of the pedal to the logics. This is very similar to the way the transistors control the drive and pump motors. The accelerator changes the duty cycle of the PWM signal to indicate different positions. The accelerator output is simply a switch to ground. The switch is turned on and off at a rate of 500 Hz or 500 times a second. One on/off cycle is called a period. The on time of the switch compared to the period is the duty cycle. In the chart below, it is shown as a percentage, where 0% means that the switch never turns on, 50% means the switch is on half the time, and 100% means the switch is on all of the time. The logic input for the accelerator is simply a resistor pulled up to +15V. When the accelerator switch is on, the resistor pulls this input low; when the accelerator switch is off, the resistor pulls this input high. Additional circuitry in the logics converts this on/off wave form to a voltage that the logics can read and convert back to a position. The duty cycles for the accelerator as are follows:

Pedal Position

Duty Cycle (%)

Voltage on P1-15

10.1

12.3

17.6

11.2

22.6

10.6

27.6

9.9

32.6

9.2

37.6

8.5

42.6

7.8

47.6

7.2

52.6

6.5

57.6

5.8

62.6

5.1

67.6

4.4

72.6

3.8

77.6

3.1

82.6

2.4

87.6

1.7

As shown, the duty cycle is never 0% or 100% during normal operation. This means that if you measure 0V or 15V at the input to the logics, something is not working correctly.

SIGNAL RECEIVER

VANE SIGNAL GENERATOR

OPTICAL SWITCH B75533P1

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Circuits Accessory Circuits Horn Circuit The horn will operate when the battery is connected and the horn button is pushed. Current flows from battery positive through the lights’ fuse, horn button and horn, back to battery negative.

DC-DC Converter The DC-DC Converter changes the forklift truck battery voltage to 12 volts. This 12 volts is used to power accessories such as floodlights, brake/side lights, and horn. The positive of the 12 volt output is common to the positive of the battery voltage. The negative of the 12 volt output is pulsed to maintain a steady 12 volt supply. The 12 volt output of the converter is protected against short circuits and overloading by an internal 15 amp current limit circuit. A fuse on the converter protects it from reverse connection to battery voltage.

97812-15600

NOTICE: Do not connect the 12 volt negative output of the DC-DC converter to battery negative. Damage to system components could occur.

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Drive Circuit

Depressing the accelerator pedal will cause the accelerator voltage on P1-15 to change as explained under Accelerator Control. The logics detects the voltage change at P1-15, activates the correct direction contactor, regen contactor (if used) and starts pulsing the drive power transistors.

Control Circuit With the actuation circuit complete, the logics supplies a HIGH voltage (15 volts) to the direction switch at P19 and P1-10. A HIGH voltage is also supplied to the accelerator control at P1-15. Battery voltage is supplied to the accelerator at P9-B.

With the forward direction selected, current flows from the logics P3-18 through the forward direction and regen contactor coils (if used) to logics P3-12 and P314 back to battery negative. The forward and regen contact tips close.

Selecting a direction will change the voltage from HIGH to LOW on P1-10 for forward or P1-9 for reverse. 3 3

LIGHTS FUSE 15A

P12-13 3

KEY FUSE 10A

P5-4

P3-4

P5-12

P6-4

P5-16

P6-3

P3-5 P2-12 P3-3

P1-14

P46-1

LIFT LIMIT SW 127 P5-21

P6-2

P6-1

SEAT OPERATED BRAKE SW P60-C P60-A SEAT SWITCH

P2-13 P1-13

HORN BUTTON 4 KEY SWITCH

P46-2

P5-3

R320 P3-18

R319

P5-7

HORN

PUMP MOTOR THERMOSTAT P3-2

P5-25

P3-1

P1-11

P5-19

1 DRIVE MOTOR THERMOSTAT

P5-23

113

SERVICE BRAKE SWITCH P40-C P40-B

P5-22

34 P3-17 39 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P1-9

P5-15

P33-2 P7-B DIR SW

14 15

P7-C

4 P7-A

REV

LOGICS

P38-8

P1-2

P13-5

LIFT 1 SW 81

P5-27

P61-1 REV

P61-3 13

P5-13

FWD

P61-2 FOOT DIR SW

P1-1

P33-1

FWD

P13-6

LIFT 2 SW P1-3

P5-34

P3-16

P13-2 TILT SW 88

P5-33

P1-4

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1TON

P13-3

P32-3

P32-4

3 4

AUX 1 SW P1-5 P1-6

LINE CTR

P5-32

P1-19

P5-26 TWISTED PAIR 116

P1-18

115

BATTERY 36/48 VOLT OR 72/80 VOLT

P1-15

P5-8

P13-4

AUX 2 SW 78 P24-2 TWISTED PAIR P5-31 P52-2 P5-30

P52-1

P9-C

P1-21

P2-21

P3-21

P3-20

ACCEL CONTROL

P13-1 P24-1

PRESSURE SWITCH SPEED SENSOR SWITCH

1 1 4 1

P9-A P9-B

P5-1

P5-14

106

P5-2 P5-36

P1-10

3 1

1 BRAKE FLUID SWITCH

PARK BRAKE SW P2-20

P5-24

P1-12

P5-37

100

P12-12

DISPLAY

P12-11

2FBC1513

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Drive Circuit

controlled separately from the pump motor circuit by the TR3000 Control System.

Power Circuit

The logics generates an optional 375Hz or 187.5Hz pulsing signal on P2-5. This is faster than can be seen on a voltmeter and must be viewed with an oscilloscope. When this signal is low, it indicates the power transistors T1D and T2D should be on. When this signal is high, it indicates they should be off. When P2-5 goes low, current flows from Battery positive through the emitter/base junction of T314 and T315, through R-312, through P2-5 to Battery Negative.

NOTE: Shaded lines illustrate current flow in the circuit diagrams. Other circuits can be activated at the same time, but each one is shown separately to illustrate current flow in each individual circuit. The high amperage current that provides the power and torque necessary to drive the forklift truck flows in this circuit. The speed of the drive motor is

P12-15

T R316

R317

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

P8-1

T2D

46 34 P2-12 P3-3 100 P2-13

R312

T1D

D311

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2) DU2

P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

101 PUMP MOTOR CIRCUIT

102

E1 (F1)

P32-1

FWD CTR

E361

P12-7

D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

D5D

D371

REV CTR

T371

HEAD CAP D4D

D6D

ARM

A1 A2 DRIVE MOTOR

E2 (F2) BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 FWD CTR

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

LOGICS

P1-21

P12-4

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1503

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Power Transistors

The percent “on-time” of the voltage at logics P2-5 is also the percent “on-time” of the power transistors. As the “on-time” increases, the average voltage applied to the drive motor increases, which increases the speed of the forklift truck. The percent “on-time” out of the logics is determined by how far the accelerator is depressed.

When the current flows through the base emitter junction of T314 and T315, this turns the transistors ON. When T314 and T315 are ON, current flows through T314,T315 emitter/collector into the base of the drive power transistors T1D and T2D, causing them to turn ON. With the power transistors ON, high amperage motor current can flow through them, the motor field, forward contact tips, motor armature, forward contact tips, current sensor, and regen contact tips back to battery negative. When T314 and T315 are OFF, the drive power transistors are OFF.

At the same time the logics is pulsing the drive motor circuit, a constant voltage (about 12V) is being supplied on P2-1 to the gate of T371, turning it 100% ON. With T371 ON, current can flow through the drive shunt field fuse, drive shunt field and T371 back to battery negative. When the drive shunt field is ON 100% at maximum strength, it adds to the motor torque.

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

P8-1

T2D

46 34 P2-12 P3-3 100 P2-13

R312

T1D

D311

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

P32-6

DU2

PUMP MOTOR CIRCUIT

FWD CTR

A1 A2 DRIVE MOTOR REV CTR

P32-1

D5D

FWD CTR

92 D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

T371

E361

P12-7

D4D

D371

HEAD CAP

D6D

ARM

P12-10

102

E1 (F1) E2 (F2)

BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 101

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

LOGICS

P1-21

P12-4

D2 (S2)

68 LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1504

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When the drive power transistors (T1D and T2D) are ON, battery current flows through the field windings of the drive motor, and a magnetic field is created around the windings. When the power transistors are turned OFF, battery current through the windings stops, and the magnetic field collapses. The collapsing magnetic field induces current, which is used to power the drive motor while the power transistors are OFF (during pulsing). Induced current flows from the field windings through the forward contact tips, armature, forward contact tips, current sensor regen contact tips and diode D4D back to the field windings. Because of this, the average drive motor armature current will be greater than the average battery current. The drive shunt field remains activated during flyback. Average Current Flow

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

P8-1

T2D

46 34 P2-12 P3-3 100 P2-13

R312

T1D

D311

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2) DU2

P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON PUMP MOTOR CIRCUIT

FWD CTR

A1 A2 DRIVE MOTOR REV CTR

P32-1

D5D

FWD CTR

92 D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

T371

E361

P12-7

D4D

D371

HEAD CAP

D6D

ARM

P12-10

102

E1 (F1) E2 (F2)

BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 101

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

LOGICS

P1-21

P12-4

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1505

WENB8604-02

Electrical Braking (Regenerative and Plugging) Electrical braking permits the forklift truck operator to slow, stop, and change the direction of travel electrically without having to use the service brake. This action allows for smooth shuttle operation while saving wear on the service brakes. Trucks equipped with regenerative braking (“regen”) use regenerative power to bring the truck to a stop. Trucks not equipped with regen use plugging to bring the truck to a stop. Plugging is the standard form of electrical braking on 2FBC15/18 trucks, although regen can be added as an option. Regen is the standard electrical braking on 2FBC20-30 trucks. Regen applies when armature generated current is forced to flow backwards through the battery. This system has much better braking characteristics than “plug only” systems. The braking energy is used to charge the battery momentarily, reduce heat build-up in the drive motor, and extend motor brush life.

WENB8604-02

Regenerative Brakes: Braking Circuit 2FBC20-30 Standard Configuration)

Battery current through the drive shunt field maintains the magnetic field necessary for the motor rotation to generate a voltage across the armature.

Regen electrical braking begins when the operator selects a direction opposite the truck’s motion while keeping the accelerator depressed. The logics will deactivate the regen and bypass contactors (if activated), turn the drive shunt field ON (if it was OFF), and change the direction contactor to the new direction selected. The logics will pulse the power transistors at a slow rate.

The generated voltage produces a current that flows through the armature, through the direction contactor tips, current sensor, regen diode D6D, power transistors, motor series field, direction contactor tips, and back through the armature. This generated current energizes the drive motor series field, which tries to turn the armature opposite the rotation caused by truck motion. This brakes the truck electrically. The logics controls the power transistor pulse rate to keep the current below a preset level as monitored by the current sensor. Refer to the Testing and Adjusting section of this manual for proper setup procedures.

When the drive power transistors (T1D and T2D) are ON with the drive shunt field energized and the drive motor turning opposite the direction selected, the drive motor begins to act like a generator.

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

P8-1

T2D

46 34 P2-12 P3-3 100 P2-13

R312

T1D

D311

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2) DU2

P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON PUMP MOTOR CIRCUIT

FWD CTR

A1 A2 DRIVE MOTOR REV CTR

P32-1

D5D

FWD CTR

92 D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

T371

E361

P12-7

D4D

D371

HEAD CAP

D6D

ARM

P12-10

102

E1 (F1) E2 (F2)

BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 101

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

LOGICS

P1-21

P12-4

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1506

WENB8604-02

When current peaks at its preset value, the logics will turn OFF the power transistors. The generated current will flow from the drive motor field and armature, through the current sensor, D6D, line fuse, line contactor tips, battery, flyback diode D4D back to the drive motor field. This is the charging cycle for the battery. When the current decreases, the logics will turn ON the power transistors, and the cycle starts again.

As electrical braking slows the truck, the motor generates less and less current. The logics makes up for the decreasing generated current by increasing the pulse rate of the power transistors.

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

P8-1

T2D

46 34 P2-12 P3-3 100 P2-13

R312

T1D

D311

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2) DU2

P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON PUMP MOTOR CIRCUIT

FWD CTR

A1 A2 DRIVE MOTOR REV CTR

P32-1

D5D

FWD CTR

92 D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

T371

E361

P12-7

D4D

D371

HEAD CAP

D6D

ARM

P12-10

102

E1 (F1) E2 (F2)

BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 101

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

LOGICS

P1-21

P12-4

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1507

WENB8604-02

Plugging Circuit

The logics monitors this condition through the current sensor and reactivates the regen contactor. To prevent contactor tip arcing, the electrical braking of the truck is paused while the regen contactor tips close.

When the speed of the truck slows to less than 2kph (1.2mph) the drive motor is no longer turning fast enough to generate enough current to charge the battery.

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

34 P2-12 P3-3 100 P2-13

R312

T2D

P8-1

D311

B T1D

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2) DU2

P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

101 PUMP MOTOR CIRCUIT

A1 A2 DRIVE MOTOR REV CTR

P32-1

D5D

FWD CTR

92 D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

T371

E361

P12-7

D4D

D371

HEAD CAP

D6D

ARM

P12-10

102

E1 (F1) E2 (F2)

BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 FWD CTR

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

LOGICS

P1-21

P12-4

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1508

WENB8604-02

Plugging Circuit (2FBC15/18 Standard Configuration)

Plugging electrical braking (the standard configuration for 2FBC15 and 2FBC18 trucks) begins when the operator selects a direction opposite the forklift truck’s motion, while keeping the accelerator depressed. The logics will deactivate the bypass contactor if activated and turn off the drive shunt field. It will change the direction contactor to the new direction selected. The logics will then begin to pulse the drive shunt field. Because the motor is turning it acts like a generator, and current begins to flow through D5D. This causes wire #1 at the logics to become more positive than the sensing wire #51 at P2-17, due to the voltage drop

The logics generates a 750Hz pulsing signal on P2-5. This is faster than can be seen on a voltmeter and must be viewed with an oscilloscope. When this signal is low, it indicates the power transistors T1D and T2D should be on. When this signal is high, it indicates they should be off. When P2-5 goes low, current flows from BAT+ through the emitter/base junction of T314 and T315, through R312, through P2-5 to BAT-.

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

P8-1

T2D

46 34 P2-12 P3-3 100 P2-13

R312

T1D

D311

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2)

68 DU2 P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON PUMP MOTOR CIRCUIT

FWD CTR

E1 (F1) ARM

A1 A2 DRIVE MOTOR REV CTR

P32-1

FWD CTR

E361

P12-7

D361 T361

C371

CURRENT SENSOR

P12-9

Z371

R371

T371 P12-10

102

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

P3-21

D5D

HEAD CAP D4D

D371

E2 (F2) BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 101

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13

LOGICS

P12-4

P5-28

D1 (S1)

P1-21

P3-20 P2-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1509

WENB8604-02

Drive Motor duty cycle. When the transistors are ON, battery current flows through the power transistors, drive motor field, direction contactor tips, and current sensor back to BAT-. The generated current will flow from the armature through plugging diode D5D, back to the armature.

The current in the drive motor is monitored and used to adjust the duty cycle of the drive shunt field to maintain plugging current. When the duty cycle on the drive shunt field has reached 100% and the current starts to fall below the plugging current limit, the main power transistors T1D and T2D are turned on at a very low

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

34 P2-12 P3-3 100 P2-13

R312

T2D

P8-1

D311

B T1D

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2) DU2

P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

101 PUMP MOTOR CIRCUIT

A1 A2 DRIVE MOTOR REV CTR

P32-1

D5D

FWD CTR

92 D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

T371

E361

P12-7

D4D

D371

HEAD CAP

D6D

ARM

P12-10

102

E1 (F1) E2 (F2)

BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 FWD CTR

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

LOGICS

P1-21

P12-4

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1510

WENB8604-02

When the power transistors are OFF, flyback current from the collapsing motor field flows through the direction contactor tips, armature, direction contactor tips, current sensor, and flyback diode D4D back to the motor field. This current continues the electrical braking action. As long as truck momentum is turning the armature opposite the pulsed direction, the motor continues to act as a generator. The generated current flows through the current sensor, plugging diode D5D, and

back to the armature. When the truck has come to a stop, the armature no longer is turning opposite the pulsed direction. The motor stops generating current, D5D no longer conducts, and the logics no longer detects that sensing wire #51 is lower voltage than wire #1. The logics will switch into drive mode, and normal acceleration in the opposite direction starts.

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

P8-1

T2D

46 34 P2-12 P3-3 100 P2-13

R312

T1D

D311

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2) DU2

P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

101 PUMP MOTOR CIRCUIT

A1 A2 DRIVE MOTOR REV CTR

P32-1

D5D

FWD CTR

92 D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

T371

E361

P12-7

D4D

D371

HEAD CAP

D6D

ARM

P12-10

102

E1 (F1) E2

BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 FWD CTR

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

LOGICS

P1-21

P12-4

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1511

WENB8604-02

Current Limit The logics monitors the current flow through T1D and T2D and limits this current flow to a preset value. As this current flows through T1D and T2D, the drive motor and the current sensor, a voltage is created by the sensor. This voltage is proportional to the current flowing through the sensor and will increase or decrease as current changes The logics uses this voltage to monitor the current in the circuit. When the current has increased too high, the logics decreases the pulse rate to the transistors to prevent current higher than the preset value.

Current Limit Setting

Current In ARM

“On”

“Off”

Time Current In Relation To Time Current Limit

WENB8604-02

Thermal Protection Circuits Control Panel If the power transistors overheat, heat is transferred to a thermal switch mounted in a common heatsink. The thermal switch will open at a predetermined temperature. When it opens, voltage at logics connection P3-3 will go HIGH (15 volts). The instrument panel will display a “Run Time” diagnostic symbol. The logics will decrease the current limit setting of the drive system. It will also reduce hydraulic speed 6 and 7 to speed 5. Speeds 8, 9, and 10 are not affected because these speeds use the pump contactor, which does not add heat to the panel.

Failure Protection Circuit If the logics detects an improper voltage at P2-6 wire #37 (drive circuit), P2-10 wire #45 (pump circuit) P2-2 wire #92 (drive shunt field circuit) or P2-4 wire #71 (pump shunt field circuit), the line contactor will be deactivated and a “Run Time” diagnostic code (display 10 through 69) will replace the speedometer indicator. Once a failure has been detected, the truck must be repaired before normal operation can resume.

Hydraulic Pump Motor If the pump motor overheats, a thermal switch mounted in the pump motor housing will open at a predetermined temperature. When it opens, voltage at logics connection P3-2 will go HIGH. The instrument panel will display a “Run Time” diagnostic symbol. To decrease the amount of current allowed to flow through the pump motor, the logics will restrict the hydraulic pump motor to speed 8. When the hydraulic pump motor cools and the thermal switch closes, the truck will return to normal operation.

Drive Motor If the drive motor overheats, a thermal switch mounted in the drive motor housing will open at a predetermined temperature. When it opens, voltage at logics connection P3-1 will go HIGH. The instrument panel will display a “Run Time” diagnostics symbol. To decrease the amount of current allowed to flow through the drive motor, the Logics will restrict the current limit to 80% of P1 potentiometer and will also deactivate the bypass contactor. When the drive motor cools and the thermal switch closes, the truck will return to normal operation.

WENB8604-02

Bypass Circuit With Shunt Field Activated

full battery voltage to the drive motor. If the accelerator pedal is fully depressed and the logics has pulsed T1D and T2D up through 90% “on-time”, the logics will activate the BYPASS CTR in 1 to 4 seconds.

The bypass circuit bypasses T1D and T2D and connects the drive motor in series with the battery, applying

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

P8-1

T2D

46 34 P2-12 P3-3 100 P2-13

R312

T1D

D311

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2)

51 DU2

P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

101 PUMP MOTOR CIRCUIT

A1 A2 DRIVE MOTOR

P32-1

REV CTR

FWD CTR

92 D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

T371

E361

P12-7

D371

D4D

D5D

HEAD CAP

D6D

ARM

P12-10

102

E1 (F1) E2 (F2)

BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 FWD CTR

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

P1-21

LOGICS

P12-4

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1512

WENB8604-02

Bypass Circuit Without Shunt Field Activated

decreases to a preset limit, the logics turns the shunt field OFF. With the shunt field OFF, both armature current and motor speed will increase. If the drive motor increases above the preset limit (e.g. climbing a ramp or a hill) the logics turns the shunt field back ON. This gives maximum torque to climb ramps or steep grades.

With the accelerator fully depressed and the bypass contactor closed, the logics starts to monitor drive current and truck speed. When the drive motor current

P12-15

T R317

R316

R315

P12-14 BYPASS CTR

P8-2 CONTROL THERMOSTAT

T315

T314

P8-1

T2D

46 34 P2-12 P3-3 100 P2-13

R312

T1D

D311

R313

Z313

R311

P12-16

1 31

P12-5

P2-5

P2-6

101 82 51 102

P2-14 P1-7 P2-17 P2-15

P12-3 1

D2 (S2)

68 DU2 P32-6

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

101 PUMP MOTOR CIRCUIT

102

E1 (F1)

REV CTR

P32-1

D5D

FWD CTR

92 D361 T361

C371

CURRENT SENSOR

REGEN CTR

P12-9

Z371

R371

T371

E361

P12-7

D371

HEAD CAP D4D

D6D

ARM

A1 A2 DRIVE MOTOR

E2 (F2) BATTERY 36/48 VOLT OR 72/80 VOLT

REV CTR

R361

LINE CTR

108

107 FWD CTR

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P16-1 P16-2 P16-3

97 92

P3-16

2 42 85

P3-7 P3-8 P3-6 P2-11 P2-2 P2-1

LOGICS

P1-21

P12-4

P5-28

D1 (S1)

P3-20 P2-21

P3-21

DRIVE SHUNT FIELD FUSE 15 AMP

92 96

2FBC1501

WENB8604-02

Testing and Adjusting Accessing Stored Fault Codes The logics stores the thirty-two faults or warnings that occurred on the forklift truck. This information is useful for troubleshooting intermittent faults, determining which motor has worn brushes, or which thermal switch overheated. The stored information can also be useful in determining the application in which the truck is being used. Example: pump motor thermal indication has been ON; could mean that the truck is used in a heavy duty hydraulic application. The stored faults are accessed by the following procedure (called a “fault dump”): 1. Start with the key switch OFF. 2. Remove the logics cover. 3. Place the DIAG/RUN/SETUP switch to DIAG. 4. Turn the key switch ON while pulling back on the LIFT and TILT levers. The fault codes will appear on the display, beginning with the most recent.

To toggle to the next code, cycle the DIAG/RUN/ SETUP switch from DIAG to RUN and back to DIAG. When you reach the end of the list (or if there are no stored codes), the word “DONE” will appear. To get back to the beginning from the end of the list, cycle the DIAG/RUN/SETUP switch from DIAG to RUN to DIAG again. To clear the fault code memory, cycle the DIAG/ RUN/SETUP switch from DIAG to SETUP, then wait until the display starts to flash done, then switch back to DIAG. The following is a list of possible stored codes: E1 - DRIVE HOT E2 - PUMP HOT E3 - CONTROLLER HOT B1 - DRIVE BWI B2 - PUMP BWI AA-HEADCAP FAILURE NOTE: These fault codes only show up during the fault code dump.

WENB8604-02

Troubleshooting The following Troubleshooting Check List is an aid in troubleshooting TR3000 forklift trucks. The troubleshooting checklist, “Run Time” diagnostic indications, “Self” diagnostic tests, problem list and problem flow charts will assist in: 1. Defining the problem and verifying that a problem exists. 2. Performing the checks in a logical order. 3. Making the necessary repairs. 4. Verifying that the problem has been resolved.

! WARNING The forklift truck can move suddenly. Battery voltage and high amperage are present. Injury to personnel or damage to the forklift truck is possible. Safely lift both drive wheels off the floor. Put blocks of wood under the frame so the drive wheels are free to turn. During any test or operation check, keep away from drive wheels. Before any contact with the control panel is made, disconnect the battery and discharge HEAD CAP. Rings, watches, and other metallic objects should be removed from hands and arms when troubleshooting the TR3000 Control System. NOTICE: Damage can be caused to the test equipment. Make resistance and continuity checks only after the battery is disconnected. NOTICE: Damage can be caused to the control panel. Do not use steam or solvent to clean the controls. Use pressure from an air hose with a maximum pressure of 205kPa (30 psi) to clean the control panel when necessary. Make sure the air pressure supply is equipped with a water filter. NOTICE: Damage can be caused to the control panel. Do not switch the direction lever from one direction to the other (plug the forklift truck) when the drive wheels are off the ground and in rotation at full speed.

Troubleshooting Checklist 1. Perform Preparations Tests and Checks. 2. Correct any display problems and “Run Time” diagnostic faults. 3. Correct the “Self” diagnostic faults. 4. Perform Operational Checks. 5. Correct “Other Problems” in the Troubleshooting Problem List. 6. Perform Operational Checks to verify repairs.

WENB8604-02

Cell Voltage Test

Preparation Tests and Checks Battery Tests A weak battery can cause or contribute to problems in the TR3000 control and power circuits. Verify the battery is good before investigating other possibilities. 1. Verify proper polarity at the battery connector and the TR3000 control panel. Positive cable should be at the line contactor and negative at the negative standoff or regen contactor. 2. If the forklift truck is operational, perform a battery load test. 3. If the truck is not operational and the battery is suspected, perform a cell voltage or specific gravity test.

Battery Load Test 1. Turn the range switch on the multimeter to read battery voltage.

With the truck powered up and the power steering motor running, measure the voltage at each cell. Normal voltage should be between 1.95V and 2.12V per cell. If the voltage on each cell is below 1.95, the battery must be charged or repaired before continuing to troubleshoot. NOTE: The indication between cells should not differ more than 0.05 volts. If it does, the battery must have an equalizing charge or be repaired.

Hydrometer Test Test each cell of the battery with a Battery Hydrometer. If the specific gravity indication is below 1.140, the battery must be charged. The battery is fully charged if the indication is 1.265 to 1.285. NOTE: The indication between cells should not differ more than.020. If it does, the battery needs an equalizing charge or needs to be repaired.

Battery Maintenance

2. Connect the battery.

NOTE: It is important that all batteries be charged and maintained according to the battery manufacturers instructions. The care and maintenance of batteries is most important to maximum battery life and efficient truck operation. Periodic inspection and service will increase the life of batteries. Special attention should be given to the rules that follow:

2 97C54-00300

3. Connect the multimeter leads between positive(+) cable connection (1), and negative (-) cable connection (2). 4. In a safe area, operate the hydraulic system, (hold tilt lever to maximum position momentarily) while reading the voltage indicated on the multimeter. 5. If the indication is less than 33.1 volts for 36 volt trucks or 44.2 volts for 48 volt trucks, the battery needs to be charged or repaired before continuing to troubleshoot.

1. Keep batteries clean at all times. Cleaning will prevent corrosion, current leakage, and shorts to chassis. Tighten all vent plugs, wash the battery with water and a brush, then dry with an air hose. It may be necessary to use a baking soda solution if water alone will not clean the top of the battery. 2. Add enough water to cover the plates before charging. This will ensure the proper chemical reaction over the entire plate surface. After charging is complete, add water until it is about 12.7 mm (.50 in) above the plates. Use distilled water or water that has tested free from minerals. 3. Charge the battery correctly. A battery should be discharged to 80% of its capacity, then fully recharged. It should cool four to eight hours to allow the voltage to stabilize before being put back in use. The battery should have an equalizing charge (an extra three or four hour charge at a low finish rate) once a month to make sure all cells are in a fully charged condition. Properly charged batteries should be identified to prevent low batteries from being installed in trucks.

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4. Operation with a low battery must be prevented. Low battery operation may damage the battery and will cause higher than normal current in the electrical system. High current draw due to a low battery will damage contactor tips and shorten motor brush life. 5. The battery’s maximum temperature is critical. The electrolyte temperature should never exceed 43°C (110° F) either while operating or charging. Overcharging a battery will cause overheating and warp the battery plates. Maximum battery life will result from maintaining 25°C (77°F) electrolyte temperature. Most of the charging equipment is fully automatic but should be checked periodically to assure proper working order. 6. Keep accurate battery records. Regular battery readings should be taken with a battery tester or voltmeter and a written record kept. Specific gravity and voltage of each cell should be checked and recorded at least once each month. This inspection should be made after an equalizing charge. Readings should never be taken directly after water has been added. Records of all battery maintenance should be made and filed so it will be known which batteries are being abused or wearing out. Repairs should be made immediately, otherwise the battery may become damaged. Batteries stored in a discharged condition may be difficult to recharge due to sulfate formation.

Visual Checks 1. Verify all components and wires are in their proper place. Check fuses, components, contactor tips, wires and connections. Verify that they are not burned, broken, or loose. 2. Verify there is no mechanical binding or interference in the contactors. 3. Visually check the parking brake switch, the service brake switch, hydraulic lift switch, and accelerator linkage for adjustment or interference problems.

Resistance To Chassis Checks Resistance between any point in the truck wiring and the chassis should be a minimum of 10,000 ohms or more. Many malfunctions are caused by shorts to chassis. Usually, two shorts must exist before a malfunction will occur. But, since batteries can have chassis leakage, only one short to chassis in the truck wiring can cause problems. To prevent problems because of shorts, do the following: 1. Disconnect the battery and discharge the HEAD CAP. 2. Measure from the chassis to both sides of the line contactor, component connection or wiring connection in respect to the forklift truck chassis for a minimum resistance of 10,000 ohms. Any test point with low resistance must have the short to chassis removed. 3. Always keep batteries clean to minimize current leakage to the chassis. 4. Routinely clean the brush dust from the motors. 5. Be sure that all attachments, such as horns and lights, are designed for no chassis connection (a two-wire system).

Removal Of Shorts To Chassis When a short is found, it must be cleared even if the machine has normal operation. It is necessary to narrow the field of possible problem areas before inspection of individual wires and components. When a low resistance circuit is located, it should be opened at various points. This will permit the shorted wire or component to be pinpointed for repair or replacement.

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Control And Power System Operational Checks All operational checks are to begin with: programmable features set to the default values, battery connected, directional switch in neutral, drive wheels off the ground, and the accelerator and parking brake released. NOTE: Perform all operational checks before returning to the Troubleshooting Check List.

Check 1: Key And Seat Switch 1. Actuate the key and seat switch. The line contactor activates and the hydraulic motor runs. After five seconds the line contactor deactivates and the motor turns off.

Check 2: Power Steering Performance 1. Turn the steering wheel. The pump motor should provide adequate hydraulic flow for the steering system.

Check 3: Lift, Tilt, and Auxiliary Performance 1. Slowly pull the lift control lever. The pump motor will activate. 2. Pull the lift control lever further and the motor speed will increase to the maximum speed. 3. Slowly pull and push the tilt and auxiliary levers. The pump motor increases speed with each lever movement.

Check 4: Forward Drive Performance 1. Engage the parking brake. Select forward direction and depress the accelerator slightly. The forward contactor will not activate and the drive wheels will not turn. The park brake action light will be on.

Check 5: Reverse Drive Performance 1. Select reverse direction and depress the accelerator slightly. The reverse contactor will activate and the drive wheels will turn in reverse slowly. 2. Slowly increase the amount of accelerator depression. The reverse contactor will remain activated. The drive wheels will turn in reverse and slowly increase in speed. 3. Depress the accelerator fully. The reverse contactor will remain activated and bypass contactor will activate. The drive wheels will turn in reverse at full speed.

Check 6: Electrical Braking Performance NOTICE: Do not perform this check with the lift truck in bypass mode. Damage to the control panel can result. 1. Select forward direction and depress the accelerator to the point just before bypass occurs. While continuing to depress the accelerator, change the direction switch to reverse. The forward contactor should deactivate and the reverse contactor should activate. There should be a smooth deceleration of forward tire rotation and a smooth acceleration of reverse tire rotation. 2. While continuing to depress the accelerator in reverse direction change the direction switch to forward. The reverse contactor should deactivate and the forward contactor should activate. There should be a smooth deceleration of reverse tire rotation and a smooth acceleration of forward tire rotation.

2. Release the parking brake, select forward direction and depress the accelerator slightly. Depending upon the setting of Option 13, the forward contactor may activate and the drive wheels may turn forward slowly. 3. Slowly increase the amount of accelerator depression. The forward contactor will remain activated. The drive wheels will turn forward and slowly increase in speed. 4. Depress the accelerator fully. The forward contactor will remain activated and the bypass contactor will activate. The drive wheels will turn forward at full speed.

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Built-In Diagnostic Operation The logics and the display provide built-in diagnostic analyzer functions. Numerous diagnostic functions occur while the truck is in operation. These are called “Run-time” diagnostics. The other diagnostics are called “Self” diagnostics. They are performed when the forklift truck is not in operation by using a switch located in the logics.

“Run-Time” Diagnostics (forklift truck in Operation) The diagnostics functions that follow would occur during normal forklift truck operation and are shown on the LCD display. The speedometer portion of the LCD display is used to indicate the fault codes. There are a total of 31 possible Run-Time fault codes. Listed below are some common codes and their possible causes, with references to the Troubleshooting Problem list and flow charts found later in this section of the manual. Refer to that list and the flow charts for the specific code, and the problem it indicates, that you are trying to troubleshoot.

Brush Wear Indicator ON - forklift truck operation is normal. See Troubleshooting Problem 5. Possible cause, worn brushes on pump and/or drive motor. Overtemperature Indicator ON - forklift truck accelerates slower than normal. See Troubleshooting Problems 6, 7, and 8. Fault codes E1, E2, or E3 may be stored. Possible causes, control panel, drive or pump motor overtemperature; faulty thermal switch. Display = 20 - No forklift truck operation. See Troubleshooting Problem 15. Possible cause: current limit out of adjustment, Drive Pulsing Stall Timer option, or Bypass option set incorrectly. Display = 60 - No forklift truck operation. See Troubleshooting Problem 32. Possible cause, serial communications fault between the display and the logics. Display = 65 - No forklift truck operation. See Troubleshooting Problem 34. Possible cause, truck size not initialized. (Programmable Setup option 30). Display = 68 or 69 - No forklift truck operation. See Troubleshooting Problem 36. Possible cause, battery volts too low or too high for chosen jumper.

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“Self” Diagnostics (Forklift Truck Not In Operation) The “Self” diagnostic procedure should be used to help troubleshoot after a problem has occurred. Self Diagnostics are most useful for finding faulty circuits or components. Complete all the tests before returning to the Troubleshooting Check List. NOTE: The Self Diagnostics procedure as well as the LCD display readouts for test pass and fail is printed on a decal located on the inside door to the control panel. Following the procedure on the decal is recommended.

! WARNING The forklift truck can move suddenly. Injury to personnel or damage to the forklift truck is possible. Disconnect the battery and disconnect the line fuse to prevent forklift truck movement. 4. Release the park brake to close the park brake switch. 5. Loosen the two screws (2) and remove the logics cover (3).

Before beginning the Self Diagnostics tests, do the following: 1. Turn the key switch OFF. 2. Disconnect the battery and check the head capacitors for discharge below 5 volts. If the head capacitors are not discharged, discharge them by holding a discharge resistor in place for 20 seconds. See the topic, “Discharging the Head Capacitor” in the Testing And Adjusting section of this manual. C0000 Logics Board

2 3

6. Move the switch to the DIAG position. This places the controller in diagnostics when the key switch is turned on. If any of the tests that follow fail [except the line (drive) fuse test where the display = “dd”], continue through the tests that remain. Make a note of all failed tests for detailed troubleshooting. To bypass a failed test and allow the next test to be performed, move the switch to the RUN position then back to the DIAG position.

Location of Components (1) Line fuse. (2) Screws. (3) Logics cover.

3. Disconnect the line fuse (1) to prevent forklift truck movement.

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Circuit Tests Test A: Internal Circuitry Connect the battery and turn the key switch ON. Display = “blank” See Troubleshooting Problems 1, 2, or 3. Display = FF Logics failure. Replace logics. You may also bypass this failure by toggling the DIAG/RUN/SETUP switch to RUN and back to DIAG. NOTE: This test does not check all the logics circuits, so the logics may pass this test and still have a failure. Display = dd Line fuse not disconnected or head capacitors not discharged below 5 volts. Return to Step 2.

Test B: Line (drive) Fuse Out This test will take place automatically if Test A is completed successfully. Display = 01 Line (drive) fuse is out and head capacitors are discharged, as they should be f or these tests. The 01 display indicates a pass for this test. Display = dd Line fuse not disconnected or head capacitors not discharged below 5 volts. Return to Step 2.

Test C: Seat Switch Circuit Press and release seat to close and open seat switch. Display = 01 Seat switch circuit defect. Move hand around on seat and press again. If still 01, see Troubleshooting Problem 37. Display = 02 Seat switch circuit OK.

Test D: Direction Switch Circuit Cycle the direction lever from neutral to reverse to neutral again and then to forward. Display = 02 Direction switch circuit defect. See Troubleshooting Problem 38. Display = 03 Direction switch circuit OK.

Test E: Park Brake Circuit Engage and release the park brake. NOTE: The Park Brake action light may come on. This does not indicate a problem. Display = 03 Park brake circuit defect. See Troubleshooting Problem 40. Display = 04 Park brake circuit OK.

Test F: Service Brake Circuit NOTE: It is not necessary for the park brake to be released for this test. Depress and release the service brake. Display = 04 Service brake circuit defect. See Troubleshooting Problem 41. Display = 05 Service brake switch circuit OK.

Test G: Accelerator Circuit Fully depress and release the accelerator. Display = 05 Accelerator circuit defect. See Troubleshooting Problem 42. Display = Flashing 00 Accelerator circuit OK, ready to perform the accelerator speed test.

Test H: Accelerator Speed Check Depress the accelerator again. Display shows flashing accelerator position, 00 - 15. If some speeds are missing, at the beginning or the end of travel, for example, then the pedal probably needs to be adjusted. To bypass the flashing speed number and proceed to the next test, toggle the DIAG/RUN/SETUP switch from DIAG to RUN and back to DIAG.

Test I: BDI Circuit This test is performed automatically after the DIAG/RUN/SETUP switch is toggled in the preceding test. The BDI test happens quickly; in fact, if the BDI is OK, 06 (indicating a pass for Test H) may be bypassed too quickly to be seen. Display = 06 BDI circuit failure. See Troubleshooting Problem 43. Display = 07 BDI circuit OK.

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Test J: Lift Switch Circuit Pull the lift lever back to maximum and release. Display = 07 Lift switch circuit defect. See Troubleshooting Problem 44. Display = 08 Lift switch circuit OK.

Test K: Tilt Switch Circuit

Test M: Aux2 Switch Circuit NOTE: If AUX2 does not exist on the test truck, bypass by toggling the DIAG/RUN/SETUP switch. Pull the aux2 lever back to maximum and release. Display = 10 Aux1 switch circuit defect. See Troubleshooting Problem 47. Display = Flashing 00 Aux2 switch circuit OK.

Pull the tilt lever back to maximum and release. Display = 08 Tilt switch circuit defect. See Troubleshooting Problem 45. Display = 09 Tilt switch circuit OK.

Test L: Aux1 Switch Circuit Pull the aux1 lever back to maximum and release. Display = 09 Aux1 switch circuit defect. See Troubleshooting Problem 46. Display = 10 Aux1 switch circuit OK.

Test N: Hydraulic Speed Check After a successful aux2 circuit test, the flashing number in the display can show the speed associated with each hydraulic function. For example, if you pull back on the tilt lever, you will see the tilt speed on the display. Only one lever should be tested (pulled back) at a time. Exception: If you are using only the lift0 and lift1 switches, you can test them both at the same time. The speed displayed represents the second lift speed. To exit the hydraulic speed check (bypass the flashing 00), toggle the DIAG/RUN/SETUP switch from DIAG to RUN and back to DIAG. Display = 11 Ready for the next test.

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Test R: Forward Contactor Circuit

Tests “O” Through “T”

Move the DIAG/RUN/SETUP switch to RUN. Display = 15 and the forward contactor (4) does not close. Circuit is defective. See Troubleshooting Problem 50. Display = 15 and forward contactor (4) closes. Forward contactor circuit OK. Move the DIAG/RUN/SETUP switch to DIAG. Display = 16 and the forward contactor (4) opens.

The remaining tests check contactor operation. You will toggle the DIAG/RUN/SETUP switch from DIAG to RUN to activate the contactor being tested, then toggle the switch back to DIAG to deactivate it. You must visually observe the contactors for proper operation during these tests.

Test S: Reverse Contactor Circuit Move the DIAG/RUN/SETUP switch to RUN. Display = 16 and the reverse contactor (5) does not close. Circuit is defective. See Troubleshooting Problem 50. Display = 16 and reverse contactor (5) closes. Reverse contactor circuit OK. Move the DIAG/RUN/SETUP switch to DIAG. If the panel does not have regen, the display will = donE. The self diagnostics are complete for nonregen (plug only) panels. If the panel has regen, the display = 17 and the reverse contactor (5) opens. Go to Test T.

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Contactor Locations. Panel with regen is shown. Plug-only panels will not have regen contactor (6). (1) Line contactor. (2) Pump bypass contactor. (3) Drive bypass contactor. (4) Forward contactor. (5) Reverse contactor. (6) Regen contactor.

Test T: Regen Contactor Circuit Move the DIAG/RUN/SETUP switch to RUN. Display = 17 and the regen contactor (6) does not close. Circuit is defective. See Troubleshooting Problem 50. Display = 17 and regen contactor (6) closes. Regen contactor circuit OK. Move the DIAG/RUN/SETUP switch to DIAG. Display = donE and the regen contactor (6) opens.

Test O: Line Contactor Circuit Move the DIAG/RUN/SETUP switch to RUN. Display = 12 and the line contactor (1) does not close. Circuit is defective. See Troubleshooting Problem 50. Display = 12 and line contactor (1) closes. Line contactor circuit OK. Move the DIAG/RUN/SETUP switch to DIAG. Display = 13 and the line contactor (1) opens.

Test P: Pump Bypass Contactor Circuit Move the DIAG/RUN/SETUP switch to RUN. Display = 13 and the pump bypass contactor (2) does not close. Circuit is defective. See Troubleshooting Problem 50. Display = 13 and pump bypass contactor (2) closes. Pump bypass contactor circuit OK. Move the DIAG/RUN/SETUP switch to DIAG. Display = 14 and the pump bypass contactor (2) opens.

Test Q: Drive Bypass Contactor Circuit Move the DIAG/RUN/SETUP switch to RUN. Display = 14 and the drive bypass contactor (3) does not close. Circuit is defective. See Troubleshooting Problem 50. Display = 14 and drive bypass contactor (3) closes. Drive bypass contactor circuit OK. Move the DIAG/RUN/SETUP switch to DIAG. Display = 15 and the drive bypass contactor (3) opens. 56

Location of components: 1.Line Fuse 2.Screws 3.Logics Cover

This completes the self-diagnostics tests. The contactor tests may be repeated by moving the DIAG/RUN/SETUP switch to RUN and back to DIAG. If you are finished with self diagnostics, do the following: 1. Disconnect the battery and install the line fuse (1). 2. Move the DIAG/RUN/SETUP switch to the RUN position. 3. Install the logics cover (3) and tighten screws (2).

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Troubleshooting Charts Problem #

Problem Type Display Problems

When seat switch is closed, speedometer area of display goes blank. No forklift truck drive or pump motor operation.

Display does not work at all. Forklift truck operation is normal.

Display does not work. No forklift truck operation.

BDI # does not change with a change in battery voltage.

“Run Time” Diagnostic Problems 5

Brush wear indicator is on.

Overtemperature indicator is “ON”, forklift truck accelerates slower than normal. Truck goes into bypass. Pump motor speeds 6 and 7 are reduced. Fault code E3 is stored.

Overtemperature indicator is “ON” forklift truck accelerates slower than normal. Truck goes into bypass. Bypass contactor will not close.Pump motor operation normal. Fault code E1 is stored.

Overtemperature indicator is ON, lift speed slower than normal. Drive motor operation normal. Fault code E2 is stored.

Display = 10: Drive armature transistor fault (high). No forklift truck operation.

Display = 11: Drive armature transistor fault (low). No forklift truck operation.

Display = 15: D6D anode fault (low). No forklift truck operation. (Trucks with regen).

11A

Display = 15: D6D sense wire fault. No forklift truck operation.

Display = 16: D6D anode fault (high). No forklift truck operation.

Display = 18: Drive shunt field transistor drain fault (high). No forklift truck operation.

Display = 19: Drive shunt field transistor drain fault (low). No forklift truck operation.

Display = 20: Drive stall timer failure. No forklift truck operation.

Display = 21: Drive current sensor failure. No forklift truck operation.

Display = 24: Drive output overcurrent fault. No forklift truck operation.

Display = 25: Accelerator fault (low). No forklift truck operation.

Display = 26: Accelerator fault (high). No forklift truck operation.

Display = 29: Speed sensor failure. No forklift truck operation.

Display = 30: Pump armature transistor emitter fault (high). No forklift truck operation.

Display = 31: Pump armature transistor emitter fault (low, B terminal). No forklift truck operation.

Display = 32: Pump armature transistor emitter fault (low, B0 Terminal). No forklift truck operation.

Display = 33: Combination of F31 and F32. No forklift truck operation.

Display = 38: Pump shunt field transistor drain fault (high). No forklift truck operation.

Display = 39: Pump shunt field transistor drain fault (low). No forklift truck operation.

Display = 40: Pump stall timer failure. No forklift truck operation.

Display = 41: Pump current shunt failure. No forklift truck operation.

Display = 44. Pump output overcurrent fault. No forklift truck operation.

Display = 50: Combination of F10 and F30. No forklift truck operation. 57

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Problem #

Problem Type

Display = 51: Combination of F11, F31, F32, and F33. No lift truck operation.

Display = 60: Serial communications fault. No lift truck operation.

Display = 61: EEPROM error. No lift truck operation.

Display = 65: Truck size not initialized. No lift truck operation.

Display = 66: Watchdog timer failure. No lift truck operation.

Display = 68 or 69: Battery volts too low for chosen jumper. No lift truck operation.

“Self” Diagnostic Problems 37

Seat switch circuit defect.

Direction switch circuit defect.

Foot-operated direction switch defect.

Park brake circuit defect.

Service brake circuit defect. Note: Must be repaired before moving on!

Accelerator circuit defect.

BDI circuit defect.

Lift switch circuit defect.

Tilt switch circuit defect.

Aux 1 switch circuit defect.

Aux 2 switch circuit defect.

Hydraulic speed check.

Incorrect contactor operation.

Other Problems 50

Any contactor closes when key switch is closed.

Drive motor does not operate or operates with low power or is erratic. Pump system operation normal.

Poor acceleration, loss of power on ramps.

Forklift truck has long electrical braking distance or sudden stop at end of braking cycle. Pump system operation normal.

Current limit and/or electrical braking limit adjustment cannot be made.

Auxiliary lighting and/or alarm does not function correctly. Lift and drive systems operation normal.

Slow steering, but pump motor does turn. Drive and lift systems operation normal.

Steering idle speed runs fast. (Pump motor runs at high power steering speed continuously.) Pump motor runs continuously in neutral (no chat mode).

Forklift truck speed reduced to 2.0 mph (no code).

Display = FFFF.O: Change display.

Code H: Hydraulic Switch is closed when key is turned on.

61A & B

Code E: Accelerator depressed before key is turned on. Seat Switch open when it should be closed.

Note: Check for shorts to chassis or open wiring at the start of any problem. Use a 6V4042 Wiring Harness Test Group to find a wire-to-wire short, shorts to chassis, and continuity. Always follow the sequence defined here using the display and built-in analyzer functions to aid in troubleshooting. 58

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PROBLEM 1 Speedometer portion of display works until seat switch is closed, then blank. No lift truck drive or pump motor operation.

POSSIBLE CAUSE Line contactor defect: line fuse open circuit: wire #34 at P2-12 open circuit: logics defect.

CHECKS Does the line contactor remain closed?

YES

Check voltage at bottom of line fuse with line contactor activated.

See problem 49, Incorrect Contactor Operation.

Battery Voltage

Less Than Battery Voltage

Check voltage at top of line fuse with line contactor activated.

Repair or replace line contactor tips or power connection.

Battery Voltage Check voltage at logics connector P2-12 (wire #34) on the silver area. Do not disconnect the logics connector.

Battery Voltage Replace logics.

Less Than Battery Voltage Check for possible shorts in the power circuit (Head capacitor, diodes, shorted cables) and replace line fuses. If repeat failures occur, check drive motor current limit and/or lift truck.

Less than Battery Voltage Repair open circuit between line fuse and P2-12, wire #34.

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PROBLEM 2 Display does not work at all: lift truck operation normal. If only part of the display works, replace the whole display unit.

POSSIBLE CAUSES Disconnected display connector P6: open circuit from P6-1 to battery negative: open circuit from key switch to P6-2: defective display unit.

CHECKS Is display connector P6 connected?

YES

Connect multimeter positive lead to P6-2 (wire #4) and negative lead to P6-1 (wire #1.) Measure the voltage.

Connect P6 connector to display unit.

Battery Volts

0 Volts

Replace the display unit.

Repair or replace open circuit between key switch and P6-2 wire (wire #4) or between P6-1 (wire #1) and battery negative.

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PROBLEM 3 Display does not work: no lift truck operation.

POSSIBLE CAUSES Battery polarity not correct on control panel: key fuse open circuit: key switch defect: logics defect: defective display unit.

CHECKS With battery connected, check control panel battery connections for correct polarity. Positive battery is connected to negative heat sink.

If Correct

If Not Correct

Disconnect battery and check key fuse for continuity.

Continuity Check for continuity from key fuse holder to control panel battery positive connection at the line contactor (wire #3). Also check continuity from key fuse to holder to wire #3 on key switch.

Continuity

No Continuity

Close key switch. Measure voltage on P3-18 and P6-2.

Repair or replace open circuit.

Battery Voltage Check continuity from battery negative to logics P1-21, P2-21, P3-21, P3-20, and display P6-1 (wire #1).

Continuity Replace logics or display unit.

No Continuity

Make correction to cables.

Check for shorts and replace fuse.

Less Than Battery Voltage Replace key switch or repair broken wire #4 between key switch and P62 or key switch and P3-18.

No Continuity Repair or replace open wire.

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PROBLEM 4 Battery Discharge Indicator (BDI) number does not change with a change in battery voltage.

POSSIBLE CAUSES BDI setting is out of adjustment: BDI jumper positioned incorrectly: defective logics.

CHECKS Check BDI jumper for proper positioning: J1 = 36V

J2 = 48V

J3 = 72V

J4 = 80V

Follow BDI adjustment procedure to verify correct BDI settings. (Be sure to cycle key switch between adjustments.) See the topic “Battery Discharge Indicator (BDI) Adjustment” in the Systems Operation section of this manual.

Cannot Adjust to Specifications Replace logics.

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PROBLEM 5 Brush Wear Indicator (BWI) is ON.

POSSIBLE CAUSES Worn brushes on pump and/or drive motor: display unit defect.

CHECKS Check the stored fault code area to determine if the indication is for the pump motor or the drive motor.

b1 - Drive

b2 - Pump

Check drive motor brushes.

Check pump motor brushes.

Look OK Disconnect the drive motor wear indicator (wires #107 and #108) at the motor. Turn the key switch OFF, then ON. Check display for BWI.

Replace display.

Worn to low limit Replace brushes.

Look OK Disconnect the pump motor wear indicator (wires #109 and #110) at the motor. Turn the key switch OFF, then ON. Check display for BWI.

Display OK

BWI Still ON

Display OK

BWI Still ON

Check for short to battery negative inside the motor.

Check for continuity from wires #109 and #110 to battery negative.

Check for short to battery negative inside the motor.

Check for continuity from wires #109 and #110 to battery negative.

Continuity

Repair shorted wire.

No Continuity

Replace display unit.

Neither b1 nor b2

Continuity Repair shorted wire.

Worn to low limit Replace brushes.

No Continuity Replace display unit.

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PROBLEM 6 Overtemperature indicator ON. Truck accelerates slower than normal. Truck goes into bypass. Pump motor speeds 6 and 7 are reduced. E3 stored in fault code area.

POSSIBLE CAUSES Control panel overheated: thermal switch defect: open wiring: logics defect: display unit defect.

CHECKS Open control panel compartment. Allow truck to cool 15 minutes.

Overtemperature Indicator Still ON

Display OK

Check stored fault codes. Verify E3 is present.

Control Panel was overheated. Resume normal operation. If condition repeats, check the following: • Current Limit Calibration

No E3

Check stored fault codes. Verify E3 is present.

Replace display unit.

High

Low

Disconnect the battery. With the control panel at close to room temperature, disconnect the thermal switch connector P8. Check continuity of thermal switch. Should have continuity below 69°C (156°F).

Replace logics.

Continuity Check continuity from P3-3 on the logics board (silver area) to P8-2 (wire #46). Continuity

No Continuity

Check continuity from P8-1 to battery negative Repair or (wire #1). replace wire and/or connector P3. Continuity Repair or replace wire.

No Continuity Verify problem still exists.

No Continuity Replace thermal switch.

• BDI Calibration • Operating Cycle for excessive ramp climbing, towing, or pushing • Brake drag, park brake adjustment • Service Brake interrupt switch operation.

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PROBLEM 7 Overtemperature indicator ON. Truck accelerator slower than normal. Bypass contactor will not close. Pump motor operation normal. E1 stored in fault code area.

POSSIBLE CAUSES Drive motor overheated: drive motor thermal switch defect; open wiring; logics defect; display unit defect.

CHECKS Allow truck to cool 15 minutes.

Overtemperature Indicator Still ON

Display OK

Check stored fault codes. Verify E1 is present.

Drive motor was overheated: resume normal operation. If condition repeats, check the following: • Current limit calibration

No E1

Measure the voltage at P3-1 (wire #76) on the logics board (silver area). Scrape coating off board if needed. Do NOT disconnect from logics.

Replace display unit.

High

Low

Disconnect the battery. With the drive motor at close to room temperature, disconnect the thermal switch connector P8. Check continuity of thermal switch. Should have continuity below 69°C (156°F).

Replace display unit.

Continuity

No Continuity

Disconnect P3 from the display unit. Check continuity from P3-1 to battery negative (wire #1).

Replace thermal switch.

Continuity

No Continuity

Find short to battery negative in the harness. Repair or replace wire.

Verify problem still exists.

• BDI calibration • Operating cycle for excessive ramp climbing, towing, or pushing • Brake drag, park brake adjustment • Service brake interrupt switch operation.

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PROBLEM 8 Overtemperature indicator ON. Lift speed slower than normal. Drive motor operation normal. E2 stored in fault code area.

POSSIBLE CAUSES Pump motor overheated: pump motor thermal switch defect; open wiring; logics defect; display unit defect.

CHECKS Allow truck to cool 15 minutes.

Overtemperature Indicator Still ON

Display OK

Check stored fault codes. Verify E2 is present.

Pump motor was over-heated: resume normal operation. If condition repeats, check the following: • Pump motor brushes

No E2

Measure the voltage at P3-2 (wire #77) on the logics board (silver area). Scrape coating off board if needed. Do NOT disconnect from logics.

Replace display unit.

High

Low

Disconnect the battery. With the pump motor at close to room temperature, disconnect the thermal switch connector P8. Check continuity of thermal switch. Should have continuity below 69°C (156°F).

Replace logics.

No Continuity

Continuity

Disconnect P3 from the display unit. Check continuity from P3-1 to battery negative (wire #1).

Replace thermal switch.

No Continuity

Continuity

Verify problem still exists.

Find short to battery negative in the harness. Repair or replace wire.

• BDI calibration • Attachment pressures • Heavy hydraulic application.

WENB8604-02

PROBLEM 9 Display = “10” : (!) action light flashing: no lift truck operation. Line contactor closes and opens.

POSSIBLE CAUSES Shorted T1D or T2D: Shorted bypass contactor tips: open wiring: failed drive driver board: failed logics. Slow bypass contactor.

CHECKS Disconnect the battery: check bypass contactor for welded or shorted tips. Check contactor for free tip movement.

Tips not shorted

Tips shorted

Disconnect battery: remove logics cover: check continuity of wire #37 at emitter bus bar of power transistor to logics P2-6.

Repair or replace contactor. Check BDI adjustment. Check current limit adjustment. Check bypass dropout current.

Continuity

No Continuity

Check T1D, T2D for failure.

Repair or replace wiring.

Test OK

Failed

Test Drive Driver Board.

Replace failed components.

Test OK

Failed

Replace logics.*

Replace drive driver board.*

* = See NOTICE.

NOTICE: Damage to the control panel could result. To prevent further damage, before T1D, T2D, or the drive driver board are replaced, complete the following checks. 1. Check diode D4D for failure. 2. Check diode D5D for failure.

Field Failure Notes: 1. Field failures indicate that a traction motor shunt field to series field short may also cause this code. 2. Also, slow bypass contactors. 3. Current sensor.

3. Check T1D, T2D for failure. 4. Check drive driver board for failure. 5. Check head capacitors for failure. 6. Check for continuity from emitter bus bar of power transistors (wire #37) to logics P2-6. 7. Check drive motor for shorts, shorts between shunt and series field, shorts to frame, and opens.

WENB8604-02

PROBLEM 10 Display = “11” : (!) action light flashing: no lift truck operation. Line contactor opens and closes.

POSSIBLE CAUSES Faulty wire connections: T1D or T2D failed: current limit set too low: failed D4D or D5D: failed drive driver board: failed logics.

CHECKS Disconnect the following wires. Visually inspect them for burnt or discolored terminals, loose connections, smashed or compressed connectors, corrosion or foreign material. Wire #31 at P2-5. Wire #37 at P2-6 and emitter bus bar of drive power transistors. Wire #31 and #32 at resistor R312. Wire #34 from drive driver board to positive heatsink. Wire #1 from drive driver board to negative heatsink. Wire #42 from logics P3-8 to current sensor. Wire #85 from logics P3-6 to current sensor. Wire #2 from logics P3-7. Repair any defects, then reconnect the wires.

Display = “11”

Display Normal

Check T1D, T2D for failure.

Return truck to operation.

Not Failed

Failed

Perform Rapid Tune-up procedure for current limit and regen potentiometers.

Replace failed transistor.

Display Normal

Display = “11”

Measure voltage at P3-8 (wire #42) with the key switch closed. Recalibrate current limit, regen current adjustments to specifications.*

Voltage = 3.6 tp to 4.0V Check continuity from P3-3 on the logics board (silver area) to P8-2 (wire #46).

Any Other Voltage

Perform steps 1 through 5 of the Current Sensor Tests. All Failed All Not Failed Checks Checks Test drive driver board for a Replace failed OK not OK failure. components. Not Failed Recalibrate Replace Replace logics. Failed current limit and the Replace failed current regen to Replace components. sensor. logics. specifications.* Recalibrate current limit and regen to specifications.*

*NOTICE: Damage to the control panel could result. To prevent further damage, before T1D, T2D, or the drive driver board are replaced, complete the following checks: 1. Check diode D4D for failure. 2. Check diode D5D for failure. 3. Check T1D, T2D for failure. 4. Check drive driver board for failure. 5. Check for continuity from emitter bus bar of power transistors (wire #37) to logics P2-6. 6. Check drive motor for shorts, shorts to frame, and opens.

WENB8604-02

PROBLEM 11 FOR TRUCKS EQUIPPED WITH REGEN. FOR TRUCKS WITHOUT REGEN, SEE PROBLEM 11A. Display = “15” and (!) action light flashing: no lift truck operation: line contactor closes and opens.

POSSIBLE CAUSES Logics not programmed correctly: open circuit on sensing wire between logics pin P2-11 and regen diode D6D (wire #97): regen contact failure: diode D6D failure. Burned contact at A2, contact drops out and picks up after regen closes and arcs. Low battery “ON” without regen.

CHECKS Verify Option #30 is set correctly.

Correct

Not Correct

Verify Option #21 is set correctly.

Set Correctly.

Correct

Not Correct

Check regen contactor for normal operation or welded tips.

Set correctly.

Not Failed Check regen diode D6D for shorted condition.

Not Shorted

Shorted

Replace logics.

Replace regen diode D6D.

Failed Replace regen contactor.

Display = “15”

Display Normal

Replace logics.

Return truck to operation.

Field Notes Other Checks: 1. Check ohms of Regen direction and line contactors (should be 35 to 40 ohm). 2. Check for any wear on direction contactors on armature guide plate. (Replace if wear is found). 3. Check for correct position of wires 68 and 92, they could be reversed. 4. Check for the correct position of wires 101 and 102. 5. Check cable connection at motor S1, S2, A1 and A2. 6. Replace current sensor, if all other tests are OK. 69

WENB8604-02

PROBLEM 11A FOR TRUCKS EQUIPPED WITH REGEN. FOR TRUCKS WITHOUT REGEN, SEE PROBLEM 11. Display = “15” and (!) action light flashing: no lift truck operation: line contactor closes and opens.and closes.

POSSIBLE CAUSES Logics not programmed correctly: P2-11 (wire #97) open or shorted: logics failure.

CHECKS Battery Voltage Verify C set correctly.

Correct

Not Correct

Verify Option #21 is set correctly.

Set Correctly.

Correct

Not Correct

Check continuity and connections on wire #97 between P2-11 and positive heat sink.

Set correctly.

Continuity

No Continuity

Replace logics.

Repair open wiring.

Field Failure Notes: 1. Slow regen contactor operation incorrect ohm coil. 2. Wire 97 stacked incorrectly in between bus bars.

WENB8604-02

PROBLEM 12 Display = “16”: (!) action light flashing: no lift truck operation: line contactor closes and opens.

POSSIBLE CAUSES Logics not programmed correctly: open circuit on sensing wire between logics pin P2-11 and regen diode D6D (wire #97): regen contactor failure: diode D6D failure.

CHECKS Verify Option #30 is set correctly.

Correct

Not Correct

Verify Option #21 is set correctly.

Set Correctly.

Display = “16”

Display Normal

Check continuity and connections on wire #97 between P2-11 and diode D6D anode. Replace wire if no continuity. Repair loose connection if found.

Return truck to operation.

Not Failed

Failed

Check regen diode D6D for shorted condition.

Using Problem 49 as a guide, troubleshoot the regen contactor. Repair as needed.

Not Shorted

Shorted

Replace logics.

Replace regen diode D6D.

WENB8604-02

PROBLEM 13 Display = “18”: (!) action light flashing: no lift truck operation: line contactor opens and closes.

POSSIBLE CAUSES Open wire #96: shorted diode D371: Open T371 transistor: short in drive motor: logics defect.

CHECKS Remove logics connector P2. Inspect P2-2 and P2-1 for corrosion, foreign material, poor crimp or loose contact with logics pin. Also check the following for continuity: Wire #92 from P12-7 to P32-1 to P2-2. Wire #96 from P12-9 to P2-1. Wire #1 from P12-10 to negative HS. Wire #34 from P12-3 to positive HS. Wire #68 from P12-4 to P32-6.

Wires OK

Wires Defective

Check resistance of the drive motor shunt field at wires #68 and #92 at connector P32-1 and P32-6. Measure the diameter of the drive motor, then see the table “Drive and Pump Motor Shunt Field Resistances” in the Specifications section for the correct resistance.

Repair or replace defect.

See the topic Driver Board Tests, Shunt Field Tests.

Tests OK

Low Resistance

Disconnect P32. Check for short from drive SE to A1, A2, S1, S2, and motor.

Replace drive motor.

Short

Check drive driver board (drive shunt field components only.)

Repair motor.

Not Failed

Failed

Replace logics.

Replace drive driver board.

WENB8604-02

PROBLEM 14 Display = “19”: (!) action light flashing: no lift truck operation: line contactor opens and closes.

POSSIBLE CAUSES Logics not programmed correctly: open drive shunt field fuse: poor wire connections: open drive shunt field: shorted T371 transistor: logics defect.

CHECKS Disconnect the following wires. Visually inspect them for burnt or discolored terminals, loose connections, smashed or compressed connectors, corrosion or foreign material. Also check the following: Wire #92 from P12-7 to P32-1 to P2-2. Wire #96 from P12-9 to P2-1. Wire #1 from P12-10 to negative HS. Wire #34 from P12-3 to positive HS. Wire #68 from P12-4 to P32-6.

Display = “19”

Display Normal

Check drive shunt field fuse.

Return truck to operation.

Not Failed

Failed

Check continuity of wire #34 from positive heatsink to logics P2-2, wire #92.

Replace drive shunt field fuse. Verify drive motor shunt field resistance. Measure the diameter of the drive motor, then see the table “Drive and Pump Motor Shunt Field Resistances” in the Specifications section for the correct resistance. Display Normal Display Still “19”

36/48V =12.35 - 13.65 ohms 72/80V = 11.40 - 38.85 ohms

No Continuity

Check drive driver board. (Shunt field components only.)

Repair or replace open Check continuity of wire #34 from positive heatsink to logics P2-2, wire #92. wire or connection. No 36/48V =12.35 - 13.65 ohms Continuity 72/80V = 11.40 - 38.85 ohms

Not Failed

Failed

Replace logics.

Replace drive driver board.

Check drive driver board. (Shunt field components only.) Not Failed

Failed

Replace logics.

Replace drive driver board.

Return truck to operation.

Repair or replace open wire or connection.

WENB8604-02

PROBLEM 15 Display = “20”: (!) action light flashing: no lift truck drive operation.

POSSIBLE CAUSES Current limit potentiometer P1 out of adjustment. Excessive drive motor current due to severe ramps, abuse, or misapplication. Drive Pulsing Stall Timer Option set too short for application. 80% Bypass Option ON (Option #15). Current sensor defects: logics defect.

CHECKS Verify current limit setting. Do problem #16 procedure. Increase value of Option #12 (pulse stall timer). Disable Option #15 if ramp application requires more current than set with P1 current limit potentiometer. (Change setting to “0”).

WENB8604-02

PROBLEM 16 Display = “21”: (!) action light flashing: no lift truck operation. Line contactor closes and opens.

POSSIBLE CAUSES Wiring defect: current sensor defect: logics defect.

CHECKS Disconnect current sensor. Check continuity from P16-1 to P3-7 (wire #2). Check continuity from P16-2 to P3-8 (wire #42). Check continuity from P16-3 to P3-6 (wire #85).

Continuity not OK

Continuity OK Check for short to battery negative (wire #1) in wire #2. Check for short to battery negative (wire #1) in wire #85. Check for short between wire #42 and wire #85.

Repair or replace open wires.

No Shorts

Shorts

With current sensor and logics plugged in and truck powered up, measure the voltage between P3-6 (wire #85) and P3-7 (wire #12). It should measure between 7.15 and 7.5 volts.

Repair Shorts.

Voltage OK

Voltage Not OK

Plug in known good current sensor. Power up truck.

With current sensor and logics plugged in, power up truck. Measure the voltage between P3-8 (wire #42) and P3-7 (wire #2). It should measure between 3.6V and 4.0V.

Truck Powers Up Normally

Display = “21”

With known good current sensor plugged in and logics plugged in, power up truck. Measure the voltage between P3-6 (wire #85) and P3-7 (wire #2). It should measure between 7.15 and 7.5 volts.

Replace logics.

Voltage OK Truck OK, return to operation.

Voltage Not ON Plug in known good sensor. Power up truck.

Voltage OK

Voltage Not ON

Truck Powers Up Normally

Truck OK, return to operation.

Replace logics.

With known good current sensor plugged in and logics plugged in, power up truck. Measure the voltage between P3-6 (wire #85) and P3-7 (wire #2). It should measure between 7.15 and 7.5 volts. Voltage OK Truck OK, return to operation.

Display = “21” Replace logics.

Voltage Not ON Replace logics. 75

WENB8604-02

PROBLEM 17 Display = “24”: (!) action light flashing: no lift truck operation. Line contactor opens and closes.

POSSIBLE CAUSES Wiring defect: drive driver board defect: logics defect.

CHECKS Check continuity between P2-5 and R312 (wire #31). Check continuity between R312 and P12-15 (wire #32). Check continuity between P12-16 and positive HS (wire #34).

Continuity OK

Continuity Not OK

Check wires #31, #32, and #34 for burnt,. crushed, or shorted areas.

Repair or replace open wires.

Wires OK

Wires Not Ok

Measure the resistance of R312. It should be: 36/48V = 34.2-37.80 ohms 72/80V =71.25-78.75 ohms.

Repair or replace wire(s).

Resistance OK

Resistance Not OK

Perform drive driver board tests.

Replace logics.

Test OK

Test Not OK

Replace logics.

Replace drive driver board.

WENB8604-02

PROBLEM 18 Display = “25”: (!) action light flashing: no lift truck operation.

POSSIBLE CAUSES Accelerator control not adjusted or defective: dirt on optical switches: open wiring: logics defect.

CHECKS Check accelerator control adjustment. See the Systems Operation section of this manual.

Adjustment OK

Adjustment Not OK

Disconnect P9 connector. With keyswitch closed, check for battery voltage between P9-A (wire #1) and P9-B (wire #4). (Be sure that the problem is not a defective keyswitch.)

Adjust control to proper specifications.

If Low

Check voltage between P9-C and P9-A.

Repair open wire between P9-A(wire #1) and battery negative or P9-B (wire #4) and battery positive. Check continuity of wire #8 between logics P1-15 and P9-C.

15 Volts Plug accelerator back into P-9 connector. Check voltages at logics P1-15 as follows: Accelerator Pedal Position Fully UP Fully depressed

Voltage 1.2 to 12.5 volts 1.6 to 2.0 volts

Voltage should decrease from max to min as pedal is depressed.

Not 15 Volts Check continuity of wire #8 between logics P1-15 and P9-C.

Continuity OK

Continuity Not OK

Check for short to battery negative (wire #1) in wire #8.

Repair or replace broken wire.

No Short

Short

Replace logics.

Repair or replace shorted wire.

Voltage Voltage OK readings OK but problem persists Replace accelerator Replace control. logics.

WENB8604-02

PROBLEM 19 Display = “26”: (!) action light flashing: no lift truck operation.

POSSIBLE CAUSES Accelerator control not adjusted or defective: dirt on optical switches: open wiring: logics defect.

CHECKS Check accelerator control adjustment. See the Systems Operation section of this manual.

Adjustment OK

Adjustment Not OK

Disconnect P9 connector. With keyswitch closed, check for battery voltage between P9-A (wire #1) and P9-B (wire #4). (Be sure that the problem is not a defective keyswitch.)

Adjust control to proper specifications.

If Low

Check voltage between P9-C and P9-A.

Repair open wire between P9-A(wire #1) and battery negative or P9-B (wire #4) and battery positive.

15 Volts

Not 15 Volts

Plug accelerator back into P-9 connector. Check voltages at logics P1-15 as follows:

Check continuity of wire #8 between logics P1-15 and P9-C.

Accelerator Pedal Position Fully UP Fully depressed

Voltage 1.2 to 12.5 volts

Continuity OK Check for short to battery negative (wire #1) in wire #8.

1.6 to 2.0 volts

No Short

Voltage should decrease from max to min as pedal is depressed.

Replace logics.

Voltage readings Not OK

Voltage OK but problem persists

Replace accelerator control.

Replace logics.

Short Repair or replace shorted wire.

Continuity Not OK Repair or replace broken wire.

WENB8604-02

PROBLEM 20 Display = “29”: (!) action light flashing: no lift truck operation. Line contactor closes and opens.

POSSIBLE CAUSES Logics not programmed correctly: open circuit/short circuit in wire #115 and #116 connecting speed sensor to logic: faulty speed sensor: faulty logics.

CHECKS Measure the resistance of the speed sensor. It should be 2.3kΩ +/- 0.2 kΩ.

Resistance OK

Resistance Not OK

Check wires #115 and #116 for opens or shorts between speed sensor connector P52 and logics connector P1.

Adjust control to proper specifications.

Wires OK

Wires Not OK

Using the AC Volts setting on the volt-ohmmeter, measure the voltage between P1-18 and P1-19. This voltage should increase as the wheels turn faster and decrease as the wheels turn slower.

Replace speed sensor.

Voltage OK

Voltage Not OK

Replace accelerator control.

Replace speed sensor.

Field Notes Other Checks: 1. If Code 29, 15 and/or 16 are found together in history, then check regen and line contactors. 2. Check ohms of Regen direction and line contactors (should be 35 to 40 ohm). 3. Check for any wear on direction contactors on armature guide plate. (Replace if wear is found). 4. Check for correct position of wires 68 and 92, they could be reversed. 5. Check for the correct position of wires 101 and 102. 6. Check cable connection at motor S1, S2, A1 and A2. 7. Current sensor can check good and still code 29. 8. Replace current sensor, if all other tests are OK. Current sensor can still check good and still code 29. 9. Loose connection on directional contactors.

WENB8604-02

PROBLEM 21 Display = “30”: (!) action light flashing: no lift truck operation. Line contactor closes and opens.

POSSIBLE CAUSES Shorted T1P or T2P: open wiring: failed pump driver board: failed logics: open circuit in pump motor PA1, PS2 cables: welded pump contactor tips.

CHECKS Disconnect the battery: check pump motor contactor for welded or shorted tips. Check contactor for free tip movement.

Tips Not Shorted

Tips Shorted

Connect battery: close the seat key switches.

Repair or replace contact. Check BDI adjustment.

Line contactor closes then opens. Pump Line contactor closes then opens. Pump motor does not turn. Display = “30”. motor turns a small amount. Display = “30”. Disconnect battery: remove logics cover: check continuity or wire #45 at emitter connector of T2P to logics P2-10.

No Continuity

Continuity

Replace logics.

Check continuity from PA1 to PS2 at panel.

Continuity Replace logics.

No Continuity Check motor and cables and repair.

Check T1P, T2P for a short circuit.

No Shorts

Shorts

Test pump driver board.

Replace failed components.*

Test OK

Test Failed

Replace logics.

Replace pump driver board.

*NOTICE: Damage to the control panel could result. To prevent further damage, before T1P, T2P, or the drive driver board are replaced, complete the following checks: 1. Check diode D4D for a failure. 2. Check diode D5D for a failure. 3. Check T1P, T2P for a failure. 4. Check pump driver board for a failure. 5. Check head capacitors for a failure. 6. Check for continuity from T2P emitter (wire #45) to logics P2-10.

WENB8604-02

PROBLEM 22 Display = “31”: (!) action light flashing: no lift truck operation. Line contactor closes and opens.

POSSIBLE CAUSES Faulty wire connections: D4P or T1P and T2P failed: failed pump driver board failed logics.

CHECKS Disconnect the following wires. Visually inspect them for burnt or discolored terminals, loose connections, smashed or compressed connectors, corrosion or foreign material. Also check: Wire #45 from emitter of transistor T1P and T2P to P4-7 and P2-10. Wire #34 from pump driver board to positive heatsink. Wire #1 from pump driver board to negative heatsink. Wire #229 from pump shunt (+) to P2-18. Wire #29 from pump shunt (-) to P2-19. Repair any defects then reconnect the wires.

Display = “31”

Display Normal

Check diode D4P for a failure.

Return truck to operation.

Not Failed

Failed

Check transistors T1P, T2P for a failure.

Replace failed diode*.

Not Failed

Failed

Check pump driver board.

Replace transistor.*

Not Failed

Failed

Replace logics.

Replace pump driver board.

*NOTICE: Damage to the control panel could result. To prevent further damage, before T1P, T2P, or the drive driver board are replaced, complete the following checks: 1. Check diode D4P for a failure. 2. Check head capacitors for a failure. 3. Check T1P, T2P for a failure. 4. Check pump driver board for a failure. 5. Check for continuity from emitter bus bar of power transistors (wire #45) to logics P2-10.

WENB8604-02

PROBLEM 23 Display = “32”: (!) action light flashing: no lift truck operation. Line contactor closes and opens.

POSSIBLE CAUSES Faulty wire connections: D4P or T1P and T2P failed: failed pump driver board failed logics.

CHECKS Disconnect the following wires. Visually inspect them for burnt or discolored terminals, loose connections, smashed or compressed connectors, corrosion or foreign material. Also check: Wire #45 from emitter of transistor T1P and T2P to P4-7 and P2-10. Wire #34 from pump driver board to positive heatsink. Wire #1 from pump driver board to negative heatsink. Wire #119 from pump shunt (+) to P2-18. Wire #29 from pump shunt (-) to P2-19. Repair any defects then reconnect the wires.

Display = “32”

Display Normal

Check diode D4P for a failure.

Return truck to operation.

Not Failed

Failed

Check transistors T1P, T2P for a failure.

Replace failed diode.*

Not Failed

Failed

Check pump driver board.

Replace transistor.*

Not Failed

Failed

Replace logics.

Replace pump driver board.

*NOTICE: Damage to the control panel could result. To prevent further damage, before T1P, T2P, or the drive driver board are replaced, complete the following checks: 1. Check diode D4P for a failure. 2. Check head capacitors for a failure. 3. Check T1P, T2P for a failure. 4. Check pump driver board for a failure. 5. Check for continuity from emitter bus bar of power transistors (wire #45) to logics P2-10.

WENB8604-02

PROBLEM 24 Display = “33”: (!) action light flashing: no lift truck operation: line contactor closes and opens.

POSSIBLE CAUSES Failure in pump circuit.

CHECKS See problems 22 and 23, Display = “31” and “32”. Do both procedures.

WENB8604-02

PROBLEM 25 Display = “38”: (!) action light flashing: no lift truck operation. Line contactor closes and opens.

POSSIBLE CAUSES Open wire #72: shorted diode D351: open transistor T351: shorted shunt field: failed logics.

CHECKS Remove logics connector P2. Inspect P2-4 and P2-3 for corrosion, foreign material, poor crimp or loose contacts with logics pin. Also check the following: Wire #72 from P12-8 to P2-3. Wire #71 from P12-6 to P32-2 to P2-4. Wire #1 from P12-10 to positive HS. Wire #69 from P12-2 to P32-5.

Wires OK

Not OK

Check resistance of pump motor shunt field at wires #69 and #71. Measure the diameter of the pump motor, then see the table “Drive and Pump Motor Shunt Field Resistances” in the Specifications section of this manual for the correct resistances.

Repair or replace defect.

Resistance OK

Low Resistance

Check pump driver board. (Shunt field components only.)

Repair or replace pump motor.

Not Failed

Failed

Replace logics.

Replace pump driver board.

WENB8604-02

PROBLEM 26 Display = “39”: (!) action light flashing: no lift truck operation.

POSSIBLE CAUSES Open shunt field fuse: poor wire connections: open shunt field: shorted transistor T351: failed logics.

CHECKS Disconnect the following wires. Visually inspect them for burnt or discolored terminals, loose connections, smashed or compressed connectors, corrosion or foreign material. Wire #72 from P12-8 to P2-3. Wire #71 from P12-6 to P32-2 to P2-4. Wire #1 from P12-10 to negative HS. Wire #34 from P12-1 to positive HS. Wire #69 from P12-2 to P32-5. Repair any defects, then reconnect the wires.

Display = “39”

Display Normal

Check drive shunt field fuse.

Return truck to operation.

Not Failed

Failed

Check continuity of wire #34 from positive heatsink to logics P2-4, (wire #71).

Replace shunt field fuse. Verify pump shunt field resistance. Measure the diameter of the pump motor, then see the table “Drive and Pump Motor Shunt Field Resistances” in the Specifications section for the correct resistance.

7 to 10 ohms Check pump driver board (shunt field components only.)

Not Failed Replace logics.

No Continuity

Display Normal Display Still “39” Repair or Return truck to replace open Check continuity of wire #34 from positive operation. heatsink to logics P2-4, (wire #71). wire or connection. No 7 to 10 ohms Failed Continuity Check pump driver board Replace Repair or pump driver (shunt field replace open board. components only.) wire or connection. Not Failed

Failed

Replace logics.

Replace pump driver board.

WENB8604-02

PROBLEM 27 Display = “40”: (!) action light flashing: no lift truck operation. Line contactor closes then opens.

POSSIBLE CAUSES Excessive pump current: pump shunt defect: wiring defect: pump/pump motor defect: failed logics.

CHECKS Check continuity between P2-18 and pump shunt. (Wire #119, side closest to negative heatsink.) Check continuity between P2-19 and pump shunt. (Wire #29, side attached to standoff.)

Continuity OK

Continuity Not OK

Check wire #29 for burnt, smashed, cut or shorted areas.

Repair or replace open wires.

Wires OK

Wires Not OK

Check pump shunt connections to make sure they are tight and there is no corrosion between the terminals for wire #29 or #119 and the shunt.

Repair or replace defective wires.

Tight

Not Tight

Attach clamp-on ammeter to PS2 cable. Power up truck and check current. In steer idle, current should be less than 50A.

Tighten bolts.

Current OK

Current High

Replace logics.

Correct pump/motor pump problem. Pump could be binding. Cables running to pump motor could be connected incorrectly. Pump motor could be defective.

WENB8604-02

PROBLEM 28 Display = “41”: (!) action light flashing: no lift truck operation. Line contactor closes then opens.

POSSIBLE CAUSES Pump shunt defect: wiring defect: pump/pump motor defect: failed logics.

CHECKS Check continuity between P2-18 and pump shunt. (Wire #119, side closest to negative heatsink.) Check continuity between P2-19 and pump shunt. (Wire #29, side attached to standoff.) Wire #119 and #29 are reversed. (Wire #29 is on heat sink.)

Continuity OK

Continuity Not OK

Check wires #29 and #119 for burnt, smashed, cut or shorted areas.

Repair or replace open wires.

Wires OK

Wires Not OK

Check pump shunt connections to make sure they are tight and there is no corrosion between the terminals for wire #29 or #119 and the shunt. Scrape coating off board if needed. Do NOT disconnect from logics.

Repair or replace defective wires.

WENB8604-02

PROBLEM 29 Display = “44”: (!) action light flashing: no lift truck operation. Line contactor closes then opens.

POSSIBLE CAUSES Wiring defect: pump driver board defect: failed logics.

CHECKS Check continuity between P2-7 and P4-1 (wire #79). Check continuity between P2-8 and P4-2 (wire #117). Check continuity between P2-9 and P4-4 (wire #118). Check continuity between P4-5 and Positive HS (wire #34).

Continuity OK

Continuity Not OK

Check wires #79, #117, #118, and #34 for burnt, smashed, cut or shorted areas.

Repair or replace open wires.

Wires OK

Wires Not OK

Perform pump driver board tests. See the topic, “Pump Driver Board Tests” in this section of the manual.

Repair or replace defective wires.

Pump Driver Board OK

Pump Driver Board Not OK

Replace logics.

Replace pump driver board.

* Typical Amps at steer idle 15 - 50 and 250 at steer lock.

WENB8604-02

PROBLEM 30 Display = “50”: (!) action light flashing: no lift truck operation. Line contactor closes then opens.

POSSIBLE CAUSES Bypass contactor tips and pump contactor shorted. Shorted T1D, T2D, T1P, T2P, and T3D: poor connection at logics connector: defective drive and/or pump driver boards.

CHECKS See problems 9 and 21, Display = “10” and Display = “30”. Perform both procedures.

WENB8604-02

PROBLEM 31 Display = “51”: (!) action light flashing: no lift truck operation. Line contactor closes then opens.

POSSIBLE CAUSES Blown line fuse: failed logics: faulty wiring.

CHECKS See problems 10, 22, and 23 (Display = “11”, Display = “31”, Display = “32”, and Display = “33”). Perform all four procedures.

WENB8604-02

PROBLEM 32 Display = “60”: (!) action light flashing: no lift truck operation. Line contactor closes then opens.

POSSIBLE CAUSES Serial communications fault between display and logics.

CHECKS Check the following wires for continuity. Also visually inspect their connections for burnt or discolored terminals, loose connections, smashed or compressed connectors, corrosion or foreign materials. P3-4 to P6-4 (wire #12). P3-5 to P6-3 (wire #16). P6-2 to key switch (wire #4). P6-1 to battery negative (wire #1). P3-18 to key switch (wire #4). P3-20, P3-21, P1-21 to battery negative (wire #1).

Checks OK

Checks Not OK

Check for short to battery negative (wire #1) in the following wires: Wire #12. Wire #16. Wire #4.

Repair or replace open wires.

Checks OK

Checks Not OK

Connect a spare display unit to harness plug P6 and turn the key switch on.

Fix shorts.

Spare Display Functions Properly

Display = “60”

Replace display.

Replace logics.

WENB8604-02

PROBLEM 33 Display = “61”: (!) action light flashing: no lift truck operation. Line contactor closes then opens.

POSSIBLE CAUSES Internal EEPROM memory error in microprocessor or logics.

CHECKS Replace logics.

WENB8604-02

PROBLEM 34 Display = “65”: (!) action light flashing: no lift truck operation. Line contactor never closes.

POSSIBLE CAUSES Truck size not initialized.

CHECKS Enter setup mode and access Option #30, Truck Size and Type (see the topic “Setup Options” in the Systems Operation section of this manual). Set the value of the option according to the size of your cushion truck. All service replacement logics boards are shipped with Option #30 set to “0.00”. You must always enter setup mode and set the value according to the size of your cushion truck. Remember, Option #30 will not be programmed to new values until the DRS switch is moved to the RUN position while in the SETUP mode. This will cause the “triple bar” display to show up, indicating successful programming of the new truck size and type. Exit Setup mode and power up the truck in Run mode. If the display still reads “65”, replace logics.

WENB8604-02

PROBLEM 35 Display = “66”: (!) action light flashing: no lift truck operation.

POSSIBLE CAUSES Internal microprocessor “Watchdog” timer failure.

CHECKS Replace logics.

WENB8604-02

PROBLEM 36 Display = “68” or “69”: (!) action light flashing: no lift truck operation. Line contactor closes and opens.

POSSIBLE CAUSES 68: Battery volts too low for chosen jumper. 69: Battery volts too high for chosen jumper. Short between connector P5-16 and P6-1

CHECKS Check the following wires for continuity. Also visually inspect their connections for burnt or discolored terminals, loose connections, smashed or compressed connectors, corrosion or foreign materials. P3-4 to P6-4 (wire #12) P3-5 to P6-3 (wire #16) P6-2 to key switch (wire #4) P6-1 to battery negative (wire #1) P3-18 to key switch (wire #4) P3-20, P3-21, P1-21 to battery negative (wire #1).

Checks OK

Checks Not OK

Check for short to battery negative (wire #1) in the following wires: Wire #12. Wire #16. Wire #4.

Repair or replace open wires.

Checks OK

Checks Not OK

Connect a spare display unit to harness plug P6 and turn the key switch on.

Fix shorts.

Spare Display Functions Properly

Display = “60”

Replace display.

Replace logics.

Field Notes Also Check: 1. Open line Contactor Coil.

WENB8604-02

PROBLEM 37 Seat switch or circuit defect.

POSSIBLE CAUSES Seat switch defect: wiring to seat defect: logics defect.

CHECKS Measure the voltage at logics P1-13 (wire #7, silver area) with weight on and off seat. Scrape coating off card pins if needed. Voltage measured should be: High with weight off the seat. Low with weight on the seat.

Voltage OK

Voltage Not OK

Disconnect seat switch and check the continuity with weight on and off the seat. Resistance should be: Less than 50 ohms with weight on the seat. OL (infinite) with weight off the seat.

Not OK

Check continuity from P1-13 to seat switch (wire #7). Check continuity from seat switch to battery negative (wire #1).

Replace seat switch.

Not OK

Check for short to battery negative (wire #1) in wire #7. Correct short.

Correct any open wires.

Verify problem still exists. If it does, replace logics.

WENB8604-02

PROBLEM 38 Direction switch circuit defect.

POSSIBLE CAUSES Direction switch defect: wiring to direction seat defect: logics defect.

CHECKS Measure the voltage on logic card (silver area) at P1-10 (wire #14) and P1-9 (wire #15.) Scrape coating off pins if needed. Use the following chart to determine proper voltages. Logics Pin

FWD

REV

Neutral

P1-10

Low

High

P1-9

High

Low

High

Voltage Not OK

Voltage OK

Disconnect direction switch and check switch for proper continuity.

Lever Position

FWD (wire #14) to BAT (wire#1)

REV (wire #15) to BAT (wire #1)

FWD

<50 ohms

OL (infinite)

Neutral

OL (infinite)

REV

OL (infinite)

<50 ohms

Verify problem still exists. If it does, replace logics.

Check OK

Check Not OK

Check continuity from logics P1-10 (wire #14) and P1-9 (wire #15) to direction switch.

Replace seat switch.

Not OK

Check for short to battery negative (wire #1) in wire #14 or #15. Correct short.

Correct any open wires.

WENB8604-02

PROBLEM 39 Foot-operated direction switch circuit defect.

POSSIBLE CAUSES Direction switch defect: wiring to direction seat defect: service brake interrupt switch defect: logics defect.

CHECKS Measure the voltage on logic card (silver area) at P1-10 (Wire #14) and P1-9 (wire #15). Scrape coating off card pins if needed. Use the following chart to determine proper voltages. Logics Pin

FWD

REV

Neutral

P1-10

Low

High

P1-9

High

Low

High

Voltage Not OK

Voltage OK

Disconnect direction switch and check switch for proper continuity.

Lever Position

FWD (wire #14) to BAT (wire#1)

REV (wire #15) to BAT (wire #1)

FWD

<50 ohms

OL (infinite)

Neutral

OL (infinite)

REV

OL (infinite)

<50 ohms

Check Not OK

Check OK Check continuity from P1-10 to P61-2 (wire #14). Check continuity from P1-9 to P61-3 (wire #15). Check continuity from P61-1 to battery negative (wire #1). OK

Not OK

Check for short to battery negative (wire #1) in wire #14 or #15. Correct short.

Correct any open wires.

Verify problem still exists. If it does, replace logics.

Replace direction switch.

WENB8604-02

PROBLEM 40 Park brake switch circuit defect.

POSSIBLE CAUSES Park brake switch defect: wiring defect: logics defect.

CHECKS Check park brake switch adjustment to make sure park brake switch is activated by park brake lever.

Adjustment OK

Adjustment Not OK

Measure the voltage at logics P1-11 (wire #91) with park brake applied and released. Scrape coating off pin card if needed. Voltage should be: High—Brake applied. Low—Park brake released.

Voltage Not OK

Voltage OK

Disconnect park brake switch and check continuity with park brake applied and released.

Verify problem still exists. If it does, replace logics.

Adjust lever to make proper engagement with switch.

Resistance should be: <50 ohms with park brake applied. OL (infinite) with park brake released.

Not OK

Check for continuity from park brake switch to P1-11 (wire #91).

Replace park brake switch.

Check for continuity from park brake switch to battery negative (wire #1).

Checks OK

Checks Not OK

Check for short to battery negative (wire #1) in wire #91. Repair short.

Correct open wire.

WENB8604-02

PROBLEM 41 Service brake switch circuit defect.

POSSIBLE CAUSES Service brake switch defect: wiring defect: logics defect.

CHECKS Check service brake switch adjustment to make sure service brake switch is activated by service brake lever.

Adjustment OK

Adjustment Not OK

Measure the voltage at logics P1-12 (wire #113) with service brake applied and released. Scrape coating off card pins if needed. Voltage should be: High—Service brake applied. Low—Service brake released.

Voltage OK

Voltage Not OK Disconnect service brake switch and check continuity with service brake applied and released. Resistance should be: <50 ohms—Service brake applied. OL (infinite)—Service brake released.

Not OK

Check for continuity from service brake switch to P40-C to P1-12 (wire #113). Check for continuity from service brake switch P40-A to battery negative (wire #1).

Checks OK

Checks Not OK

Check for short to battery negative (wire #1) in wire #113. Repair short.

Correct open wire.

100

Replace service brake switch.

Verify problem still exists. If it does, replace logics.

Adjust pedal to make proper engagement with switch.

WENB8604-02

PROBLEM 42 Accelerator switch circuit defect.

POSSIBLE CAUSES Accelerator control not adjusted or defective: dirt on optical switches: open wiring: logics defect.

CHECKS Check accelerator control adjustment. See the Systems Operation section of this manual.

Adjustment OK

Adjustment Not OK

Disconnect P9 connector. With keyswitch closed, check for battery voltage between P9-A (wire #1) and P9-B (wire #4). (Be sure that the problem is not a defective keyswitch.)

Adjust control to the proper specifications.

If Low

Check voltage between P9-C and P9-A.

Repair open wire between P9-A (wire #1) and battery negative or P9B (wire #4) and battery positive.

15 Volts

Not 15 Volts

Plug accelerator back into P9 connector. Check voltages at logics P1-15 as follows:

Check continuity of wire #8 between logics P1-15 and P9-C.

Accelerator Control Pedal Position

Voltage

Fully UP

12 to 12.5 volts

Fully depressed

1.6 to 2.0 volts

Continuity OK Check for short to battery negative (wire #1 in wire #8).

Voltage should decrease from max to min as pedal is depressed. Voltage Readings Not Ok

Voltage Ok But Problem Persists

Replace accelerator control.

Replace logics.

No Short

Short

Replace logics.

Repair or replace shorted wire.

Continuity Not OK Repair or replace broken wire.

101

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PROBLEM 43 Battery Discharge Indicator (BDI) display shows no bars. Drive may be slow: power steering is normal. No hydraulics (lift or tilt). BDI circuit defect.

POSSIBLE CAUSES Option #16 (BDI Reset value) set too high: battery discharged or defective: logics defect: J1, J2, J3, or J4 jumper missing or in wrong position: BDI needs adjustment.

CHECKS Verify that the value of Setup Option #16 is as expected. Typical value is 6.

Value OK

Value Set Too High

Connect battery, turn on key switch, close seat switch, and measure voltage from line contactor to negative heatsink. Voltage readings should be:

Reset Value.

36V Battery—greater than 34.8V 48V Battery— greater than 46.4V 72V Battery—greater than 69.6V 80V Battery—greater than 77.3V

Voltage OK

Voltage Low

Make sure jumper connector in the logics is in the correct position for the battery used. (J1=36V, J2=48V, J3=72V, J4=80V).

Verify problem still exists. If it does, replace logics.

Jumper Position Correct

Not Correct

With key on, seat switch and line contact closed, measure voltage at logics P3-18.

Move jumper to correct position and recycle key switch.

Battery Voltage Adjust BDI to specifications. The key must be turned off between each adjustment of P5*. If BDI will not adjust, replace logics.

Less than Battery Voltage Repair shorted wire or high resistance connection causing the improper voltage.

*NOTE: Display will show no bars until BDI is adjusted far enough to change the display to a six-bar reading.

102

WENB8604-02

PROBLEM 44 Lift switch 1 and 2 circuit defects.

POSSIBLE CAUSES Lift switch 1 and 2 not adjusted properly or defective: wiring defect: logics defect.

CHECKS Check mechanical linkage for proper operation. Switch 1 should “click” in before switch 2.

Linkage OK

Linkage Not OK

Measure the voltage on logics card (silver area) at P1-1 and P1-2. Scrape coating off card pins if needed. Use the following chart to determine proper voltages:

Adjust linkage.

Logics Pin

Lift Lever Fully FWD

Lift Lever Fully BACK

Lift Lever 1/2 BACK

Lift Lever NEUTRAL

P1-1

High

Low

High

P1-2

High

Low

High

Voltage NOT OK

Voltages OK

Disconnect switches and check continuity with lever in neutral position and pulled fully back. Resistance for these switches should be: Neutral—OL (infinite) Fully Back—<50 ohms. CHECK OK

Verify problem still exists. If it does, replace logics.

NOT OK

Check continuity between P13-5 to P1-1 (wire #13). Check continuity between P13-6 to P1-2 (wire #81).

Replace defective switches.

Check continuity between P13-1 to battery negative (wire #1). Checks OK Check for short to battery negative (wire #1) in wire #13. Check for short to battery negative (wire #1) in wire #81.

Checks Not OK Repair or replace open wire.

Repair shorts.

103

WENB8604-02

PROBLEM 45 Tilt switch circuit defects.

POSSIBLE CAUSES Tilt switch not adjusted properly or defective: wiring defect: logics defect.

CHECKS Check mechanical linkage for proper operation. Switch should “click” when depressed.

Linkage OK

Linkage Not OK

Measure the voltage on logics card (silver area) at P1-13. Scrape coating off card pins if needed. Use the following chart to determine proper voltages:

Adjust linkage.

Logics Pin

Lift Lever Fully FWD

Lift Lever Fully BACK

Lift Lever NEUTRAL

P1-3

Low

High

Voltage NOT OK

Voltages OK

Disconnect switches and check continuity with lever fully forward, in neutral position and pulled fully back. Resistance for these switches should be:

Verify problem still exists. If it does, replace logics.

Fully FWD—<50 ohms Neutral—OL (infinite) Fully Back—<50 ohms.

CHECK OK

NOT OK

Check continuity between P13-2 to P1-3 (wire #89). Check continuity between P13-2 to battery negative (wire #1).

Checks OK Check for short to battery negative (wire #1) in wire #89. Repair shorts.

104

Checks Not OK Repair or replace open wire.

Replace defective switches.

WENB8604-02

PROBLEM 46 Aux 1 switch circuit defect.

POSSIBLE CAUSES Aux 1 switch not properly adjusted or defective: wiring defect: logics defect.

CHECKS Check mechanical linkage for proper operation. Switch should “click” when depressed.

Linkage OK

Linkage Not OK

Measure the voltage on logics card (silver area) at P1-4. Scrape coating off card pins if needed. Use the following chart to determine proper voltages:

Adjust linkage.

Logics Pin

Aux 1 Fully FWD

Aux 1 Lever Fully BACK

Aux 1 Lever NEUTRAL

P1-4

Low

High

Voltage NOT OK

Voltages OK

Disconnect switches and check continuity with lever fully forward, in neutral position and pulled fully back. Resistance should be:

Verify problem still exists. If it does, replace logics.

Fully FWD—<50 ohms Neutral—OL (infinite) Fully Back—<50 ohms. CHECK OK

NOT OK

Check continuity between P13-3 to P1-4 (wire #88). Check continuity between P13-3 to battery negative (wire #1).

Checks OK Check for short to battery negative (wire #1) in wire #88. Repair shorts.

Replace defective switches.

Checks Not OK Repair or replace open wire.

105

WENB8604-02

PROBLEM 47 Aux 2 switch circuit defect.

POSSIBLE CAUSES Aux 2 switch not properly adjusted or defective: wiring defect: logics defect.

CHECKS Check mechanical linkage for proper operation. Switch should “click” when depressed.

Adjustment OK

Adjustment Not OK

Measure the voltage on logics card (silver area) at P1-5. Scrape coating off card pins if needed. Use the following chart to determine proper voltages:

Adjust lever to make proper engagement with switch.

Logics Pin

Aux 2 Fully FWD

Aux 2 Lever Fully BACK

Aux 2 Lever NEUTRAL

P1-5

Low

High

Voltage NOT OK

Voltages OK

Disconnect switches and check continuity with lever fully forward, in neutral position and pulled fully back. Resistance should be:

Verify problem still exists. If it does, replace logics.

Fully FWD—<50 ohms Neutral—OL (infinite) Fully Back—<50 ohms. CHECK OK

NOT OK

Check continuity between P13-4 to P1-5 (wire #87). Check continuity between P13-4 to battery negative (wire #1).

Checks OK Check for short to battery negative (wire #1) in wire #87. Repair short.

106

Checks Not OK Repair or replace open wire.

Replace park brake switch.

WENB8604-02

PROBLEM 48 Hydraulic speed check. (Hydraulic Speed less than desired.)

POSSIBLE CAUSES Speed options set to incorrect value for Lift, Tilt, or Aux in programmable Setup Options.

CHECKS Enter Setup Mode and access Option #2 (First Group) Lift 1 Speed. (See the topic “Setup Options” in the Systems Operation section of this manual). Set the option to the correct value. Exit Setup Mode and power up the truck in RUN mode. Check lift speed. Repeat procedure if lift speed still needs adjustment. Remember, Option #2 will not be programmed to new values until the DRS switch is moved to the RUN position while in SETUP mode. This will cause the “Triple Bar” display to show up, indicating successful programming of the new truck size and type. Repeat the procedure if necessary for other hydraulic functions: Option 3 – Lift 2 Option 4 – Tilt Speed Option 5 – Aux 1 Speed Option 6 – Aux 2 Speed.

107

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PROBLEM 49 Incorrect contactor operation.

POSSIBLE CAUSES Wiring defect: contactor defect: logics defect.

CHECKS During the self-diagnostic test, which of the following occurs?

Contactor does not pull in or does not remain pulled in. Disconnect the battery. Check for free mechanical movement of contactor bridge (tips).

Movement OK

Movement Not Free

Remove logics cover. Disconnect P3. Check continuity from P3-16 (wire #38) to coil X terminal of the contactor with correct operation.

Repair or replace contactor.

Continuity Measure continuity from the appropriate P3 socket to the coil terminal Y of the contactor that has incorrect operation. Determine the P3 socket with respect to the contactor that has incorrect operation as follows: Line . . . . . . . . . . . . . . .P3-9, wire #26 Pump Bypass . . . . . . .P3-10, wire #30 Drive Bypass . . . . . . . .P3-11, wire #35 Reverse Direction . . . .P3-13, wire #19 Forward Direction . . . .P3-12, wire #20 Regen . . . . . . . . . . . . .P3-14, wire #75. Continuity

No Continuity

Perform contactor tests. (Coil Resistance, Coil Suppression, Coil Pulsing).

Repair or replace wire.

Tests OK

Tests Not OK

Connect P3 and run “Self” diagnostics again. If contactor does not close, replace logics.

Repair or replace contactor.

108

No Continuity Replace display unit.

Contactor remains in whenever the key switch is closed through all tests. See OTHER PROBLEMS list, “Any contactor closes when key switch is closed.”

WENB8604-02

PROBLEM 50 Any contactor closes when key switch is closed.

POSSIBLE CAUSES Wiring defects: failed logics.

CHECKS Connect the battery. Does the line contactor close when the key switch is closed?

Yes Check stored fault codes. Verify E1 is present.

No See the SELF DIAGNOSTICS PROBLEMS list; “Seat Switch circuit defect.”

Yes Which contactor closed? Disconnect the battery. Remove logics cover and disconnect logics P3 connector. Check for a short circuit from control panel battery negative (negative heat sink) to P3 harness connector socket. Determine the P3 socket with respect to the contactor that closed as follows: Line . . . . . . . . . . . . . . .P3-9 Pump Bypass . . . . . . .P3-10 Drive Bypass . . . . . . . .P3-11 Reverse Direction . . . .P3-13 Forward Direction . . . .P3-12 Regen . . . . . . . . . . . . .P3-14.

Continuity

No Continuity

Repair or replace shorted wire.

Replace logics.

109

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PROBLEM 51 Drive motor does not operate or operates with low power or is erratic. Pump and power steering systems operation normal.

POSSIBLE CAUSES Accelerator control defective: drive driver board defective: current limit set too low: wiring defect: failed logics.

CHECKS Perform self-diagnostics.

Passed

Failed

Turn current limit potentiometer P1 clockwise and check operation.

See respective PROBLEM for defective circuit.

Wheels Don’t Spin

Wheels Spin

Check R312 for correct resistance.

Adjust current limit to specification.

36/48V = 34.20 - 37.80 ohms 72/80V = 71.25 - 78.75 ohms

In Specification Check wires #31 and #32 for a good connection on R312. Check wires #36 to base of transistors T1D and T2D. Check continuity of wire #37 from emitter T2D to logics P2-6.

All OK

Defective

Check diodes D5D and D4D for shorts or open circuits.

Repair or replace.

Diodes OK

Defective

Check drive motor for open circuit. Check current shunt and wiring for continuity. Check drive driver board for defects.

Replace defective diode.

Checks OK

Defective

Replace logics.

Replace drive driver board.

Not in Specification Replace resistor R312.

*NOTE: Reset current limit to specifications after repairs are complete.

110

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PROBLEM 52 Poor acceleration: loss of power on ramps.

POSSIBLE CAUSES Current limit out of adjustment: cables or connections to motor defective: T1D and T2D degenerative or defective: motor defective: failed logics.

CHECKS Verify the value of Setup Option #8 (Variable Acceleration) is set high enough.

Value OK

Value Too Low

Verify value of Setup Option #15 (80% Bypass).

Value = 1 (ON)

Value = 0 (OFF)

Reset to 0 (off). By setting this option to 0, you are removing a feature that helps protect the drive motor from abuse. This may be necessary in some applications that have steep ramps. However, use caution when turning off this option, as increased motor drive failures may occur.

Make sure the truck passes all self-diagnostic tests. Passes SelfDiagnostics

Reset to higher value.

Fails Self-Diagnostics Replace failed circuit.

Check the current limit setting of the drive motor.

If Correct

If Not Correct

Check motor and cables for poor connections.

Adjust current limit to specifications.

Connections Good Check drive motor for defect or mechanical drag of drive train.

Connections Loose

Cannot Adjust

Repair or tighten loose connections.

See Problem 54.

111

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PROBLEM 53 Lift truck has long electrical braking distance or sudden (jerk) stop at end of electrical braking cycle. Pump system operation normal.

POSSIBLE CAUSES Wire #51 defective: current limit set too low: electrical braking diode D5D defective: current sensor defective: electrical braking current not adjusted properly.

CHECKS Disconnect current sensor. Check continuity from P16-1 to P3-7 (wire #2). Check continuity from P16-2 to P3-8 (wire #42). Check continuity from P16-3 to P3-6 (wire #85).

Continuity OK

Continuity Not OK

Set current limit. Adjust potentiometer P3 to electrical braking specifications if needed.

Cannot Adjust Check continuity from FWD contactor (wire #51) to logics connection P2-17.

Repair or replace open wires.

Adjustment corrected Return truck to service.

112

Continuity

No Continuity

Check diode D5D for defect.

Repair or replace wire.

Defective

Replace logics.

Replace diode D5D.

WENB8604-02

PROBLEM 54 Current limit and/or electrical braking limit adjustment cannot be made.

POSSIBLE CAUSES Current sensor defect: motor cables incorrect: logics failure.

CHECKS Disconnect current sensor. Check continuity from P16-1 to P3-7 (wire #2). Check continuity from P16-2 to P3-8 (wire #42). Check continuity from P16-3 to P3-6 (wire #85).

Continuity OK

Continuity Not OK

Check motor cables for proper connections. If not OK, repair. If connections are OK, replace T1D and T2D.

Repair or replace open wires.

If replacing T1D and T2D doesn’t fix the problem, replace logics.

113

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PROBLEM 55 Auxiliary lighting and/or alarm does not function correctly. Lift and drive operations normal.

POSSIBLE CAUSES Open fuse: faulty wiring: defective switch: shorted load: open load: loss of input voltage to DC-DC converter: defective DC-DC converter.

CHECKS Is lift truck equipped with a DC-DC converter?

Yes

Connect the battery and close the key switch. Measure from the DC-DC converter 12V positive terminal to the 12V negative terminal.

No Voltage

Voltage above 13V

Voltage below 11V

See Chart 55A.

See Chart 55B.

See Chart 55C.

Voltage 11 to 13V With the faulty auxiliary circuit activated, check for voltage on the load side of the auxiliary fuse.

Battery Voltage Check for voltage on the low side of the auxiliary switch. Battery Volts

0 Volts

Check for voltage at the nega- Repair or tive connection of the load. replace Battery Volts open wire 0 Volts from fuse Repair or Repair or or replace replace open wire replace open defective from the auxiliary wire from switch. fuse or switch or replace replace the defective defective auxiliary switch. component.

114

No Voltage Check for short circuits. Replace auxiliary fuse.

WENB8604-02

PROBLEM 55A No Voltage Output (See problem 55).

CHECKS Measure the voltage from (POS INPUT) to (NEG INPUT).

Battery Voltage

0 Volts

Measure the voltage from (12V POS) terminal of the DC-DC converter to battery negative.

Measure the voltage from the battery positive cable at the line contactor to the (NEG INPUT) terminal of the DC-DC converter.

Battery Voltage

0 Volts

Measure the voltage from (ENABLE) terminal of the DC-DC converter to battery negative.

Replace the DC-DC converter.

Battery Voltage

0 Volts

Test the fuse at the DC-DC converter for continuity.

Fuse Good Remove the load connections at the (12VPOS) and (12VNEG) terminals of the DC-DC converter.

11 to 13 Volts Check for a short circuit in each auxiliary circuit. No Shorts Found

Short Found

Replace the DC-DC converter.

Repair or replace faulty wiring or components.

<11V or >13V Replace the DC-DC converter.

Repair or replace open wiring from the key Fuse Open switch to the Replace fuse. If (ENABLE) fuse continues terminal of to fail, replace the DC-DC the DC-DC converter. converter.

Battery Voltage

0 Volts

Check for open fuse or wiring between the line contactor and the (POS INPUT) terminal of the DC-DC converter.

Repair open negative connection from converter (NEG INPUT) to battery negative.

Open Fuse

Open Replace fuse and Wiring check wiring for Repair or shorts. If no replace shorts are found faulty and the fuse con- wiring. tinues to fail, replace the DCDC converter.

115

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PROBLEM 55B Voltage Below 11 Volts (See problem 55).

CHECKS Measure the (POS INPUT) or (+IN) terminal to the (NEG INPUT) or (- IN) terminal of the DC-DC converter.

35 Volts or Above

Below 35 Volts

Remove all connections at the (12V POS) and the (12V NEG) or the (+OUT) and the (-OUT) terminals of the DC-DC converter. Measure the voltage from the (12V POS) to (12V NEG) or (+OUT) to (-OUT).

Perform “Battery Load Tests”.

11 to 13 Volts

Below 11 Volts

Check for a short or low resistance in the auxiliary circuits and loads. NOTE: Excessive loading places the converter into current limit. (12A maximum)

DC-DC converter faulty. Replace converter.

116

Battery Low

Battery Good

Charge or replace battery.

Check all DC-DC converter input connections from the battery, fuse, and key switch or relay.

All Connections Good

Poor Connections

Replace plug-in relay at the relay printed circuit board (if equipped with a relay).

Repair or replace faulty wiring or connections.

WENB8604-02

PROBLEM 55C Voltage above 15 volts (see problem 55).

CHECKS Remove all connections at the (12V POS) and (12V NEG) or the (+OUT) and the (-OUT) terminals of the DC-DC converter. Measure the voltage from the (12V POS) to (12V NEG) or (+OUT) to (-OUT).

11 to 13 Volts

Above 11 Volts

Check the output load circuits for incorrect wiring or shorts to battery negative.

DC-DC converter faulty. Replace converter.

117

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PROBLEM 56 Slow steering, but pump motor does turn. Drive and lift systems operation normal.

POSSIBLE CAUSES Steering pressure switch defect: wiring defect: failed logics.

CHECKS Check the battery, close the seat switch and key switch. Put the direction lever in forward. Disconnect pressure switch connector P24.

Pump Motor Speed Remains The Same. With P24 disconnected, check for a short circuit between P1-6 (silver area) and battery negative.

Not Shorted

Shorted

Test the head capacitors. Inspect the capacitor wiring to positive and negative heatsinks. Verify correct torque for capacitor hardware.

Repair or replace faulty wiring.

118

Test OK

Test Failed

Replace logics.

Replace failed capacitors or repair connections and wiring.

Pump Motor Speed Increases Replace the steering pressure switch.

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PROBLEM 57 Steering idle speed runs fast. Pump motor turns at high power steering speed continuously. Pump motor runs continuously when neutral is selected (no chat mode).

POSSIBLE CAUSES Steering pressure switch defect: pressure switch connector disconnected: wiring defect: failed logics.

CHECKS Check steering pressure switch connector P24 for proper connection.

Connected

Disconnected

Disconnect the pressure switch connector P24. Place a jumper wire from P24-1 to P24-2. With the key switch ON, seat switch closed, and a direction selected, the pump motor should run at slow speed.

Connect P24.

Remains at High Speed

Runs at Slow Speed

Disconnect the battery and discharge the head capacitors. Check continuity from P24-1 to the control panel battery negative. Also check continuity from P24-2 to logics P1-6 (wire #78).

Replace the pressure switch.

Continuity

No Continuity

Replace logics.

Repair or replace open wire.

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PROBLEM 58 Travel Speed reduced to 2.0 mph (no code).

POSSIBLE CAUSES Speed set at 2.0 mph: service or park brake switch out of adjustment or broken: wiring defect.

CHECKS Run Self Diagnostic.

Failed

Passed

Check failed circuit and repair.

Check Lift Setup.

Brake Switch Failed Check adjustment & operation of switch.

Not OK

Check wiring to switch.

Repair switch and adjust.

Not OK Check logics.

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PROBLEM 59 Display = “FFFF.O” .

POSSIBLE CAUSES Display is defective.

CHECKS

Replace Display.

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PROBLEM 60 Display = Code “H” .

POSSIBLE CAUSES Hydraulic switch closes before turning key switch on.

CHECKS Adjustment of hydraulic switches.

Adjust or repair as needed.

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PROBLEM 61A Display = Code “E” (Not Flashing).

POSSIBLE CAUSES Accelerator depressed before turning key switch on.

CHECKS

Adjust accelerator linkage as needed.

PROBLEM 61B Display = Code “E” (Flashing) .

POSSIBLE CAUSES Seat Switch open when it should be closed.

CHECKS 1. Seat Switch. 2. Open in Seat Switch Harness.

CORRECTION 1. Replace Switch. 2. Repair Wires.

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NOTES

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Systems Operation and Test Equipment

Discharging Head Capacitor (HEAD CAP)

6V7070 Heavy Duty Digital Multimeter (1) can be used to measure voltage, resistance or current. When used to troubleshoot TR3000 control panels, 8T3224 Needle Tips (5) should be attached to the meter leads. These needle tips have a smaller diameter and are less likely to cause damage to connectors. See the enclosed Instructions for the correct operation of 6V7070. 8T0900 Clamp-On Ammeter (2) may be used to measure current. When using ammeter (2) with 6V7070 Digital Multimeter (1) as a remote readout, 6V6014 Cable (4) should be used to connect ammeter (2) to multimeter (1). See Special Instructions SEHS8420 for the correct operation of 8T0900.

! WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel. Before servicing truck, always discharge the head capacitors. The voltage measured across the capacitors should be less than 5 volts. If the capacitors are not discharged, use the following procedure to discharge them.

Resistor (3) is a 150 ohm, 25 watt resistor used to discharge the head capacitor before contact is made with the control panel. 4C4029 Trimmer Adjust Tool (6) allows easier adjustment of the adjusting screw found on potentiometers. The insulated body has a blade on each end. One blade is recessed to provide a captive screwdriver for adjustments that are difficult to see. The other end has an exposed blade to reach adjustment screws that are behind panels which have small access holes.

30703P1

1. Disconnect the battery and discharge the head capacitor. 2. Put a 150 Ohm, 25 watt resistor (1), Part No. 0358280, in position between the terminals of head capacitor (2). Hold the resistor in position for 20 seconds. This will discharge the capacitor below 5 volts.

6 5 Tools.eps (1)6V7070 Heavy Duty Digital Multimeter (2) 8TO900 Clamp-On Ammeter (3) 0358280 Resistor (4) Ammeter 6V6014 Cable (5) 8T3224 Needle Tips (6) 4C4029 Trimmer Adjust Tool

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Component Tests

Logics Removal

! WARNING

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

1. Disconnect the battery and discharge the head capacitor.

To clean the control panel, use air pressure to blow off dust and dirt. Do not use steam or solvent. NOTICE: Do not use steam or solvent to clean the controls. Damage can be caused to the control panel. Use pressure from an air hose with a maxi mum pressure of 205 kPa (30 psi) to clean the control panel when necessary. The air supply must be equipped with a water filter. NOTE: When control wires and power cables or bus bars are to be connected to the same bolt or stud, place all control wires together on the top of the bus bar or power cable. Use the wiring diagram and electrical schematic (located inside rear panel cover) to locate components referred to by name and number in the procedures that follow. All wires must be located as shown on the wiring diagram and schematic.

97C54-00301 Component Location 2) Logics cover. (3) Screws.

2. Loosen screws (1) that hold logics cover (2). 3. Remove the logics cover. 4. Disconnect connectors P1, P2 and P3. When disconnecting connectors, pull on the plastic connector housing, not on the wires. 5. Loosen screws (3) which hold the logics to control panel. 6. Remove logics and replace logics cover to prevent damage.(1)Screws.

Wiring Diagram And Schematic Inside Rear Panel Cover (Example Only)

Logics Connector Removal

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Logic Unit Quick Reference Voltage Check The chart that follows is a quick reference of the expected voltages at the logics card pin connectors. All voltage measurements are made with respect to battery negatives.

! WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels. 1. Put blocks of wood under the frame so both drive wheels are free to turn. 2. Disconnect the battery and discharge the head capacitor. 3. Remove the logics cover. 4. Connect the multimeter negative lead to control panel battery negative. 5. Set the multimeter to the 200 volt DC range. 6. Use the multimeter positive lead with an 8T3224 Needle Tip to measure the voltages under normal and activated conditions as shown in the Logic Voltage Checks chart.

Logic Board Layout

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LOGIC VOLTAGE CHECKS Logic Terminal

Wire No.

Function

*Normal Voltage

Activated Voltage

P1-1

P1-2

Lift_1

High

Low

Activated by moving lift lever OFF to full ON.

Lift_2

High

Low

Activated by moving lift lever OFF to full ON.

P1-3

Tilt

High

Low

Activated by moving tilt lever.

P1-4

Aux 1

High

Low

Activated by moving Aux 1 lever.

P1-5

Aux 2

High

Low

Activated by moving Aux 2 lever.

P1-6

Pressure Switch

Low

High

Activated by turning steering wheel.

P1-7

Drive BWI

High

Low

Activated by brush wear.

P1-8

Pump BWI

High

Low

Activated by brush wear.

P1-9

Reverse (without backup alarm)

High

Low

Activate direction lever from NEU to REV.

P1-10

Forward

High

Low

Activate direction lever from NEU to FWD.

P1-11

Park Brake Switch

Low

High

Activate park brake lever then release.

P1-12

113

Service Brake Switch

Low

High

Activate service brake then release it.

P1-13

Seat Switch

High

Low

Activated = switch closed.

P1-14

105

Lift Limit Switch

High

Low

See Note 1.

P1-15

Accel PWM

12 to 12.75

1.6 to 2.0

P1-16

Not used

P1-17

Not used

P1-18

115

Drive Motor Speed 1

2.5

P1-19

116

Drive Motor Speed 2

2.5

P1-20

Test Procedure.

Depress accelerator fully then release.

Polarizing Plug

P1-21

GND

P2-1

P2-2

Drive SF Control

0 to 1

11 to 12

Activate drive system.

Drive SF Collector

B+

0 to 1

Activate drive system.

P2-3

Pump SF Control

11 to 12

0 to 1

0 - 8 = 11 to 12

P2-4

Pump SF Collector

0 to 1

B+

0 - 8 = 0 to 1

P2-5

Drive Armature Control

B+

B+ to 0 Volts Activated as drive system runs faster. B+ to B+

P2-6

Drive Emitter

0 to 1

0 to 1 Increasing to B+

P2-7

Pump B Control

B+

Activate Pump.

P2-8

117

Pump B0 Control

B+

Activate Pump.

P2-9

118

Pump B0 Turn Off Control

P2-10

Pump Emitter

P2-11

D6D (Regen) Anode

P2-12

Heatsink

128

Battery / logic card negative.

9 = 5.5 to 6.25 10 = 0 to 1 9 = 1/2 B+

10 = B+

Activated as drive system runs faster. See Systems Operation section, “Drive System Shunt Field Operation.”

See Systems Operation section, “Pump System Shunt Field Operation.”

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Logic Terminal

Wire No.

Function

P2-13

100

Frame

P2-14

101

P2-15

102

P2-16

*Normal Voltage

Activated Voltage

Test Procedure.

Polarizing Plug

P2-17

Plug

P2-18

119

Pump Shunt +

P2-19

Pump Shunt -

P2-20

106

Brake Fluid Level

High

Low

Activated by low brake fluid level.

P2-21

GND

P3-1

Drive Thermal

Low

High

Activated by hot drive motor.

P3-2

Pump Thermal

Low

High

Activated by hot pump motor.

P3-3

Control Thermal

Low

High

Activated by hot control panel. See *

P3-4

Display (+)

P3-5

Display (-)

0 to 2.75

Test with truck in normal state.

P3-6

Current Sensor Supply

7.15 to 7.5

Test with truck in normal state.

P3-7

Current Sensor GND

Test with truck in normal state.

P3-8

Current Sensor Input

3.6 to 4.0

Increasing Output

P3-9

Line Contactor

B+

See Note 2. B+ = coil open. Pulsed voltage = coil closed.

P3-10

Pump Bypass Contactor

B+

See Note 2. B+ = coil open. Pulsed voltage = coil closed.

P3-11

Drive Bypass Contactor

B+

See Note 2. B+ = coil open. Pulsed voltage = coil closed.

P3-12

Forward Contactor

B+

See Note 2. B+ = coil open. Pulsed voltage = coil closed.

P3-13

Reverse Contactor

B+

See Note 2. B+ = coil open. Pulsed voltage = coil closed.

P3-14

Regen Contactor

B+

See Note 2. B+ = coil open. Pulsed voltage = coil closed.

Polarizing Plug

P3-15

10.9 to 13.75 10.9 to 13.75 Test with truck in normal state.

P3-16

Contactor Supply

B+

P3-17

Contactor Supply

B+

P3-18

Switched Positive

B+

P3-19

Not Used

P3-20

GND

P3-21

GND

Activated by current flow in drive circuit.

NOTES: * “Normal” = Battery connected, key switch, seat switch, park brake switch and line contactor closed. High voltage should be 14 to 16 volts. *Hi voltage is 14v without line contactor and 22v with Line contactor in.

Low voltage should be 0 to 1 volt. 1. Depending upon Option #10, voltages could be reversed. 2. Battery voltage minus the voltage drop across the contactor (18 to 28 volts).

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Conductor And Switch Continuity Tests 1. Set the multimeter to the 200 Ω range. 2. Use the multimeter to perform the continuity test. If continuity exists, the measurement will be less than 1 ohm. If the measurement is more than this, continuity does not exist and the problem will have to be repaired.

Accelerator Control

Capacitor Test, then each capacitor must be disconnected and tested separately. The failed individual capacitors must be replaced. 1. Disconnect the battery and discharge the head capacitor. 2. Visually inspect the capacitor for bulges at the terminals. 3. Verify the plastic top is not melted around the terminals and that the blow plug is not leaking.

! WARNING Head Capacitor “blow plug” will rupture with reverse polarity. Vapors and contents of Head Capacitors are toxic, flammable and corrosive. Personal injury can be caused from breathing the fumes or if its contents make contact with the skin. Be sure to always connect the positive wire from the positive heatsink to the positive terminal of the Head Capacitor. 4. Disconnect positive cable (2) from the positive heatsink connection point (1). 5. Set the multimeter to the 20KΩ range. Connect the multimeter positive lead to positive side (5) of head capacitor (3). Connect the multimeter negative lead to negative side (4) of head capacitor (3). 6. The meter must increment to above 10,000 ohms. Replace the capacitor if the indication is not correct.

P9 Connector Location (Under Floor Plate (1)P9 connector (2) Accelerator control

Refer to “Self Diagnostics” Accelerator Control in Troubleshooting section.

See Head Capacitor in Specifications Section for proper assembly order of the head capacitor connections and bolt torque specifications. 1

Capacitor (HEAD)

! WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel. NOTICE: Damage can be caused to the head capacitor. Do not remove bolts from capacitors to perform tests. Remove capacitor connecting cables at heatsink connections. On these trucks, head capacitor refers to all the head capacitors hooked together as installed in the control panel. If the capacitors hooked together fail the Head

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- +

Location Of Components (1) Positive heatsink connection point (2)Head Capacitor (3) Negative side of capacitor (4) Positive side of Capacitor

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Contactor Bypass Activation

! WARNING The lift truck can move suddenly. Injury to personnel or damage to lift truck is possible. Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels that turn. NOTE: Damage can be caused to the control panel. Do not switch the direction lever from one direction to the other (plug the lift truck) when the drive wheels are off the ground and in rotation at full speed. 1. Connect the battery and close the seat switch. 2. Turn the key to ON and release the parking brake.

Coil Suppression For Line, Bypass, and Pump Contactors

! WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel. The coil suppression diode for the line, bypass, pump, and regen contactors is built into the logics. To check the suppression diode, use the following procedure: 1. Disconnect the battery and discharge the Head Capacitor. 2. Remove the logics cover. 3. Remove connector P3 from the logics board. 4. Set the multimeter to the diode test position.

3. Select a direction and rapidly depress the accelerator pedal all the way to the floor.

5. Connect the negative multimeter lead to logics board P3-17.

4. Measure and record the time it takes the bypass contactor to close. This should be.5 to 4.5 seconds after the accelerator is fully depressed.

6. Connect the positive multimeter lead to logics board:

5. If the recorded value from step 4 is less than.5 seconds, the logics may need to be replaced. (During normal operation this time will vary with the load on the truck and width the value set in option #8 of the programmable features. See the topic “Programmable Features” in the Systems Operation section.)

P3-9 for line contactor P3-11 for bypass contactor P3-10 for pump contactor P3-14 for regen contactor 7. The multimeter must indicate .3 to .9 volts. 8. Reverse the leads. The meter must indicate OL. 9. If either test fails, replace the logics.

6. If the recorded value from step 4 is more than 4.5 seconds, check the bypass contactor tips for free movement. Check wiring for bad connec tions. Also check for drive train drag and the current limit setting (potentiometer P1). NOTE: The bypass contactor will not close if the accelerator linkage is not adjusted correctly.

C0000 Logics Board

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Coil Suppression For Direction Contactors The coil suppression diode for the direction contactors is built into the logics, but is different from the other contactors. To check the suppression diode, use the following procedure: 1. Disconnect the battery and discharge the head capacitor. 2. Remove the logics cover. 3. Remove connector P3 from the logics board. 4. Set the multimeter to the diode test position. 5. Connect the negative multimeter lead to logics board P3-17. 6. Connect the positive multimeter lead to logics board: P3-12 for forward contactor P3-13 for reverse contactor

Coil Pulsing 1. Disconnect the battery and discharge the head capacitor. 2. With the contactor coil leads and suppression assembly leads connected, set the multimeter to the 200 volt DC range. 3. Connect the multimeter negative lead to the negative coil terminal Y and the meter positive lead to the coil positive terminal X wire #38. 4. Connect the battery and activate the controls necessary for the contactor to be activated. 5. After the contactor activates the multimeter must indicate 15 to 30 volts. If the voltage is not correct and the contactor passed the Coil Suppression test and the Coil Resistance test, the logics must be replaced.

Contactor Tips

7. The multimeter must indicate OL. 8. Reverse the leads. The meter must indicate OL. 9. If either test fails, replace the logics.

1. Disconnect the battery and discharge the head capacitor. 2. Visually inspect the tips to verify they are not welded, melted, burned or pitted. 3. Press and release the tips quickly to verify there is not binding. 4. Visually inspect the contactor assembly. Verify foreign objects don’t interfere with normal contactor operation. NOTE: Perform a contactor tip gap check on direction contactors only. 5. Check contactor tip gap with a feeler gauge as shown. Refer to Specifications section for correct settings.

C0000 Logic Board Layout

Coil Resistance 1. Disconnect the battery and discharge the head capacitor. 2. Disconnect all leads to the X and Y terminals of the coil. 3. Set the multimeter to the 200 KΩ range. 4. Measure the resistance of the coil at the X and Y terminals. It must be within specifications. See Component Measurements in the Specifications section. 5. If the coil is not within specifications, the contactor assembly will have to be replaced.

132

Checking Contactor Tip Gap

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DC /DC Converter Refer to Problem 55 in the Troubleshooting section.

1. Disconnect the battery and discharge the head capacitor. 2. Remove the logics.

Diodes

! WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel. NOTE: The following test procedure can be applied to diode D4P, D4D and D5D. Diode D5D will be used in the following examples. 1. Disconnect the battery and discharge the head capacitor.

3. Disconnect the cathode and remove the diode. 4. Wipe contact surface of the diode (1) clean. Put a small amount of 5P8937 or 5P9810 Thermal Joint Compound on contact surfaces (1), but not on the threads. 5. Install the diode and tighten to the specification listed in the following chart: Diode

Torque

D4D, D5D

36 N•m (320 lb in)

D4P

13 N•m (16 lb in)

2. Disconnect the D5D cathode lead wire (5). 3. Set the multimeter to the diode test position.

6. Connect all wires that were removed.

4. Connect the negative multimeter lead on D5D cathode lead wire (5). Connect the positive multimeter lead to battery negative (7). The multimeter should indicate .3 to .9 volts. 5. Reverse the multimeter leads. The multimeter should indicate OL. If any of the measurements are not correct, replace the diode.

C25486P1 Diode Installation (Typical example) (1) Contact surfaces

Vehicle Monitoring System The display panel performs a lamp test during power up. All segments and LEDs should light for three seconds.

97C54-00300 1)D4P Cathode lead wire 2) D4P 3)D4D cathode lead wire 4)D4D 5)D5D Cathode lead wire 6)D5D 7) Battery Negative

Diode Replacement

! WARNING

P6 Harness Connector Contact Layout (end view)

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

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Driver Board Tests Drive Driver Board

C B A

Driver Board Terminal Connections(A) P12 Connector(B) B Terminals(C) BO Terminals

Pump Driver Board

C B A

(A)P4 Connector (B)B Terminals (C)BO Terminals

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Driver Board Testing Use the following charts for testing the driver boards (36/48/72/80V):

Drive Driver Board Tests Component

Multimeter Range

+ Lead

- Lead

Results

T314/T315 (B to E) R311

200Ω

P12-15 P12-16

P12-16 P12-15

3.7 to 4.1Ω 3.7 to 4.1 Ω

T314/T315 (B to C)

Diode

B P12-15

P12-15 B

OL 0.3 to 0.9

T314/T315 (C to E) Z313

Diode

B P12-16

P12-16 B

0.3 to 0.9 OL

BO Balance

200Ω

0 to 0.5 Ω

D311, R313

200Ω

P12-14 B

B P12-14

4.5 to 7.5 Ω 4.5 to 7.5 Ω

R315, R316, R317

2 KΩ

P12-14 P12-5

P12-5 P12-14

.315 to .350 kΩ .315 to .350 kΩ

Pump Shunt Field Components Pump SF Fuse

200Ω

P12-1

P12-2

0 to 0.5

D351

Diode

P12-2 P12-6

P12-6 P12-2

OL 0.3 to 0.9

T351 (D to S)

Diode

P12-6 P12-10

P12-10 P12-6

OL 0.3 to 0.9

T351 (G to S) R351, C351, Z351

2 KΩ

P12-8 P12-10

P12-10 P12-8

1.71 kΩ to 1.89 kΩ1.71 kΩ to 1.89 kΩ

T 351 (G to S) R351, C351, Z351

Diode

P12-8 P12-10

P12-10 P12-8

First reading should be OL. First reading should be greater than second reading. Neither reading should be less than 0.5

Drive Shunt Field Components Drive SF Fuse

200Ω

P12-3

P12-4

0 to 0.5

D371

Diode

P12-4P12-7

P12-7P12-4

OL 0.3 to 0.9

T371 (D to S)

Diode

P12-7 P12-10

P12-10 P12-7

OL 0.3 to 0.9

T371 (G to S) R371, C371, Z371

2 KΩ

P12-9 P12-10

P12-10 P12-9

1.71 kΩ to 1.89 kΩ 1.71 kΩ to 1.89 kΩ

T371 (G to S) R371, C371, Z371

Diode

P12-9 P12-10

P12-10 P12-9

First reading should be OL. First reading should be greater than second reading. Neither reading should be less than 0.5.

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Pump Driver Board Tests Component

Multimeter Range

+ Lead

- Lead

Results

R329, R330 R328, C322 Z324, T327 (G to S)

2 KΩ

P4-1 P4-5

P4-5 P4-1

1.375 to 1.525 kΩ 1.375 to 1.525 kΩ

R339, R340 R338, C332 Z334, T337 (G to S)

2 KΩ

P4-2 P4-5

P4-5 P4-2

.798 to .882 kΩ .798 to .882 kΩ

T337 (G to D)

Diode

P4-2 P4-7

P4-7 P4-2

OL 0.5 to OL

T327 (G to D)

Diode

P4-1 P4-7

P4-7 P4-1

OL 0.5 to OL

T337 (D to S) R332

Diode

P4-7 P4-10

P4-10 P4-7

0.5 to 1.1 OL

T327 (D to S) R332

Diode

P4-7 P4-3

P4-3 P4-7

0.5 to 1.1 OL

T341 (B to C) R343, R342

Diode

P4-7 P4-4

P4-4 P4-7

0.3 to 0.9 OL

T341 (B to E) R343, R342, R341

200 Ω

P4-4 BO

BO * P4-4

37.9 to 41.9Ω 37.9 to 41.9 Ω

T341 (C to E)

Diode

P4-7 BO

BO * P4-7

0.3 to 0.9 OL

T331/ T332 (B to E) R331

200 Ω

P4-5 P4-10

P4-10 P4-5

2.84 to 3.29 Ω 2.84 to 3.29 Ω

T331 / T322 (B to C)

Diode

P4-10 BO*

BO * P4-10

OL 0.3 to 0.9

T 331 / T332 (C to E)

Diode

P4-5 BO*

BO * P4-5

OL 0.3 to 0.9

T324 (B to E), R321

200 Ω

P4-5 P4-3

P4-3 P4-5

2.84 to 3.29 Ω 2.84 to 3.29 Ω

T324 (B to C)

Diode

P4-3 B**

B ** P4-3

OL 0.3 to 0.9

T324 (C to E) Z 323

Diode

P4-5 B**

B ** P4-5

OL 0.3 to 0.9

D321

Diode

P4-7 B**

B ** P4-7

0.3 to 0.9 OL

R327

200 Ω

B ** BO

BO* B

0.5 to 2 Ω 0.5 to 2 Ω

* *

*Test BO terminals on both transistors. **Test B terminals on both transistors.

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For 72/80V 79.9 to 83.9 Ω 79.9 to 83.9 Ω

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Traction Motor Current Sensor Test

! WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery. The head capacitor (HEAD CAP) must be discharged before any contact with the control panel is made. Disconnect the battery and discharge the HEAD CAP.

9. Move the direction selection lever to forward and depress the accelerator. The voltage being measured should increase. If the voltage decreases, the current sensor is mounted backward. If there is no voltage measured or the voltage being measured does not change, the current sensor must be replaced.

1. Disconnect the battery, discharge the head capacitors, and remove the logic cover. 2. Disconnect current sensor connector P16. 3. Check continuity from harness connector P16-3 (wire #85) to logics P3-6 and connector P16-2 (wire #42) to logics P3-7. Check for short between harness the connector P16-3 wire #85 and the control panel battery negative. Check for short between the harness connector P16-2 (wire #42) and the control panel battery negative. Repair or replace any defective wires.

! WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are elevated and free to turn. Keep your person away from the drive wheels that turn. 4. Set the multimeter to the 20V DC range. With the connector P16 reconnected, connect the multimeter positive lead to logics P3-6. Connect the multimeter negative lead to the control panel battery negative. 5. Connect the battery and turn the key ON. The measurement must be 7.15 to 7.50 volts. Connect the multimeter positive lead to logics P3-8. The measurement must be 3.6 to 4.0 volts. If both measurements are not correct, replace the logics. 6. Disconnect the battery and discharge the head capacitors. 7. Set the multimeter to the 20V DC range and connect the multimeter positive lead to logics P3-8. Connect multimeter negative lead to the control panel battery negative. 8. Connect the battery and turn the key ON. The measurement must be 3.6 to 4.0 volts.

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Hydraulics The instrument panel is also powered at this time. Current will flow through the key fuse, P5-3, key switch, wire #4,

NOTE: On these circuit diagrams shaded lines illustrate current flow.

Actuation Circuit

P6-2, and P6-1 back to battery negative. The display first does a “lamp test” which will light all the LED symbols and LCD segments for 5 seconds. The hour meter readings are then indicated.

This circuit supplies power to the TR3000 and the monitoring system instrument panel. It must be activated before power steering, hydraulics, or drive will operate.

The logics will start to perform a set of “Run-Time” diagnostics checks. The letter “E” will flash on the display indicating the key is ON with no operator in the seat.

When the battery is connected and the key switch is closed, current flows from battery positive through the key fuse, key switch, wire #4, P5-4 to the logics connection P3-18. The logics connection to battery negative is at P1-21, P2-21, P3-20 and P3-21. The logics circuits are powered up to accept voltage inputs and create voltage outputs whenever the battery is connected and the key is ON.

When the seat switch is closed, current will flow from the logics to P1-13 through P5-7 (the seat switch) to battery negative. The logics then activates the line contactor coil and P3-9 back to battery negative.

3 3

LIGHTS FUSE 15A

P12-13 3

KEY FUSE 10A

P5-4

46 34

P3-4

P5-12

P6-4

P5-16

P6-3

P3-5 P2-12 P3-3

P1-14

P46-1

LIFT LIMIT SW 127 P5-21

P6-2

P6-1

SEAT OPERATED BRAKE SW P60-C P60-A SEAT SWITCH

P2-13 P1-13

HORN BUTTON 4 KEY SWITCH

P46-2

P5-3

R320 P3-18

R319

P5-7

HORN

PUMP MOTOR THERMOSTAT P3-2

P5-25

P3-1

P1-11

P5-19

P2-20

P5-22

P1-10

P5-14

P1-9

P5-15

1 DRIVE MOTOR THERMOSTAT

P5-23

113

SERVICE BRAKE SWITCH P40-C P40-B

P3-17 39 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P7-C

4 P7-A

REV

LOGICS

P38-8

P1-2

P13-5

LIFT 1 SW 81

P5-27

P61-1 REV

P61-3 13

P5-13

FWD

P61-2 FOOT DIR SW

P1-1

P33-1

FWD

P13-6

LIFT 2 SW P1-3

P5-34

P1-4

P5-33

P3-16

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1TON

P13-2 TILT SW 88

P13-3

P32-3

P32-4

3 4

AUX 1 SW P1-5 P1-6

LINE CTR

P5-32

P1-19

P5-26 TWISTED PAIR 116

P1-18

115

BATTERY 36/48 VOLT OR 72/80 VOLT

P1-15

P5-8

P13-4

AUX 2 SW 78 P24-2 TWISTED PAIR P5-31 P52-2 P5-30

P52-1

P9-C

P1-21

P2-21

P3-21

P3-20

ACCEL CONTROL

P13-1 P24-1

PRESSURE SWITCH SPEED SENSOR SWITCH

1 1 4 1

P9-A P9-B

P5-1

P33-2 P7-B DIR SW

P5-2 P5-36

106 14

3 1

1 BRAKE FLUID SWITCH

PARK BRAKE SW

P5-24

P1-12

P5-37

100

P12-12

DISPLAY

P12-11

2FBC1513

138

WENB8604-02

Capacitor Charging Circuit

3 34

With the line contactor tips closed, the logics continues its checks for any “Run Time” faults. If no faults are detected, the display will indicate the battery charge level, the power steering system operates, the pump and drive power circuits receive battery voltage and the logics receives battery voltage on wire #34 at P2-12.

KEY FUSE 10A

P12-11 R319

R320

34 P2-12 34

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY P3-11 35 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

LINE FUSE 2 TO3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON LINE CTR

BATTERY 36/48 VOLT OR 72/80 VOLT

HEAD CAP

LOGICS

P3-16

P3-21

A charging resistor is used to maintain voltage on the head capacitor whenever the battery is connected and the line contactor is open. This voltage reduces arcing of the line contactor tips during line contactor activation. The charging resistor is installed parallel with the line contactor tips. Current flows from battery positive through the key fuse, charging resistor, line fuse and the positive heat sink into battery negative. This circuit will maintain a voltage across the head capacitor above approximately 20 volts.

P12-13

Capacitor Charging Circuit (Typical Example)

139

WENB8604-02

Hydraulic Pump Motor Circuit Only one hydraulic pump motor is used for all power steering, lift, tilt, and auxiliary hydraulic functions. To activate the pump circuit, the seat switch, key switch and line contactor must be closed first as explained in the topic, Actuation Circuit. The power steering, lift, tilt, and auxiliary circuits are explained as follows:

140

WENB8604-02

Power Steering Circuit

with an oscilloscope. During steering, when this signal is high, it indicates that the transistors should be off. When this signal is low, it indicates that the transistors should be on. When this signal goes low, current flows down through R338, R339, and R340. These resistors form a voltage divider that starts to reduce the voltage on the gate of T337. It does not reduce immediately, due to capacitor C332. Also, it will not drop further than about 7V below battery positive because of Z334. Since no current is flowing in T337, its source is held at battery positive by R331 and R332. T337 is a P-channel mosfet. A P-channel mosfet is a voltage controlled device that will turn on when the gate voltage is 5V less than the source voltage. When voltage on the gate of T337 becomes 5V less then its source, T337 turns on.

The power steering (PS) circuit has two speeds: PS Idle and PS Boost-up. NOTE: Shaded lines on the circuit diagrams indicate current flow. Other circuits can be activated at the same time, but each one is shown separately to illustrate current flow in each individual circuit.

Power Steering Idle After the line contactor closes, the logics generates a pulsing signal on P2-8 (Wire #117). This signal oscillates (moves) between battery negative and battery positive at 15,000 times each second. This is faster than can be seen on a voltmeter and must be viewed C332

R341

P8-2 CONTROL THERMOSTAT

R338

Z334

P8-1

R340 R339

T332

T2P

T331

R327

T1P

D321

T337

R331

R329 R330

R332

C322

Z324

R328

Z323 T324

R321

T327 R322

P4-5

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P2-3

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P3-21

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1515

141

WENB8604-02

When T337 turns on current flows from BAT+ through the emitter/base junction of T331 and T332 through R332 through T337 to the emitter of T1P and T2P. Because T331 and T332 are PNP transistors, the current flow through the emitter/base junction causes them to turn on. When T337 is on, T331 and T332 are on. When T337 is off, T331 and T332 are off.

C332

R341

P8-2 CONTROL THERMOSTAT

R338

Z334

P8-1

R340 R339

T332

T2P

T331

R327

T1P

D321

T337

R331

R329 R330

R332

C322

Z324

R328

Z323 T324

R321

T327 R322

P4-5

When T331 and T332 turn on, current flows through T331 and T332, through the B0/emitter junction of the power transistors T1 P and T2P through the pump armature/series field to BAT-. Since T1 P and T2P are NPN transistors, the current flow through the B0/emitter junction causes the second stage transistor in T1 P and T2P to turn on. Now when T337 is on, T331, T332, T1P (second stage), and T2P(second stage) are on.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P3-21

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P2-3

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1516

142

WENB8604-02

When the second stage transistor of T1 P and T2P turn on, current flows from BAT+ through the second stage of T1 P and T2P, through the pump armature/series field to BAT-. This causes the pump to turn. So when P2-8 (Wire #1 17) is low, the second stage of the power transistors T1 P and T2P is also on. The logic controls this ‘low” time on P2-8 to control the pump

C332

P8-1

R340 R339

R341

P8-2 CONTROL THERMOSTAT

R338

Z334

T332

T331

T2P

R327

T1P

D321

T337

R331

R329 R330

R332

C322

Z324

R328

Z323 T324

R321

T327 R322

P4-5

during steer idle. During steer idle P2-8 is low about 6% of the time, which means T1P and T2P are on 6% of the time. This results in about 6% of battery voltage being applied to the armature during steer idle. This number will not be exactly 6% because the T1 P and T2P “ON” time is adjusted by the logics (via P2-8) to help offset changes in battery voltage.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P2-3

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P3-21

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1517

143

WENB8604-02

Additional Information: Only the second stage transistor of T1P and T2P is used during steer idle and steer boost-up because of the speed at which these transistors are pulsed. The transistors are pulsed at 15,000 Hz (cycles per second) to help reduce audible whine that used to exist on older style trucks during steer idle and boost up. On these systems the transistors were pulsed at 187.5 Hz, which was audible and bothersome to some operators. Moving this pulsing frequency to 15,000 Hz has made the noise both quieter and much more difficult to hear because it is outside the range of human hearing. To accomplish this, it was necessary to speed up the switching of pump power transistors T1P and T2P. C332

R341

P8-2 CONTROL THERMOSTAT

R338

P8-1

T337 R340 R339

T332

T2P

R327

T1P

T331

D321

R330

R332

C322 R331

R329

Z334

Z324

R328

Z323 T324

R321

T327 R322

P4-5

These transistors are slow in switching and also suffer from a problem called “storage time,” which causes them to stay on for a short period of time even after the base/emitter drive is removed. Using only the second stage of the power transistors reduces both the switching time and the ‘storage time” to acceptable values for use at 15,000 Hz pulsing. When only the second stage of the transistors is used, the power transistors cannot carry as much current. But this is acceptable because the transistors are driven this way only in steer idle and boost up, where the current required is not too high.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1 ARM

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P2-3

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P3-21

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1518

144

WENB8604-02

Hydraulic Pump Shunt Field Circuit At the same time the logics is pulsing the pump armature circuit, a constant voltage (about 12V) is being supplied from the logics P2-3 to the gate of T351. T351 is an N-channel mosfet, which will turn on when the gate is 5V greater than the source. Since we have applied 12V (which helps insure that T351 is fully on), T351 is on. With T351 on current can flow from BAT+, C332

R341

P8-2 CONTROL THERMOSTAT

R338

Z334

P8-1

R340 R339

T332

T2P

T331

R327

T1P

D321

T337

R331

R329 R330

R332

C322

Z324

R328

Z323 T324

R321

T327 R322

P4-5

through the pump shunt field fuse, through the pump shunt field, through T351, to BAT-. When the pump shunt field is on 100%, it is at maximum strength. During the power steering speeds, the pump shunt field adds to the motor torque, making it a very powerful motor at low rpm. The motor during power steering idle is turning at about 200 rpm.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P2-3

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P3-21

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1519

145

WENB8604-02

Power Steering In Use If the steering wheel is turned, hydraulic pressure increases, and a pressure switch located in the steering gear load sensing line will open. This causes the voltage at logics connector P 1 -6 to change from a LOW to a HIGH signal. When a HIGH signal is present, the logics knows that more hydraulic flow is required because the operator is steering the truck. It will

increase the duty cycle applied to T1P and T2P with the signal on P2-8. Increasing the duty cycle on T1P and T2P increases the voltage applied to the armature/series field, which increases the speed of the motor and therefore the flow provided to the steer gear. When the pressure switch is open, the pump motor speed will be about 500 rpm.

3 3

LIGHTS FUSE 15A

P12-13 3

KEY FUSE 10A

P5-4

P3-4

P5-12

P6-4

P5-16

P6-3

P3-5 P2-12 P3-3

P1-14

P46-1

LIFT LIMIT SW 127 P5-21

P6-2

P6-1

SEAT OPERATED BRAKE SW P60-C P60-A SEAT SWITCH

P2-13 P1-13

HORN BUTTON 4 KEY SWITCH

P46-2

P5-3

R320 P3-18

R319

P5-7

HORN

PUMP MOTOR THERMOSTAT P3-2

P5-25

P3-1

P1-11

P5-19

1 DRIVE MOTOR THERMOSTAT

P5-23

113

SERVICE BRAKE SWITCH P40-C P40-B

P5-22

34 P3-17 39 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P1-9

P5-15

P33-2 P7-B DIR SW

14 15

P7-C

4 P7-A

REV

LOGICS

P38-8

P1-2

P13-5

LIFT 1 SW 81

P5-27

P61-1 REV

P61-3 13

P5-13

FWD

P61-2 FOOT DIR SW

P1-1

P33-1

FWD

P13-6

LIFT 2 SW P1-3

P5-34

P3-16

P13-2 TILT SW 88

P5-33

P1-4

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

P13-3

P32-3

P32-4

3 4

AUX 1 SW P1-5 P1-6

LINE CTR

P5-32

P1-19

P5-26 TWISTED PAIR 116

P1-18

115

BATTERY 36/48 VOLT OR 72/80 VOLT

P1-15

P5-8

P13-4

AUX 2 SW 78 P24-2 TWISTED PAIR P5-31 P52-2 P5-30

P52-1

P9-C

P1-21

P2-21

P3-21

P3-20

ACCEL CONTROL

P13-1 P24-1

PRESSURE SWITCH SPEED SENSOR SWITCH

1 1 4 1

P9-A P9-B

P5-1

P5-14

106

P5-2 P5-36

P1-10

3 1

1 BRAKE FLUID SWITCH

PARK BRAKE SW P2-20

P5-24

P1-12

P5-37

100

P12-12

DISPLAY

P12-11

2FBC1520

146

WENB8604-02

Flyback Circuit D4P is a flyback diode for the hydraulic pump motor circuit. Because the series field/armatures on the pump motor are inductors they need a path for the current to flow when T1P and T2P are turned off. When T1P and T2P are turned OFF, all the current flowing in the series

C332

P8-1

R340 R339

R341

P8-2 CONTROL THERMOSTAT

R338

Z334

T332

T331

T2P

R327

T1P

D321

T337

R331

R329 R330

R332

C322

Z324

R328

Z323 T324

R321

T327 R322

P4-5

field/armature goes through PS2, Pump Shunt, D4P, PA1, and back to the series field/armature. When T1P and T2P are pulsing, the flyback circuit causes the average pump motor current to be greater than the average battery current flowing through T1P and T2P.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P2-3

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P3-21

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1521

147

WENB8604-02

Lift Circuit Lift Control Circuit The 2FBC15 family of lift trucks is equipped with a two-speed lift system. The system is controlled by two microswitches that work off of the lift spool on the main hydraulic valve. As the lift lever is pulled back, Lift Switch 1 is depressed, which causes the signal on Logic Connector P1-1 to go from HIGH to LOW. This signals the logics to run the pump motor at the speed set for LIFT1 SPEED. As the lift lever is pulled back further, Lift Switch 2 is depressed, which causes the signal on Logic Connector P1-2 to go from HIGH to LOW. This signals the logics to run the pump motor at the speed set for LIFT2 SPEED. When the operator releases the lever or pushes the lever forward to lower a load, both Lift Switches are released. Options 2 and 3 in the setup mode determine at what speed the pump will run when the lift switches are depressed. The chart to the right shows the possible speeds:

HYDRAULIC PUMP MOTOR SPEED CHART PUMP SPEED

ARMATURE DUTY CYCLE

SHUNT FIELD PUMP DUTY CYCLE CONTACTOR

100%

Off

100%

Off

100%

Off

100%

Off

100%

Off

100%

Off

100%

Off

100%

Off

0 (Bypass)

100%

0 (Bypass)

50%

0 (Bypass)

If the operator pulls back on the lift lever rapidly, the logics will smoothly ramp up to LIFT2 SPEED in about 1/2 second.

148

WENB8604-02

Lift Power Circuit system described in the power steering system operation, we cannot use this system during the heavy currents involved with the lift system. The lift system is operated at 187.5 Hz and controls the B terminal of the power transistor.

When any hydraulic lever is activated (Lift, Tilt, Aux1, or Aux2), the logics stop using the control output P2-8 (Wire #117) to control the pump. Because of the current limitation of the 15,000 Hz pump control

3 3

LIGHTS FUSE 15A

P12-13 3

KEY FUSE 10A

P5-4

P3-4

P5-12

P6-4

P5-16

P6-3

P3-5 P2-12 P3-3

P1-14

P46-1

LIFT LIMIT SW 127 P5-21

P6-2

P6-1

SEAT OPERATED BRAKE SW P60-C P60-A SEAT SWITCH

P2-13 P1-13

HORN BUTTON 4 KEY SWITCH

P46-2

P5-3

R320 P3-18

R319

P5-7

HORN

PUMP MOTOR THERMOSTAT P3-2

P5-25

P3-1

P1-11

P5-19

P2-20

P5-22

1 DRIVE MOTOR THERMOSTAT

P5-23

113

SERVICE BRAKE SWITCH P40-C P40-B

P1-10

P3-17 39 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P7-C

4 P7-A

REV

LOGICS

P38-8

P1-2

P13-5

LIFT 1 SW 81

P5-27

P61-1 REV

P61-3 13

P5-13

FWD

P61-2 FOOT DIR SW

P1-1

P33-1

P13-6

LIFT 2 SW P1-3

P5-34

P1-4

P5-33

P3-16

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

P13-2 TILT SW 88

P13-3

P32-3

P32-4

3 4

AUX 1 SW P1-5 P1-6

LINE CTR

P5-32

P1-19

P5-26 TWISTED PAIR 116

P1-18

115

BATTERY 36/48 VOLT OR 72/80 VOLT

P1-15

P5-8

P13-4

AUX 2 SW 78 P24-2 TWISTED PAIR P5-31 P52-2 P5-30

P52-1

P9-C

P1-21

P2-21

P3-21

P3-20

ACCEL CONTROL

P13-1 P24-1

PRESSURE SWITCH SPEED SENSOR SWITCH

1 1 4 1

P9-A P9-B

P5-1

P7-B DIR SW

14 15

P5-15

P33-2 FWD

P5-2 P5-36

106

P5-14

P1-9

3 1

1 BRAKE FLUID SWITCH

PARK BRAKE SW

P5-24

P1-12

P5-37

100

P12-12

DISPLAY

P12-11

2FBC1522

149

WENB8604-02

When a hydraulic lever is activated, the logics senses this through the hydraulic switches and stops using control output P2-8 (Wire #117) to control the pump. It begins to use control output P2-7 (Wire #79). The logics generates a 187.5 Hz pulsing signal on P2-7. This is faster than ran be seen on a voltmeter and must be viewed with an oscilloscope. During hydraulic functions, when this signal is low, it indicates the power transistors T1P and T2P should be on. When this signal is high, it indicates the power transistors T1P and T2P should be off. When this signal goes low, current flows

C332

R341

P8-2 CONTROL THERMOSTAT

R338

Z334

P8-1

R340 R339

T332

T2P

T331

R327

T1P

D321

T337

R331

R329 R330

R332

C322

Z324

R328

Z323 T324

R321

T327 R322

P4-5

down through R328, R329, and R330. These resistors form a voltage divider that starts to reduce the voltage on the gate of T327. It will not drop further than about 7V below battery positive because of Z324. Since no current is flowing in T327, its source is held at battery positive by R321 and R322. T327 is a P-channel mosfet. A P-channel mosfet is a voltage controlled device that will turn on when the gate voltage is 5V less than the source voltage. When the voltage on the gate of T327 becomes 5V less than its source, T327 turns on.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P2-3

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P3-21

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1523

150

WENB8604-02

When T327 turns on, current flows from BAT+ through the emitter 1 base junction of T324, through R322, through T327 to the emitter of T1 P and T2P. Because

C332

P8-1

R340 R339

R341

P8-2 CONTROL THERMOSTAT

R338 T337

T332

T2P

R327

T1P

T331

D321

R330

R332

C322 R331

R329

Z334

Z324

R328

Z323 T324

R321

T327 R322

P4-5

T324 is a PNP transistor, the current flow through the emitter/base junction causes it to turn on. When T327 is on, T324 is on. When T327 is off, T324 is off.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P3-21

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P2-3

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1524

151

WENB8604-02

When T324 turns on, current flows through T324, through the B/emitter junction of the power transistors T1P and T2P, through the pump armature/series field to BAT-. Since T1P and T2P are NPN transistors the

C332

P8-1

R340 R339

R341

P8-2 CONTROL THERMOSTAT

R338 T337

T332

T2P B0

T1P

R327

T331

D321

R330

R332

C322 R331

R329

Z334

Z324

R328

Z323 T324

R321

T327 R322

P4-5

current flow through the B/emitter junction causes the entire power transistor to turn on. Now when T327 is on, T324, T1P (entire) transistor), and T2P (entire transistor) are on.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P3-21

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P2-3

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1525

152

WENB8604-02

When the power transistors T1P and T2P turn on, current flows from BAT+ through the power transistors T1P and T2P, through the pump armature/series field to BAT-. This causes the pump to turn. So when P2-7

C332

P8-1

R340 R339

R341

P8-2 CONTROL THERMOSTAT

R338

Z334

T332

T331

R327

T2P B0

D321

T1P

T337

R331

R329 R330

R332

C322

Z324

R328

Z323 T324

R321

T327 R322

P4-5

(Wire #79) is low, the power transistors T1P and T2P are on. The logics controls this ‘loW’ time on P2-7 to control the pump during hydraulic functions.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P2-3

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P3-21

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1526

153

WENB8604-02

As shown in the chart under Lift Control Circuit, lift speeds 0-8 keep the shunt field on at 100%. For speed 9 the shunt field is pulsed at 50%, and for speed 10 the shunt field is turned off. Reducing the shunt field in the pump motor serves the same function as turning off the shunt field in the drive motor. It changes the motor characteristics so that it will spin faster. This

C332

R341

P8-2 CONTROL THERMOSTAT

R338

Z334

P8-1

R340 R339

T332

T2P

T331

R327

T1P

D321

R330 B

T337

R331

R329

R332

C322

Z324

R328

Z323 T324

R321

T327 R322

P4-5

results in faster hydraulic operation. Just as the pump armature/shunt field needs a flyback diode, the shunt field also needs a path for the current to flow when T351 turns off. D351 serves this function. When T351 is turned OFF, all the current flowing in the shunt field goes through E2, through D351, through E1, and back to the shunt field.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P3-21

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P2-3

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1527

154

WENB8604-02

Pump Contactor Operation current to flow out of P3-17, through the pump contactor coil, through P3-10 to BAT-. While the pump contactor is pulling in the pump, transistors T1P and T2P are driven at 99% to reduce the arc when the contact tips touch. After this the transistors are turned off. The pump armature/series field is now connected directly to the battery.

If lift speed 8, 9, or 10 is set for Option 2 (LIFT1 Speed) or Option 3 (LIFT2 Speed), and it is necessary to provide one of these speeds because the lift lever has been pulled back, then the lift contactor will be used to provide 100% voltage to the pump armature/series field. The logic activates the pump contactor by allowing

C332

R341

P8-2 CONTROL THERMOSTAT

R338

Z334

P8-1

R340 R339

T332

B T2P

T331

R327

T1P

D321

T337

R331

R329 R330

R332

C322

Z324

R328

Z323 T324

R321

T327 R322

P4-5

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P2-3

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P3-21

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1528

155

WENB8604-02

Tilt And Auxiliary Control

Tilt Aux1 Aux2 Lift1, Lift 2

The Tilt, Aux1, and Aux2 hydraulic levers each have their own microswitch. This allows the speed for each function to be set separately using Setup Options 4, 5, and 6. The same control of pump motor that was explained earlier for the lift lever also applies to these three levers.To handle the situation when more than one lever is pulled, the following priority is given to the levers

This means that if you pull back on Tilt and Aux2, the speed associated with Tilt will be used.

3 3

LIGHTS FUSE 15A

P12-13 3

KEY FUSE 10A P12-11

34 P2-12 P3-3

P5-4

P3-4

P5-12

P6-4

P3-5

P5-16

P6-3

P1-14

P46-1

KEY SWITCH 4 DISPLAY

HORN BUTTON 4

P46-2

P5-3

R320 P3-18

R319

100

P12-12

LIFT LIMIT SW 127 P5-21

P6-1

SEAT OPERATED BRAKE SW P60-C P60-A SEAT SWITCH

P2-13 P1-13

P6-2

P5-7

HORN

PUMP MOTOR THERMOSTAT P3-2

P5-25

P3-1

P1-11

P5-19

P2-20

P5-22

1 DRIVE MOTOR THERMOSTAT

P5-23

113

SERVICE BRAKE SWITCH P40-C P40-B

P3-17 39 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

P1-9

P5-15

P33-2 P7-B DIR SW

14 15

P7-C

4 P7-A

REV

LOGICS

P38-8

P1-2

P13-5

LIFT 1 SW 81

P5-27

P61-1 REV

P61-3 13

P5-13

FWD

P61-2 FOOT DIR SW

P1-1

P33-1

FWD

P13-6

LIFT 2 SW P5-34

P1-4

P5-33

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1TON

P13-2 TILT SW 88

P13-3

P32-4

3 4

AUX 1 SW P1-5 P1-6

LINE CTR

P5-32

P1-19

P5-26 TWISTED PAIR 116

P1-18

115

BATTERY 36/48 VOLT OR 72/80 VOLT

P1-15

P5-8

P13-4

AUX 2 SW 78 P24-2 TWISTED PAIR P5-31 P52-2 P5-30

P52-1

P9-C

P1-21

P2-21

P3-21

P3-20

ACCEL CONTROL

P13-1 P24-1

PRESSURE SWITCH SPEED SENSOR SWITCH

1 1 4 1

P9-A P9-B

P5-37

P1-3

P3-16

P32-3

P5-1

P5-14

106

P5-2 P5-36

P1-10

3 1

1 BRAKE FLUID SWITCH

PARK BRAKE SW

P5-24

P1-12

2FBC1513

156

WENB8604-02

Additional Lift System Information: Two additional systems exist on the 2FBC15 family system that are new to TR3000. The first system is the pump shunt. This shunt is a precision, very low value resistor that measures the current flowing in the pump. The logics uses this information for various reasons: Because of the current limitation of the 15,000 Hz steering system (-150A), the system must not be overloaded. During steering idle or steering boost-up, the 15,000 Hz system is used, but if the any hydraulic lever is activated (Lift, Tilt, Aux1, or Aux2) or the current in the pump rises above an acceptable limit, the logics will automatically switch to 187.5 Hz pulsing. The hydraulic levers are monitored by the microswitches attached to each spool. The current is monitored with the pump shunt.

The shunt is also used to current limit the pump transistors. Just as the drive transistors are current limited to help protect them, so are the pump transistors. This current limit will not be reached during normal operation, but during a pump failure when the pump locks up, the transistors are protected from overcurrent. Finally, the shunt is used to prevent a stalled pump motor from blowing the main fuse when the pump bypass contactor i-s pulled in. Again, if the pump locks up and the pump bypass contactor is pulled in, the logics will sense the high stalled motor current and shut down the truck before the fuse blows.

157

WENB8604-02

Pump Power Transistor Turn-Off Circuit The second system is the pump power transistor turnoff circuit. This circuit helps to turn off the main power transistors T1P and T2P as quickly as possible. This helps the 15,000 Hz steering system work more consistently. The turn-off circuit is controlled by the logics control output P2-9 (Wire #118). When P2-9 is low, the turn-off circuit is active; and when P2-9 is high, the turn-off circuit is inactive. Because P2-9 controls the turn-off circuit, it will be on when P2-7 and P2-8 are

C332

R341

P8-2 CONTROL THERMOSTAT

R338

P8-1

T337 R340 R339

T332

T2P B0

T1P

R327

T331

D321

R330

R332

C322 R331

R329

Z334

Z324

R328

Z323 T324

R321

T327 R322

P4-5

off; and P2-9 will be off when either P2-7 or P2-8 are on. Because these signals change rapidly, this cannot be seen on a voltmeter, but must be viewed with an oscilloscope. When P2-9 is low, current flows from the BO terminal of T1P and T2P, through the emitter/base junction of T341, through R342 and R343 to P2-9. Because T341 is a PNP transistor, the flow of current through the emitter/base junction of T341 turns it on. So when P2-9 is low, T341 is on.

T341

46 34 P2-12 P3-3 100 P2-13

P4-1 P4-4

PUMP CTR

P4-2

P4-7 R343 R342

1 117

118 79

P12-3 DRIVE SHUNT FIELD FUSE 15 AMP

P5-29 68

69 P32-5

109 E1 (F1)

PA1

(PS2) PD2

P32-2

PUMP MOTOR

HEAD CAP

P3-16

119 P2-18 P2-19 P2-4 119 29 71

P12-10

P12-8

P1-21

TWISTED PAIR

P3-20 P2-21

P2-3

T351

SHUNT

R351

C351

P12-6

D351

E2 (F2)

DRIVE POWER CIRCUIT

110

ARM

D4P

LINE CTR

Z351

39 P3-17 LINE COIL XY 26 P3-9 LIFT COIL X Y 30 P3-10 BYPASS COIL XY 35 P3-11 FWD COIL XY 20 P3-12 REV COIL XY 19 P3-13 REGEN COIL XY 75 P3-14

DU1

P3-21

LINE FUSE 2 TO 3 TON 36/48 VOLT 675 AMP 600 AMP 1 TON

LOGICS

P12-2

PUMP SHUNT FIELD FUSE 15 AMP

P2-8 P2-9 P2-7 P2-10 P1-8

P12-1

BATTERY 36/48 VOLT OR 72/80 VOLT

117 118 79 45 83

119

119 29

29 71

71 72

2FBC1530

158

WENB8604-02

When T341 turns on, current flows from the B0 terminal of T1P and T2P, through T341 to the emitter of T1P and T2P. This flow of current is a good way to quickly turn off the pump power transistors by removing excess base charge from the second stage transistor. Without this circuit the pump transistors would not turn off

quickly, and at 15,000 Hz pulsing this would result in the pump running faster than necessary. Although this does affect the steering, it means the pump transistors are on more than necessary, which results in lower system efficiency.

2FBC1531

159

WENB8604-02

Electrical Testing

If pump circuit failed: 2. Check D4P for a failure.

Testing Transistors

3. Check T1P and T2P for a failure.

Use the following chart to test transistors. If any measurements are incorrect, replace the transistor.

4. Check pump driver board for a failure.

NOTE: If a transistor is found to be failed and it is part of a pump or drive system pair, replace both transistors of the pair.

TRANSISTOR SPECIFICATIONS MULTIMETER (+) TEST SETTING LEAD

(-) TEST LEAD

927566 RESULTS

974222 RESULTS

Resistance

Emitter

Base

45 to 135 Ω 60 to 180 Ω

Diode

Base

Collector

.3 to.9V

Diode

Collector

Base

Diode

Emitter

Collector

.3 to.9V

Diode

Collector

Emitter

NOTICE: Damage to the control panel could result. To prevent further damage before a power transistor is replaced, complete the check list that follows. 1. Check head capacitor for a failure. If drive circuit failed: 2. Check D4D for a failure. 3. Check D5D for a failure. 4. Check D6D for a failure. 5. Check T1D and T2D for a failure. 6. Check drive driver board for a failure. 7. Check continuity from T1D, T2D emitter bus bar (wire #37) to logics P2-6. 8. Check for continuity of drive current sensor wires (wires #2, #42, #85).

160

5. Check continuity from T1P, T2P emitter bus bar (wire #45) to logics P2-10. 6. Check continuity of pump shunt wires (wires #29 and #119). 2

4 C30706P2 927566 and 974222 Transistor (1)Emitter (2)Base (3)Collector (4)B0

WENB8604-02

3. Remove the transistor mounting bolts (3).

Transistor Replacement (T1P, T2P, T1D and T2D)

! WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitors (HEAD CAP) before any contact is made with the control panel. T1P is described in the procedure that follows. All transistors are replaced in the same way. 1. Disconnect the battery discharge the head capacitors, and remove the logics board.

2 1

C63562P1: Transistor Removal (Typical) (4) Contact Surface

4. Contact surface (4) of transistor (2) is coated with 5P8937 Thermal Joint Compound. Carefully remove the transistor (2). 5. To replace the transistor, wipe the contact surface (4) and the heatsink clean. Put a small amount of 5P8937 Thermal Joint Compound on contact surface (4). Coat heatsink and transistor so that compound covers only contact area. 6. Install transistor (2) with mounting bolts (3). Tighten bolts (3) to a torque of 4 to 6 N•m (35 to 53 lb in.). 7. Reinstall driver boards (1).

3 2

Location of Components (1)Driver Board (2)Transistor (3)Mounting Bolts

2. Remove drive and pump driver boards (1).

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Resistor R312

! WARNING

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitors (HEAD CAP) before any contact is made with the control panel. NOTE: Look for visual beaks or cracks on resistors. 1. Disconnect the battery, discharge the head

Resistor R312 Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitors (HEAD CAP) before any contact is made with the control panel. NOTICE: Damage to the thermal switch will occur. Do not heat the thermal switch over an open flame.

Control Panel NOTE: If the thermal switch is removed from the heatsink, it can be tested in an oven. Switch (1) will open circuit if the temperature is 81°-89°C (178°1

capacitor, and remove the logics board. Location of Components: (1) R312

2. Disconnect wire #32 from resistor R312 (1).

192°F) and close (short circuit) at 69°-77°C (156°-171°F).

3. Set the multimeter to the 200 ohm range. Connect the multimeter leads to the terminals on resistor R312 (1) to check the resistance.

Refer to the topic “Run-Time Diagnostics”, Overtemperature Indicator ON, in the troubleshooting section.

4. The measurement from the resistor must be 34 to 38 ohms (36/48V trucks) or 71 to 79 ohms (72/80V trucks).

Pump and Drive Motor

5. If the measurement is not correct, the resistor must be replaced.

97C54-11300 Location of Components: (1) Thermal switch

NOTE: If the pump or drive thermal switch is removed from the motor, it can be tested in an oven. Switches 3 and 4 will open circuit if the temperature is 144°-156°C (291°-312°F) and close (short circuit) at 124°-136°C (255°-276°F). Refer to the related problems under “Run-Time Diagnostics”, Overtemperature Indicator ON, in the Troubleshooting Section.

Location of Components: (1) Drive Motor (2) Pump Motor (3) Pump Motor Thermal Switch (4) Drive Motor Thermal Switch

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Electrical System Adjustments

Accelerator Control Linkage

Method A (Mechanical) 1. Disconnect the battery. 2. Fully depress the accelerator pedal (1) until pedal is stopped on bolt (3). Adjust bolt so that groove (4) on accelerator control shaft (2) is even with face (5) of accelerator control (6). The groove should not reach the shaft wiper. 3. Release accelerator pedal (1).

Method B (Electrical) 1. Place the truck in the “Self” Diagnostic mode and proceed to test 5. 2. Cycle the RUN/DIAG/SETUP switch so that the accelerator speed is flashed on the display. 3. Depress the accelerator pedal until the floor plate bolts stops the pedal motion.

Accelerator Control Linkage: (1) Accelerator Pedal (2) Accelerator Control Shaft (3) Bolt (4) Groove (5) Face (6) Accelerator Control

4. Adjust the floor plate bolt until a “14” is flashed on the display. If the speed flashed is less team “14”, adjust the bolt to allow more pedal travel. If the speed flashed is more than “14”, adjust the bolt to allow less pedal travel. 5. Adjust the floor plate bolt just enough to get the display to change from a flashing “14” to a flashing “15”. Ensure that the groove on the accelerator control shaft does not reach the shaft wiper when the accelerator is fully depressed.

163

WENB8604-02

Parking Brake Switch

Lift, Tilt, and Auxiliary Switches Each function has its own independent microswitch for activating the hydraulic pump motor. Refer to the topic “Programmable Features” in the System Operation section of this manual for information on adjusting lift tilt, and auxiliary speeds.

1. Close the seat switch and turn the key ON.

2. Release the parking brake and put the truck in forward. 3. Depress the accelerator. With the tires in rotation, apply the parking brake.

4. Tire rotation should slow and/or stop and the parking brake action light should turn ON. 5. If the parking brake action light did not turn ON, check the parking brake switch and wiring to the logics. Refer to problem 40, “Park Brake Circuit Defect” in the Troubleshooting Section. Location of Components: (1) Lift 1 Switch (2)Lift 2 Switch (3) Tilt Switch (4) Aux 1 Switch

Location of Components: (1) Switch

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Rapid Tune-Up Procedure

! WARNING

The rapid tune-up procedure establishes a starting point for logic card adjustments. The following procedure allows the truck to be operated for test purposes without damage to the truck or its components. Always verify that the jumper on the logic board is in its proper position for the voltage of the lift truck being tuned. J1 = 36V

J2 = 48V

J3 = 72V

J4 = 80V

Service exchange logic boards do not need a rapid tune-up procedure. These boards are pre-adjusted from the factory and their programmable features are set to the default values. However, Option #30 must be programmed to the correct truck type and size. The current limit, electrical braking, and BDI should be checked and adjusted by certified technicians.

The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Safely lift the drive wheels off the floor. Put blocks of wood under the frame so that both drive wheels are free to turn. NOTE: All programmable features should be set to their default values before making any adjustments. See the topic “Activating Default Settings” in the Systems Operation section of this manual. 1. Turn current limit potentiometer P1 fully counterclockwise, then eight turns clockwise. 2. Turn electrical braking potentiometer P3 fully counterclockwise, then eight turns clockwise. 3. Make the final adjustments, as specified in each of the Testing and Adjusting Procedures, before putting the truck back into service. Perform these procedures in the following order. 1. Battery Discharge Indicator (BDI)-P5 2. Current Limit-P1 3. Electrical Braking-P3

Logics Board

165

WENB8604-02

Current Limit Test and Adjustment

! WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Safely lift the drive wheels off the floor. Put blocks of wood under the frame so that both drive wheels are free to turn. NOTICE: Damage can be caused to the control panel. Do not switch the direction lever from one direction to the other (plug the truck) when the drive wheels are off the ground and in rotation at full speed. NOTE: Current limit is preset and sealed at the factory and should only be adjusted by certified mechanics with calibrated equipment.

4. For ease in reading the equipment, a 6V7070 Digital Multimeter may be set to the 2VDC range and connected to the 8T0900 Digital Ammeter using a 6V6014 Cable. For more information, refer to Special Instruction SEHS8030. 5. Get on the truck. Turn the key switch on. Clear any SRO conditions if necessary. Release the park brake. 6. Place the direction lever in either forward or reverse. Depress the service brake. The drive wheels must NOT turn during this procedure. 7. Depress the accelerator fully. Measure the current in A1. Values should be as follows:

MODEL

CURRENT LIMIT (AMPS) 36/48V 72/80V

2FBC15/ 18

400 ± 5%

425 ± 5%

2FBC20/ 25 / 25E

525 ± 5%

425 ± 5%

2FBC30

525 ± 5%

450 ± 5%

NOTICE: Do not stall the drive motor for more than three seconds. Damage to the motor will result. Between stalls allow the drive wheels to turn with the tires off the floor to cool the motor. If the motor remains stalled for more than three seconds, the line contactor will open and “20” will appear in the display. (1) 8T0900 Digital Ammeter

1. Begin this procedure with the key switch OFF and the park brake applied. Put blocks of wood under the frame so that both drive wheels are free to turn. 2. Enter Setup Mode and set the following Options: Option 13 = 13 Option 20 = 0 Option 22 = 13 3. Connect 8T0900 Digital Ammeter around the loop in cable A1 to check drive motor current limit. NOTE: The arrow on the ammeter points in the direction of current flow for a positive indication.

166

8. If the current value is not acceptable, adjust potentiometer P1 until the value is correct. Turn the adjustment screw clockwise to increase current. Turn the adjustment screw counterclockwise to decrease current. Between adjustments, allow the motor to turn. This will prevent sitting on one spot on the commutator, which could cause damage to the motor. 9. After the current value is correct, turn off the truck. Use setup modes to return Options 13, 20, and 22 to their original values. Current Limit is now set.

WENB8604-02

Electric Braking Current Test and Adjustment 1. Make sure the current limit is adjusted to specification before adjusting electric braking current. If current limit is changed after setting plugging current, plugging current will change.

2. Connect 8T0900 Digital Ammeter (1) around cable A1 to check plugging motor current. Check the jaws of the meter to make sure they are fully closed. NOTE: The arrow on the ammeter points in the direction of current flow for a positive indication.) 3. For ease in reading current, a 6V7070 Digital Multimeter may be set to the 2V DC range and connected to the 8T0900 Digital Ammeter using a 6V6014 cable. Refer to Special Instruction SEHS8030 for more information.

(1) 8T0900 Digital Ammeter

4. Move the lift truck FORWARD at full speed. Keep the accelerator pedal fully depressed and change the direction control to REVERSE. 5. The current measured during electrical braking (plugging) must be 300 amps ±-5%. NOTE: Though the plugging distance is an application adjustment, plugging current should not exceed 315 amps. If the recommended cur rent produces a short stopping distance, the distance may be lengthened by turning potentiometer P2 counterclockwise to reduce plugging current.

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Logic Board Layout

! WARNING IMPORTANT! Since many battery manufacturers have different types of batteries available, the Battery Discharge Indicator (BDI) should be adjusted to meet the battery manufacturer’s specifications for a discharged state. The BDI Information provided is to be used FOR REFERENCE ONLY. Please consult the battery manufacturer for the correct discharge state for your particular batteries. Before adjusting BDI, remove battery surface charge by operating hydraulic system against tilt pressure relief for five seconds.

168

1. Disconnect the battery and discharge the head capacitor. Remove logics cover and verify the DIAG/RUN switch is in the RUN position. 2. Make sure BDI jumper is positioned properly: J1 for 36V

J2 for 48V

J3 for 72V

J4 for 80V

3. Set the multimeter to measure battery voltage. Connect the multimeter positive lead to logic terminal P3-18. Connect the multimeter negative lead to control panel battery negative (negative heatsink). 4. Put the direction lever in Neutral and connect the battery. 5. Close the seat switch and turn the key ON. The measurement should be battery voltage. The display must show the correct number for the voltage measured as shown in the charts that follow:

WENB8604-02

Battery Discharge Indicator Adjustment Charts

FRENCH BATTERY DISCHARGE INDICATOR ADJUSTMENT CHART (FOR FRENCH TUBULAR TYPE BATTERIES) — 36 VOLT/48 VOLT

NORMAL BATTERY DISCHARGE INDICATOR BDI#

36V BATTERY

48V BATTERY

0 - 36.0

0 - 48.0

36.0 - 36.2

48.0 - 48.5

36.2 - 36.7

48.5 - 48.9

36.7 - 36.9

48.9 - 49.4

36.9 - 37.1

49.4 - 49.6

37.1 - 37.6

49.6 - 50.1

37.6 - 37.9

50.1 - 50.6

37.9 - 38.1

50.6 - 51.0

38.1 - 38.6

51.0 - 51.3

38.6 - 38.8

51.3 - 51.8

38.8 - 39.1

51.8 - 52.1

BDI #

36 VOLT BATTERY

48 VOLT BATTERY

0 - 36.0

0 - 48.0

36.0 - 36.2

48.0 - 48.2

36.2 - 36.5

48.2 - 48.7

36.5 - 36.7

48.7 - 48.9

36.7 - 36.9

48.9 - 49.4

36.9 - 37.4

49.4 - 49.6

37.4 - 37.6

49.6 - 50.1

37.6 - 37.9

50.1 - 50.3

37.9 - 38.1

50.3 - 50.8

38.1 - 38.3

50.8 - 51.0

38.3 -

51.0 1= Display is Incrementing

1= Display is Incrementing

NORMAL BATTERY DISCHARGE INDICATION ADJUSTMENT CHART— 72 VOLT / 80VOLT

FRENCH BATTERY DISCHARGE INDICATOR ADJUSTMENT CHART (FOR FRENCH TUBULAR TYPE BATTERIES) — 72 VOLT/80 VOLT

BDI#

72V BATTERY

80V BATTERY

BDI #

72 VOLT BATTERY

80 VOLT BATTERY

0 - 72.0

0 - 80.0

0 - 72.0

0 - 80.0

72.0 - 72.6

80.0 - 80.9

72.0 - 72.6

80.0 - 80.6

72.6 - 73.6

80.9 - 81.9

72.6 - 73.2

80.6 - 81.2

73.6 - 74.3

81.9 - 82.6

73.2 - 73.8

81.2 - 81.8

74.3 - 75.0

82.6 - 83.5

73.8 - 74.1

81.8 - 82.3

75.0 - 76.0

83.5 - 84.2

74.1 - 74.7

82.3 - 82.9

76.0 - 76.7

84.2 - 85.2

74.7 - 75.3

82.9 - 83.5

76.7 - 77.4

85.2 - 86.1

75.3 - 75.7

83.5 - 84.1

77.4 - 78.3

86.1 - 86.8

75.7 - 76.3

84.1 - 84.7

78.3 - 79.0

86.8 - 87.7

76.3 - 76.9

84.7 - 85.3

79.0 -

87.7 -

76.9 -

85.3 -

1= Display is Incrementing

EXAMPLE: If the measurement is 36.8 volts for a 36 volt battery, the display should be at 6.

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6. If the display is not correct, turn the key OFF and make an adjustment to potentiometer 5. Adjust potentiometer P5 a small amount. Turn it clock wise to increase and counterclockwise to decrease the display number. Repeat step 5. Turn the key to OFF between each adjustment. 7. If the voltage was 36.8, the potentiometer should be tuned to find the transition point between 7 and 6 on the display. This will assure that the logics is calibrated at high 6.

If the display shows a “0”, this indicates that the battery is discharged. The display will not show any battery charge level unless the battery voltage is above a level “6”. See the topic “Programmable Options: Option 17” in the Systems Operation section. There are two battery discharge indicator ranges that can be selected. See Programmable Option 25.

NOTE: Approximately 1/4 turn of potentiometer P5 changes the display one number. When the BDI of the lift truck suggests that the battery is discharged 80%, the specific gravity of the battery should be checked also. The specific gravity should then be compared to the battery manufacturer’s recommended specific gravity for 80% discharge. If the specific gravity is too low, P5 should be turned counterclockwise to reduce the BDI number. If the specific gravity is too high, P5 should be turned clockwise to increase the BDI number.

170

Logics Board

WENB8604-02

Harness Wiring Circuit Guide The main lift truck electrical harness uses multicolored wires connected to different components on the truck.

WIRE # COLOR 1A BROWN 1B BLUE 1C 1D 1E 3 3A 3B 4 7 8 12 13 14 15 16 24 53 55 56 66 68 69 71 76 77 78 81 82 83 87 88 89 91 92 106 107 108 109 110 113 115 116 122

YELLOW BLACK RED ORANGE WHITE/ ORANGE ORANGE WHITE BLACK YELLOW BROWN GRAY WHITE/ BROWN WHITE/ GREEN BROWN GREEN BLACK YELLOW/ BLACK YELLOW GREEN RED GREEN WHITE BLACK BLUE BLUE BLUE WHITE BLUE BLUE YELLOW YELLOW BLACK WHITE GREEN YELLOW YELLOW GREEN YELLOW RED RED GREEN YELLOW

CONNECTOR PIN # P13-1, P5-1 P7,P5-2,T18,P24-1, P9-A, P6-1, P60-A P5-36,P33,P40-A,T17,T9,T7 P39-7,P32-3,P38-1,P39-8 P5-37,T14,T13 P5-3,P46-2 T1, WIRE 3

The following chart can be used when troubleshooting as a guide to the circuit function. This guide applies only to the main harness wiring, not the component wiring.

EP TR3000 WIRE CONNECTIONS WIRE TERMINATIONS HYD. SW., LOGICS, BATTERY NEG DIR. CTRL,LOGICS,SEAT SW.,PRESS.SW,ACCEL.,DISPLAY,SEAT BRAKE SW,FOOT DIR. CTRL,BATT NEG LOGICS,BRAKE FLUID,FOOT BRAKE SW,PARK BRAKE SW,BATTERY NEG DC/DC CONV, SHUNT FIELD CONN., REAR OPTION, BATTERY NEG LOGICS,HORN,HORN FILTER,BATTERY NEG LOGICS,CONSOLE GENERAL, BATTERY POS HORN SW., BATTERY POS.

P39-1, P32-4 P5-4, P46-1, P9-B,39-6, P38-2, P6-2, P38-3 P5-7,T19,P60-C P5-8, P9-C P5-12, P6-4 P5-13, P13-5 P5-14, P7, P61-2

DC/DC CONV., SHUNT FIELD CONN.,BATTERY POS. LOGICS,CONSOLE GENERAL, ACCEL,DC/DC CONV, REAR OPTIONS, DISPLAY LOGICS,SEAT SWITCH,SEAT BRAKE SWITCH LOGICS, ACCEL LOGICS DISPLAY LOGICS, HYD. SW. LOGICS, DIR. CONTROL, FOOT DIR. CTRL.

P5-15, P7, P38-8, P61-3

LOGICS, DIR. CTRL.

P5-16, P6-3 T2, T15, T12 P39-4, P41-1,P42-1,P38-5,P39-5 P48,P38-6

LOGICS, DISPLAY HORN, HORN SW., HORN FILTER DC/DC CONV.,HEAD LAMP RIGHT, HEAD LAMP LEFT, REAR OPTIONS LIGHT SW., REAR OPTIONS

P48,P41-2,P42-2 P39-2,P46-3,P46-7,P39-3 P32-6,T24 P32-5,T22 P32-2, T21 P5-24,T8 P5-25,T6 P5-26,P24-2 P5-27,P13-6 P5-28,DU2-2 P5-29,DU1-2 P5-32, P13-4 P5-33,P13-3 P5-34,P13-2 P5-19,T16 P32-1,T23 P5-22,P33 DU2-1,T11 DU2-3,T10 DU1-1,T4 DU1-3,T5 P5-23, P40-C P5-30, P52-1 P5-31,P52-2 P46-8,P48

LIGHT SW., HEAD LAMP RIGHT, HEAD LAMP LEFT DC/DC CONV.,CONSOLE GENERAL SHUNT FIELD CONN.,TRACTION MOTOR SHUNT FIELD SHUNT FIELD CONN., PUMP MOTOR SHUNT FIELD SHUNT FIELD CONN., PUMP MOTOR SHUNT FIELD LOGICS,TRACTION MOTOR THERMAL SW. LOGICS,PUMP MOTOR THERMAL SW. LOGICS,PRESSURE SW. LOGICS,HYDRAULIC SW. LOGICS, DIODE BLOCK 2 LOGICS, DIODE BLOCK 1 LOGICS, HYDRAULIC SW. LOGICS, HYDRAULIC SW. LOGICS, HYDRAULIC SW. LOGICS, PARK BRAKE SW. SHUNT FIELD CONN.,TRACTION MOTOR SHUNT FIELD LOGICS, BRAKE FLUID SW. DIODE BLOCK 2, TRACTION MOTOR BWI DIODE BLOCK 2,TRACTION MOTOR BWI DIODE BLOCK 1,PUMP MOTOR BWI DIODE BLOCK 1,PUMP MOTOR BWI LOGICS, FOOT BRAKE SW LOGICS, SPEED SENSOR LOGICS, SPEED SENSOR CONSOLE GENERAL, LIGHT SW. 171

Service Manual EV100ZX SCR Motor Controller 2FBC15 2FBC18 2FBC20 2FBC25 2FBC25E 2FBC30

WENB8606-01

SAFETY PRECAUTIONS

Mitsubishi Forklift Trucks Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules and precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “CAUTION” or “WARNING” as shown below.

! WARNING The meaning of this “Safety Alert Symbol” is as follows: Attention! Become Alert! Your Safety is involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

Mitsubishi Caterpillar Forklift America Inc. cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all-inclusive. If a tool, procedure, work method or operating technique not specifically recommended by Mitsubishi Caterpillar Forklift America Inc. is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Mitsubishi Forklift Trucks dealers have the most current information available.

TABLE OF CONTENTS 1.

GENERAL INFORMATION & FEATURES Glossary....................................................................................................................................... Nameplate and Serial Number Locations.................................................................................... EV100ZX Motor Controller without SCR Hydraulics ................................................................... EV100ZX Motor Controller with optional SCR Hydraulics........................................................... Basics of Circuit Operation .......................................................................................................... Traction Control Logic Flow Chart ............................................................................................... Console (Display) ........................................................................................................................ Features of the EV100ZX Control System .................................................................................. General Maintenance for the EV100ZX Motor Controller............................................................ Trouble-shooting the EV100ZX Motor Controller......................................................................... EV100ZX SCR Control Wiring Schematic without SCR Hydraulics ............................................ EV100ZX SCR Control Wiring Schematic with SCR Hydraulics ................................................. EV100ZX SCR Control Wiring Schematic for Optional Equipment .............................................

HANDSET General Information ..................................................................................................................... Handset Function ................................................................................................................... Operation................................................................................................................................ Function Set-Up Procedures for Traction SCR ...................................................................... Accessing and Clearing Fault Codes ..................................................................................... Bench Checks and Adjustments............................................................................................. Function Numbers (Traction) ....................................................................................................... Function Settings Chart (Traction Card) ...................................................................................... Function Set-Up Procedures for Optional SCR Hydraulics ......................................................... Function Numbers (Pump)........................................................................................................... Function Settings (Pump Card) ...................................................................................................

2-1 2-1 2-2 2-2 2-3 2-3 2-4 2-8 2-11 2-11 2-15

CHECKS & REPAIRS General Information ..................................................................................................................... Fuses ...................................................................................................................................... SCR’s...................................................................................................................................... Thermal Protector................................................................................................................... Reactor Assembly................................................................................................................... Suppressors ........................................................................................................................... Capacitor C1........................................................................................................................... Diodes D3, D4 & D7 ............................................................................................................... Motor Current Sensor ............................................................................................................. Thermal Protector Test ........................................................................................................... Contactors .............................................................................................................................. Control Card ........................................................................................................................... Control Card Plugs ................................................................................................................. Brush Wear Indicators ............................................................................................................ Motor Thermal Switches......................................................................................................... Motors and Controls .................................................................................................................... Truck Management Module (TMM) ........................................................................................ Truck Management Module Connections (TMM1) ................................................................. Thermal Transfer .................................................................................................................... Trouble Shooting Tips............................................................................................................. Unsatisfactory Brush Performance .............................................................................................. Commutator Surfaces .................................................................................................................. Motor Winding Specifications ......................................................................................................

1-1 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-15 1-15 1-16 1-18 1-20

3-1 3-2 3-2 3-3 3-4 3-4 3-5 3-5 3-6 3-6 3-7 3-9 3-9 3-10 3-10 3-10 3-11 3-12 3-13 3-14 3-15 3-21 3-23

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM Main Logic Card........................................................................................................................... Component Locations .................................................................................................................. Terminal Connections for ZX Logic Cards ................................................................................... EV100ZX Logic Card Specifications............................................................................................

4-1 4-2 4-3 4-4

TABLE OF CONTENTS 4.

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM (continued) EV100ZX Current Limit Curves ................................................................................................... Secondary Troubleshooting.................................................................................................... Failures that Cause Reduced or No Motor Torque with SCR Control.................................... Failures that Cause Full or No Motor Torque with SCR Control ............................................ Mis-operation of Other Features ............................................................................................ Hydraulic Pump Control Troubleshooting .................................................................................... Failures that Cause Reduced or No Motor Torque with SCR Control.................................... Failures that Cause No Motor Torque with SCR Control .......................................................

THEORY OF OPERATION Electronic Speed Controls ........................................................................................................... Silicon Controlled Rectifier (SCR) .......................................................................................... Motor Circuit that Operates with Pulses................................................................................. Traction Circuit........................................................................................................................ Hydraulic Pump Motor ............................................................................................................ SCR “OFF” Circuit .................................................................................................................. Flyback Current from the Motor................................................................................................... Control Cards............................................................................................................................... Pulse Monitor Trip (PMT) (Traction Circuit Only) ................................................................... SRO Circuit (Traction Circuit Only) ........................................................................................ Sequence of Operation................................................................................................................ Control Card Adjustments (Traction Circuit Only) .................................................................. Accelerator Control................................................................................................................. SCR Control (Hydraulic Pump Motor) ......................................................................................... Contactors.................................................................................................................................... Circuit Protection ......................................................................................................................... Traction Circuit Fuse .............................................................................................................. Current Limit ........................................................................................................................... Thermal Protection ................................................................................................................. Truck Management Module (TMM1) ........................................................................................... Instrument Panel.......................................................................................................................... Fault Code Memory ................................................................................................................ Brush Wear Indicators ............................................................................................................

5-1 5-1 5-1 5-3 5-3 5-4 5-6 5-6 5-6 5-7 5-7 5-8 5-11 5-11 5-12 5-13 5-13 5-13 5-13 5-13 5-14 5-16 5-16

WIRING Power Cable Connections ........................................................................................................... Standard Control .................................................................................................................... Optional SCR Hydraulics Control ........................................................................................... Traction Control Card Wire Harness Connections ...................................................................... A & B Plugs ............................................................................................................................ Y Plug ..................................................................................................................................... Z Plug ..................................................................................................................................... TMM1 (Truck Management Module 1) ................................................................................... TB Connections ...................................................................................................................... Control Card Wire Harness for Optional Hydraulic Pump SCR .................................................. Panel Connector..................................................................................................................... TB Connections ...................................................................................................................... A & B Plugs ............................................................................................................................ Y Plug ..................................................................................................................................... Z Plug for Use on Option Card............................................................................................... Pump Driver ................................................................................................................................. Pump Time Delay ........................................................................................................................

4-6 4-7 4-7 4-9 4-10 4-12 4-12 4-14

6-1 6-1 6-1 6-2 6-2 6-3 6-4 6-5 6-6 6-7 6-7 6-8 6-9 6-10 6-11 6-12 6-13

DIAGNOSTIC STATUS CODES Basic Checks ............................................................................................................................... 7-1 On Board Diagnostics.................................................................................................................. 7-2 Status Codes ............................................................................................................................... 7-4

EV100ZX is a trade name of General Electric Company

GENERAL INFORMATION & FEATURES

Glossary ..................................................................................................................

1-1

Nameplate and Serial Number Locations ..............................................

1-5

Before Servicing Forklift Trucks...........................................................................

1-5

EV100ZX Motor Controller without SCR Hydraulics ........................

1-6

EV100ZX Motor Controller with SCR Hydraulics ...............................

1-7

Basics of Circuit Operation ...........................................................................

1-8

Traction Control Logic Flow Chart ............................................................

1-9

Console (Display) ...............................................................................................

1-10

Features of the EV100ZX Control System .............................................

1-11

Creep Speed........................................................................................................ Controlled Acceleration........................................................................................ Current Limit ........................................................................................................ Plugging ............................................................................................................... Pedal Position Plug ............................................................................................. Ramp Start........................................................................................................... Full Power Transition ........................................................................................... 1A Current Drop Out............................................................................................ Static Return to Off .............................................................................................. Accelerator Volts Hold-Off ................................................................................... Coil Drivers .......................................................................................................... Thermal Cutback ................................................................................................. Pulse Monitor Trip (PMT)..................................................................................... Steer Pump Time Delay....................................................................................... Internal Resistance Compensation...................................................................... Hour Meter........................................................................................................... Battery Discharge Indication................................................................................ On Board Diagnostics.......................................................................................... Reverse Battery Protection.................................................................................. Shorted 3REC Protection .................................................................................... Low Current Control Switches ............................................................................. Regenerative Braking .......................................................................................... Stored Status Codes ........................................................................................... Four Speed Modes .............................................................................................. Truck Management Module ................................................................................. Maintenance Alert ................................................................................................

1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-12 1-12 1-12 1-12 1-12 1-12 1-12 1-13 1-13 1-13 1-13 1-13 1-13 1-13 1-13 1-14 1-14

General Maintenance for the SCR Control ............................................

1-15

Trouble-shooting the EV100ZX Motor Controller ..............................

1-15

EV100ZX SCR Control Wiring Schematics............................................

1-16

EV100ZX Wiring Schematics without SCR Hydraulics ....................................... EV100ZX Wiring Schematics with SCR Hydraulics ............................................ EV100ZX Wiring Schematics for Electrical Options ............................................

1-16 1-18 1-20

GENERAL INFORMATION & FEATURES

Glossary Circuit A way for current to go from the positive (+) side of an electrical power source to the negative (–) side of an electrical power source. This can be through wires and electrical components.

Accelerator A device that converts mechanical movement into a voltage pattern to the logics for variable drive motor speed. Activate A word used with a component or circuit. To change from the normal condition to the “activated” condition because of an application of force or electricity.

Coil A component made from many circles or turns of wire used to concentrate a magnetic field.

Ammeter An electric meter used to measure current flow in amperes.

Commutator An armature component used to transfer current from the brushes to the armature windings.

Ampere (or Amp) The unit of measure of current flow. The amount of current that one volt can push through a resistance of one ohm.

Compound Motor A motor which has a field winding in series with the armature and a shunt field winding in parallel with the series winding and armature.

Anode The positive (+) side of a diode.

Conduct To allow the flow of current.

Armature The rotating portion of an electric motor or generator.

Conductor A material that provides a path for current flow.

Battery Two or more cells connected together for a supply of electric current.

Connector Part if a wire assembly or harness that connects with another wire assembly or harness. Used for ease of assembly and disassembly.

BDI (Battery Discharge Indicator) An electrically controlled display showing the operator the state of battery charge.

Contact Tips or Contacts The portion of a switch, relay or contactor where the circuit can be opened or closed.

Brush A conductor, normally a block of carbon, that makes sliding contact between the stationary and moving part of the motor or generator.

Bus Bar A heavy electrical conductor to which other smaller wires are connected. Capacitor Device used to store electrical energy for short periods of time. Cathode The negative (–) side of a diode. 1-1

Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly. Continuity Having the ability to allow current flow.

GENERAL INFORMATION & FEATURES

Glossary Electric Motor A device that changes electrical energy into mechanical energy to do work.

Electrical Braking Electrically trying to rotate the drive motor opposite to the direction of truck movement. Electromagnet A coil of wire, most often wound on an iron core, which produces a strong magnetic filed when current is sent through the coil. Electromotive Force (EMF) The force that causes an electric current to flow in a circuit. This force is measured in volts.

Current Limit The maximum allowable armature current of a stalled drive motor during pulsing.

Field Windings The stationary coils that produce a magnetic field in motors and generators.

Current Sensor A hall-effect sensor in the drive motor circuit that produces an increasing voltage output as the drive motor current increases. Current Shunt A precision low-value resistor connected in series with the armature of a motor. The logics uses the measured voltage drop across the shunt to control maximum current allowed in selected power circuits.

Filter An electrical device or component for restriction or suppression of undesired voltage spikes. Fuse A component in an electrical circuit that will open the circuit if too much current goes through it. Generator A device that transforms non-electric energy (such as mechanical, thermal, etc...) into electrical energy.

Deactivate To change from the activated condition back to the normal (deactivated) condition. It can be caused by the application of force, the removal of force, or the removal of electricity. Digital Signal A signal in which the elements may be either of two distinct values. For example high voltage, low voltage.

Grounded A wire or wires that are in contact with the metal chassis of the vehicle (ground). Can be caused by a loss of insulation from the wire, or by connecting the wire to the vehicle.

Diode A semiconductor device that allows current to flow in one direction, from the anode to the cathode.

Harness An assembly made of two or more wires that are held together.

Display An electrical device that converts voltage inputs to a visual output.

Heat Sink A mounting frame used for semiconductor cooling.

1-2

GENERAL INFORMATION & FEATURES

Glossary Hour Meter An electrically activated device used to record the amount of usage a truck receives.

Magnetic Field The area around a magnet where magnetic forces can be detected.

Horse Power A measure of the time-rate of doing work. 1 HP is defined as the equivalent of raising 33,000 pounds, one foot, in one minute.

Microprocessor A small computer chip preprogrammed to control the various electrical functions on a forklift truck. Normal Condition Words used with a switch or relay. Their normal condition is their condition when they are not controlled by the application of force, temperature, pressure, or electricity.

Linear Measure: HP = Force X Distance 33,000 X Time • Force in Pounds • Distance in Feet • Time in Minutes • 33,000 is a Constant

Normally Closed (N.C.) A switch or relay whose contacts are closed in the normal condition.

Rotational Measure:

Normally Open (N.O.) A switch or relay whose contacts are open in the normal condition.

HP = Torque X Speed 5250 • Torque in Foot - Pounds • Speed in revolutions per minute (RMP) • 5250 is a Constant

OFF-Time The amount of time a current does not flow through a semiconductor.

Indicator A lamp or LED that gives an indication of some vehicle condition when it turns on or flashes.

Ohm The unit of measurement of resistance. The amount of resistance that will let one volt push only one ampere of current through it.

Input A voltage change at the incoming connection of a component.

ON-Time The amount of time current flows through a transistor.

Insulator A material that has a very large resistance so that it will not let current flow through it.

Open Circuit Wiring or components of a circuit that have no continuity.

LED Light Emitting Diode - a diode that emits light (lights) when current flows in the forward direction.

Optical Switch An electronic device made up of an infrared light signal generator and photosensitive signal receiver that changes a digital voltage when the light pattern is conducting or blocked.

Logics or Logic Unit The main printed circuit board containing a microprocessor and circuits to condition the voltage signals that go into or come out of the logics. It electronically monitors and controls the truck’s functions.

Output The current flow from a component which initiated from a voltage change at the component’s input.

1-3

GENERAL INFORMATION & FEATURES

Glossary Resistance Opposition to the flow of current in a circuit. The unit of electrical resistance is the OHM. The lower the resistance, the greater the current flow for a given voltage.

Wiring Diagram A drawing using visual representation of components the way they actually look. It is used to show the locations of components and the connections between them.

Silicon Controlled Rectifier (SCR) An electrical switch; a solid-state device used to generate the rapid ON and OFF times. It has no moving parts. See “Theory of Operation” Section.

Zener Diode A special diode used to regulate voltage or as an overvoltage (too high a voltage) protector.

Source Terminal of a MOSFET through which the main current flows (See MOSFET). Terminal An electrical connection point on an electrical component. Torque The turning force or effect required to do work. Torque = Force X Distance • Force in Pounds • Distance in Feet to center of rotation

Varistor A component terminated across the horn connections to eliminate voltage spikes when the horn is activated. Volt The unit of measurement of electromotive force. One volt is the force needed to make one ampere of current flow through one ohm of resistance in a circuit. Watt The unit of measurement of power. The amount of power used when one volt pushes one ampere of current through a resistance of one ohm. The result of amperes (current) multiplied by volts (voltage) is watts (power). Wire A conductor used to provide a path for current to flow to and from electrical components.

1-4

GENERAL INFORMATION & FEATURES

Nameplate and Serial Number Locations

Nameplate Chassis Serial Number Mast Serial Number

Power Steering Motor Serial Number

Hydraulic Motor Serial Number

Traction Motor Serial Number

Before Servicing Forklift Trucks

! WARNING Before doing any maintenance or adjustments on the Forklift Truck, be sure to always use correct blocks to prevent the unit from rolling or falling. Raise the drive wheels off the ground. This can be done by tilting the mast all the way back, placing hard wood blocks under the mast then tilting the mast forward. Securely support with blocks. 1-5

GENERAL INFORMATION & FEATURES

EV-100ZX Motor Controller without SCR Hydraulics

1. Controller, Traction 2. Contactor, Hydraulic Pump Motor 3. Forward Contactor 4. Reverse Contactor 5. Contactor, 1A By-Pass 6. Contactor, Regenerative Braking 7. Contactor, Power Steering

8 (Under Fuses)

8. 9. 10. 11. 12. 13.

Electronic Driver Truck Management Module (TMM1) Fuse 1 (Traction Circuit) Fuse 2 (Hydraulic Pump Circuit) Fuse Panel (FU 4, FU 5, FU 6) Fuse 3 (Steering Circuit)

TYPICAL CONFIGURATIONS OF THE EV-100ZX MOTOR CONTROLLER 1-6

GENERAL INFORMATION & FEATURES

EV-100ZX Motor Controller with optional SCR Hydraulics

3 8

1. Controller, Traction 2. Controller, SCR Control for Hydraulic Pump Motor 3. Contactor, Hydraulic Pump Motor 4. Forward Contactor 5. Reverse Contactor 6. Contactor, 1A By-Pass

7. Contactor, Regenerative Braking (Option on some models) 8. Fuse 1 (Traction Circuit) 9. Fuse 2 (Hydraulic Pump Circuit) 10. Fuse Panel (FU 4, FU 5, FU 6) 11. Fuse 3 (Steering Circuit) 12. Contactor, Power Steering

TYPICAL CONFIGURATIONS OF THE EV-100ZX MOTOR CONTROLLER WITH OPTIONAL SCR HYDRAULICS 1-7

GENERAL INFORMATION & FEATURES

Basics of Circuit Operation During the off time, the energy stored in the motor, by virtue of the motors inductance, will cause current to circulate through the motor around the loop formed by 3REC. Thus, providing what is called “flyback current”. The figure below shows the nature of the motor current which is composed of both battery current and the inductive flyback current.

The control circuit is energized by closing the key switch, seat switch, and moving the forward or reverse lever to either position, and then depressing the accelerator closing the start switch. This applies power to the control card which will close the selected directional contactor and complete the circuits to the drive motor. (See elementary drawings on page 6 & 7). The control card then supplies a gate pulse to 2REC turning it on to a conducting state, allowing current to flow from the battery through 1C, 1X, 2REC, motor field, motor armature, sensor , and back to the battery. After 1C charges, 2REC shuts off due to lack of holding current. The control card checks that 1C is charged and unlocks the gate to 1REC and 5REC, The control card then supplies a gate pulse to 1REC turning it on to a conducting state, allowing current to flow from the battery through 1REC, motor field, motor armature, sensor, and back to the battery. 5REC turns on and allows current to flow T4-T3, 1C, 1REC, 5REC to T4-T3. This current charges the bottom of 1C positive with respect to the battery positive bus. This charging cycle occurs in less than 1 millisecond (.001 sec.) and 5REC shuts off. This charge is now stored on the capacitor until it is time to turn off 1REC. Current continues to flow in 1REC until the control card fires 2REC. When 2REC conducts, capacitor 1C discharges around the circuit composed of 1C, 1X, 2REC, and 1REC. This discharge current opposes the battery current through 1REC so that the resultant current is zero. With reverse voltage across 1REC, 1REC is turned off. Current continues to flow in the 2REC, 1C, motor and battery loop until the capacitor (card terminal 14) is fully charged negative. This charge exceeds battery voltage by an amount which is a function of peak motor current, and 2REC turns off. The figure below illustrates the pulsing of current from the battery.

1-8

It should be noted that the average motor current measured will be greater than the average battery current. The SCR control, in effect, converts battery current at battery volts into a higher motor current and a lower motor volts. The time for the next ON and OFF cycle to start is determined by the time that the control card takes to oscillate. This frequency of oscillation is controlled by the potentiometer in the accelerator and automatic circuitry in the card. Slow speed is obtained by having maximum ohms in the potentiometer. As the resistance in the potentiometer decreases, the speed of the motor increases. The SCR circuit is capable of delivering approximately 95% speed. For full speed operation, the 1A contactor is closed to apply full battery voltage across the motor.

GENERAL INFORMATION & FEATURES

Traction Control Logic Flow Chart Circuit is energized to allow the Direction Contactor to Close when a direction is selected

Connect Battery

Close Key Switch

was Truck in Neutral?

YES

is Truck in Neutral?

NO Power is applied to the Control Card

is Seat Switch Closed?

The selected Contactor closes

Regen Braking Contactor closes

YES

Battery Positive at T2?

YES

are Brake and Accelerator Switches closed?

YES

YES PMT check completed

INCORRECT

PMT Fault Sequence

CORRECT PMT Fault Sequence Accelerator Start Switch closes and the Accelerator moves

retest T2 to see if 1C is welded or 1REC is on

continue where you left 2REC is turned on by a signal from the Control Card

Capacitor (C1) charges up, and turns off 2REC

• Current flows through 1REC to the Motor and back to the Battery • Current flows through 5REC charging C1 to reverse battery volts

the Control Card turns on 2REC, 1C discharges through 1REC to the Motor 1REC shuts off when 1C is discharged

1-9

open Forward and Reverse Direction Contactors

YES did 1REC shut off?

1REC shuts off when 1C is charged

PMT Fault Sequence

GENERAL INFORMATION & FEATURES

Console (Display)

Mode Check

Fault Code Park Brake

Brake Fluid

Mode Change

Battery Low Over Temp BWI Service Due

Mode Change: The ZX control allows the operator to select from 4 different speed ranges by use of this button on the console. Each speed from 1 to 4 provides increasing acceleration rates as well as top speed. These are preset by the technician through the Handset Functions 48 through 60. Mode Check: The console will display the speed range currently selected when this button is pressed in the event the operator is uncertain. The operator may complain that a truck is running too slow or fast if unaware of how to check the speed. Fault Code: When the ! is lit the number being displayed on the dash gauge is a fault code indicating a problem.

Brake Fluid: This lamp will light when the brake fluid is low in the reservoir. Battery Low: When the battery state of charge gets to 20 on the meter this light comes on to give the operator advance warning that the lift will soon reach cut out. Over Temp: This light will come on when either drive or pump motor thermostat switches close. The truck will also slow down. BWI: This light will come on when the brushes in either the drive or pump motor wear to the point that they require maintenance. The truck will also slow down.

Service Due: This is the wrench light that will come Park Brake: This will warn the operator the park brake on when the Maintenance Hour Meter reading is applied. programmed into the card is reached. 1-10

GENERAL INFORMATION & FEATURES

Features of the EV100ZX Control Systems The EV100ZX Control System uses a microprocessor in the main card. This microprocessor is programmable in the field allowing for more features to be adjustable and there is a greater range over which they can be set. This allows us to fine tune the control for a customers specific needs.

Creep Speed This is the rate at which the Main SCR is turned on and off when the accelerator is at it’s slowest speed position. This is adjustable to meet the individual needs of each customer. It can be set from 5% to 15% on time. Controlled Acceleration This is the pace at which the oscillator increases the percent of on time of the Main SCR. It allows for adjustments in the time required to go from creep speed to 96% applied battery voltage to the motor on hard acceleration. It can be set from 0.1 seconds to 22.0 seconds. The 1A bypass contactor will then close .2 seconds after top control speed is reached and controlled acceleration stops. Current Limit This feature monitors the current through the motor circuit. It looks at actual motor current where older controls were only able to look at battery current. This is important since motor current includes flyback (*) current and can be 2 to 3 times battery current. When heavy motor loading takes place this feature overrides the oscillator and limits the average current to the value at which it is set. The factory setting should be adhered to for this adjustment. (*) flyback - When the Main SCR shuts off and stops conducting the magnetic field in the drive motor field collapses. This collapsing of a magnetic field moving across a set of windings induces a current of opposite polarity voltage. We then use this voltage to continue driving the armature during the off time of the Main SCR. The average motor current then is the sum of the flyback and the amount conducted by the Main SCR. We will see exactly how this works later. Plugging This feature allows the operator to change the direction the truck is traveling without coming to a stop first. When the direction lever is reversed the truck comes to a smooth stop and gradually accelerates in the other direction. The severity of this feature is adjustable for individual customer preferences. We will cover this in more detail later. 1-11

Pedal Position Plug This feature allows the operator to control the severity of the stopping and acceleration during a plug. The operator simply positions the accelerator for the plugging severity desired. Letting up on the accelerator during the plug reduces the severity (increasing the stopping distance) and pushing down increases the severity (reducing the stopping distance). This feature is adjustable, however it should be noted that it interacts with the plugging adjustment and if changed the plugging adjustment may also have to be reset. This feature is new with the programmable ZX control system.

Ramp Start This feature allows the operator to stop on an incline and restart without the truck rolling. The control remembers if the directional switch has changed position. If it has it assumes the operator is in a plugging mode, if not it assumes they have stopped on a ramp.

Full Power Transition This feature prevents arcing and burning of the 1A bypass contactor tips. It keeps the Main SCR pulsing during the pick-up and drop out of the 1A bypass contactor. This is helpful to keep in mind when troubleshooting.

1A Current Drop Out This feature will open the 1A bypass contactor under excessive motor currents. This puts the truck back in control range where the currents are limited as preset. In certain operations this can protect the motor from damage. The control does not utilize full power transition when the feature is operational and therefore some burning of the 1A tips will take place.

Static Return To Off This is a safety feature to assure that the operator cannot accidentally make the truck drive when climbing on. If the key switch is left on and the directional switch is left with either forward or reverse selected the truck could drive, if the operator accidentally depressed the accelerator while climbing on the truck. This is done through the installation of a seat switch which opens when the operator exits the seat of the vehicle. There is a time delay built in of approximately 1.5 seconds to allow for momentary opening of the seat switch in the event of a bump. This feature is not adjustable.

GENERAL INFORMATION & FEATURES

Features of the EV100ZX Control Systems 2. The PMT circuit will shut down the control during operation if certain faults occur. These include failure of the Main SCR to turn off or for the 1A contactor to remain closed when it is supposed to be open. The control will then open the Forward or Reverse contactor. 3. After opening the contactor the PMT circuit closes the contactor and checks again to see if the fault still exists. If so it opens the contactor again and will not allow it to close until the key switch is cycled. At that time depending on the fault the look ahead PMT circuit may refuse to let the control start up.

Accelerator Volts Hold-Off The EV100 control checks the accelerator circuit to assure that the voltage is above 2.5 before the control will start. This is to assure that in the event of an accelerator related failure the truck will not start up at full speed immediately when the accelerator is first depressed. It is not adjustable. Coil Drivers The early EV100 utilized drivers to actuate and carry the current load of the contactors. These helped reduce the need for coil filters in spike suppression. Drivers also eliminated any need to incorporate interlock switches. Advancing technology has allowed these drivers to be incorporated within the main solid state card on the ZX system. The contactors on the early EV100 had a compromise 42 volt coil which would work on either 36 or 48 volt systems. The contactors on the ZX are 24 volt which reduces current. Battery voltage for the coils is reduced by a chopper circuit in the card. The card has internal spike suppressions which eliminates the need for external suppressors. This reduction of components improves reliability and reduces maintenance costs. Thermal Cutback Heat is the primary cause of failure for electrical components. If the control should be subjected to excessive loading for a lengthy time period it will cause the control to overheat. When this occurs the control will gradually cut back the current allowed to flow through the system to the motor. This will reduce the vehicle speed as the system cools due to handling less current. If the overheating is severe the control will also not be allowed to close the 1A bypass contactor. This is to prevent the truck from lurching as a result of the lower control range speed and the transition to full bypass speed. Pulse Monitor Trip (PMT) This feature will prevent the control from operating if a condition exists which would result in the truck operating in an uncontrolled (run away) condition. Understanding the three separate aspects will assist you in proper troubleshooting and repairing any failures. 1. The PMT circuit will check ahead to see if certain faults exist prior to start up. If found the control will be prevented from starting. The items checked include a shorted Main SCR, welded 1A contactor tips, shorted Forward or Reverse contactors coil drivers, or a shorted 3 REC.

Steer Pump Time Delay Actuation of the steering pump contactor on the ZX system is done through the Main Control Card. This allows the time delay for opening of the contactor to be adjustable. These controls are usually set to open the steer sump contactor after the directional switch has been returned to neutral for 3.5 seconds. There is also an override feature which will drop the steer contactor out after the seat switch has been opened for 1.5 seconds. Internal Resistance Compensation All batteries have a small amount of internal resistance and this value varies significantly. Likewise the internal resistance of individual trucks will vary depending on size of power cables, length of power cables, routing of cables, etc. This feature allows the adjustment of the control to compensate for these varying resistances. This will allow the Battery Discharge Indicator feature to be considerably more accurate than on earlier control systems. This adjustable feature became available with the LX and ZX controls. Hour Meter The truck hour meter is built into the card and will automatically record control hours on the ZX controls. Each time the key switch is turned on the display will show 8 8 8 8 briefly so that the LED’s can be checked to prevent possible erroneous readings if one of them fails. When the key switch is turned off the hours will display briefly. The hour meter display is a four digit display.

1-12

GENERAL INFORMATION & FEATURES

Features of the EV100ZX Control Systems Battery Discharge Indication

Regenerative Braking

During the normal run mode the Display indicates the state of battery charge. It has a range of from 0% to 100% of charge state. When properly adjusted the gauge will read 10% when the battery has reached an 80% discharge state. Battery manufacturers recommend this to be the maximum amount of discharge prior to recharging. When the gauge reads 20% the display will start to blink as an early operator alert. Lift interrupt is incorporated in the ZX card. When the gauge reads 10 the control will disable the pump contactor. This feature is adjustable but should not be set so that it will allow over discharging of the battery. The BDI display is a three digit display.

This feature is activated when the vehicle is moving and the directional lever is moved from one direction to the other. This initiates a plugging signal by reversing the motor field. Once the generated current reaches a particular current level, the plugging mode transitions to regenerative braking mode. The major advantage is longer motor life due to reduced motor heating.

On Board Diagnostics The ZX Control includes diagnostic readouts of fault codes on the battery indicator gauge. Readouts make it possible for technicians to take advantage of the fault codes displayed prior to going out to work on the truck. This may prove helpful in knowing what parts, tools, etc. to take with them. The fault code is a two digit number preceded by a dash for the traction control. With the optional SCR hydraulic control this will be a three digit number preceded by a dash if the problem is in the pump control. In the event that the fault is intermittent the last code will not be displayed, however it will be maintained in the cards memory and can be accessed through the use of the Hand Set. The ZX control stores up to 16 of the most recent fault codes. We will discuss how to access these later.

If the battery connections are reversed, the control will not operate.

This feature prevents the control from operating if the flyback diode (3REC) is in a shorted condition.

This feature furnishes a function register that contains the last fault that shut down truck operation (PMT type fault that is reset by cycling the key switch). This status code will be overwritten each time a new status code occurs and can be cleared from memory by adjusting the value to zero.

Four Speed Modes There is a button on the dash console which allows the operator to select 4 different speed modes of control operation. This will allow the operator to select the best control operating characteristics for individual plant operating conditions. The ranges effect acceleration and top speed. Each speed mode number increase gives an increase in acceleration and/or top speed. With factory settings the following ranges may be selected:

Speed #1 – 10.9 seconds to accelerate to top possible speed. No 1A available.

Reverse Battery Protection

Shorted 3REC Protection

Stored Status Codes

Speed #2 – 2.6 seconds to accelerate to top possible speed. No 1A available. Speed #3 – 2.6 seconds to accelerate to top possible speed. 1A is available. Speed #4 – No minimum time to accelerate to top possible speed. 1A is available.

Low Current Control Switches This feature is used for the directional input switches. The only coil current carrying switches are the key, brake, seat and start switches.

The preset speeds can be changed only with the Handset and the operator can only select one of the four possible preset speeds. In this way, if desired, the amount of difference in these speed settings can be minimized or eliminated. Each speed, however, must be equal to or more aggressive than the one preceding it. 1-13

GENERAL INFORMATION & FEATURES

Features of the EV100ZX Control Systems Truck Management Module This feature slows the truck down should certain conditions arise. This will occur anytime we have overheating of either the pump or the drive motor. It also happens if either the pump or drive motor brush wear indicators actuate. In these situations truck speed will be reduced to half SCR range speed and 1A will be held off. When the situation is rectified, the truck will return to full speed. A 90 series status (fault) code will be displayed on the dash gauge but will not be retained in memory. These speed reductions may be disabled or changed as a customer may require. When the truck is equipped with SCR hydraulics this function is done in the hydraulic SCR card and we do not need the TMM card.

Maintenance Alert The main card can be programmed to illuminate a wrench shaped light on the dash when the truck is due for Planned Maintenance. The time interval can be programmed into the card. The factory setting will turn the light on at 200 hours. The factory setting will not effect the truck speed but if desirable this can be done with the proper programming. The light will stay on until a new hour meter reading is programmed into the card.

Notes

1-14

GENERAL INFORMATION & FEATURES

General Maintenance for the SCR Control

Trouble-shooting the EV100ZX Motor Controller

The SCR control, like all electrical apparatus, does have some thermal losses. The semiconductor junctions have finite temperature limits above which these devices may be damaged. For these reasons, normal maintenance should guard against any action which will expose the components to excessive heat, such as steam cleaning; or which will reduce heat dissipating ability of the control, such as restricting air flow.

If mis-operation of the vehicle occurs, a Status Code will be displayed on the Dash Display (for trucks equipped with a Dash Display) or by plugging a Handset into the Logic Card’s plug “Y” location and then reading the status code. With the Status Code Number, follow the procedures outlined in the Status Code Section of this manual. to determine the problem.

The following DO’S and DON’TS should be observed: Any controls that will be used in ambients of 100° F (40° C) or over should be brought to the attention of the truck manufacturer. All external components having inductive coils must be filtered. Refer to vehicle manufacturer for specifications. The control should not be steam cleaned. In dusty areas, use low-pressure air to blow off the control. In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used to wash off the control and then blow completely dry with low-pressure air. For the SCR panel to be most effective, it must be mounted against the frame of the truck. The truck frame, acting as an additional heat sink, will give improved truck performance by keeping the SCR control package cooler. The use of a heat-transfer grease (Dow Corning 340) is recommended. Terminal boards and other exposed SCR control parts should be kept free of dirt and paint that might change the effective resistance between points.

Checking and replacement of components are also outlined in this manual. Please refer to this section as needed. Important Note: Due to the interaction of the logic card with all vehicle functions, almost any status code or control fail could be caused by the Logic Card. After all other status code procedures have been followed and no problem is found the logic card should then be replaced as the last option to correct the problem. The same device designations have been maintained on different controls but the wire numbers may vary. Refer to the elementary and wiring diagrams for your specific control. The wire number shown on the elementary diagram will have identical numbers on the corresponding wiring diagrams for a specific truck.

! WARNING Before trouble-shooting, jack up wheels, disconnect the battery and discharge the capacitor 1C. Reconnect the battery as needed for the specific check.

! CAUTION The truck should not be plugged when the truck is jacked up and the drive wheels are in a free wheeling position. The higher motor speeds can create excessive voltages that can be harmful to the control.

If capacitor 1C terminals are not accessible, discharge capacitor by connecting from SCR POS terminal to 2 REC anode. Check resistance on RX1000 scale from frame to SCR power and control terminals. A resistance of less than 20,000 ohms can cause misleading symptoms. Resistance less than 1000 ohms should be corrected first.

Do not hipot (or megger) the control. Unless the terminals of each semiconductor and card are connected together, the control may be damaged. Refer to control manufacturer before hipotting.

Before proceeding visually check for loose wiring, maladjusted linkage to the accelerator switch, signs of overheating of components, etc.

Tools and test equipment required are: (a) 6-volt lamp, Use a lead-acid battery with the voltage and ampere 6-volt battery, two A14 diodes (1Amp 400V), clip hour rating specified for the vehicle. Follow normal leads, volt-ohm meter (20,000 ohms per volt) and battery maintenance procedures, recharging before 80 general hand tools. percent discharged and with periodic equalizing charges. 1-15

GENERAL INFORMATION & FEATURES

EV100ZX SCR Control Wiring Schematic Optional Equipment

1-20

HANDSET

General Information .......................................................................................... 2-3 Handset Functions............................................................................................... 2-1 Operation ............................................................................................................. 2-2 Function Set-up Procedures for Traction SCR .................................................... 2-2 Accessing and Clearing Fault Codes................................................................... 2-3 Bench Checks and Adjustments.......................................................................... 2-3

Function Numbers (Traction) ....................................................................... 2-4 Function Settings Chart (Traction Card).............................................................. 2-8

Function Set-Up Procedures for Optional SCR Hydraulics ......... 2-11 Function Numbers (Pump)................................................................................... 2-11 Function Settings Chart (Pump Card) ................................................................. 2-15

HANDSET

General Information NOTE: The vehicle will operate with the Handset connected, however, the adjustment knob MUST BE SET FULLY CLOCKWISE to make sure the control can operate at maximum speed. This section has the control card checks and adjustments that can be made using the Handset. The control card checks and adjustments are usually made with the control card installed in the forklift truck. Bench checks and adjustments can also be made with the control card connected as shown in FIGURE 4. The checks show the stored setting numbers that have been stored for the different control card functions. This section also includes a description of each of the different functions. Use the adjustment knob on the Handset to adjust the function settings. See FIGURE 1. The Handset is available from Mitsubishi under part #97124-07400.

Handset Functions The purpose of the Handset is to permit authorized personnel to perform checks and adjustments:

1. Adjustment Knob 2. LED Display 3. Keypad

4. Coil Cord 5. Plug PY (14 Pin) 6. Modular Plug (8 Pin Hand Set)

FIGURE 1. Handset The Handset is a multifunctional tool to be used with the EV-100ZX series motor controllers. The Handset is used to access the memory elements called “Registers” which have electronic data stored in them to control an operation. There are 128 Registers in the ZX series of Control Cards. The Handset will access the registers for the traction or pump motor functions, indicate Status Codes (possible faults) and make adjustments to the operating limits set in the Control Cards. Some of the registers in the “ZX” series of control cards can not be accessed with the Handset. The Handset can access the registers that control the operation of the forklift truck. The values for the limits on the control card functions must be set with either the Handset or a PC. The Handset has a Light Emitting Diode (LED) display, a keypad for data entry and an adjustment knob for changing function values. See FIGURE 1. 2-1

✦ Monitor existing system fault codes for both traction and pump SCR systems ✦ Monitor intermittent random status code ✦ Monitor battery state of charge ✦ Monitor hourmeter reading on traction and pump SCR systems. ✦ Monitor or adjust the following control functions: ✧ Creep speed ✧ Controlled acceleration and 1A time ✧ Current limit ✧ Steer pump time delay and define signal input (seat switch or directional switch) ✧ Plugging distance (Current) ✧ Pedal position plug range or disable ✧ 1A drop out current or disable ✧ Field Weakening drop out ✧ Field Weakening pick up ✧ Regenerative braking current limit ✧ Regenerative braking drop out ✧ Speed limit points (SL1, SL2, and SL3) ✧ Truck management fault speed limit ✧ Internal resistance compensation for battery state of charge indication ✧ Battery voltage (36/48 volts is auto ranging) ✦ Selection of card operation type: ✧ Standard traction card selection: ✧ Std. traction with field weakening ✧ Std. traction with speed limits ✧ Std. traction with regenerative field weakening ✧ High or low current limit for all of the above

HANDSET

Operation

Function Set-Up Procedures For Traction SCR

! WARNING

With the Handset connected, hold down the CONT button while turning on the Key Switch. The Handset will now show the segment checking display. This places you in the set up mode, ready to monitor or adjust control function settings. If a fault code is displayed simply push the CONT button to clear.

Before connecting or disconnecting the Handset tool, 1) Jack up the drive wheels of the vehicle, 2) Turn off the key switch, 3) Unplug the battery and 4) Discharge the capacitors.

Push down one of the function numbers on the keypad to check that setting. If for example we push down on function key ➄ we will see:

At the SCR Control Traction Card, unplug the “Y plug” if the dash display is in use and plug in the Handset to the plug location “Y” on the control card. After installing the Handset tool, plug in the battery and turn on the key switch. The following is the start-up display sequence that will occur:

Example:

After one second we will see the value which is stored under this function:

START-UP DISPLAY SEQUENCE

Example:

Verify each LED Segment 8888

We now turn the adjustment knob to the desired setting (the values will continue to blink). When we reach the desired setting we push STORE. This value will be displayed but will no longer be blinking. Next we push the ESC button and we will get the Segment Check display again. This indicates we are still in the programming mode. We can continue this process to check or set all the functions. Each time you change a value you should go back and verify that the setting is correct. The value adjustment range available on the Handset is 0 to 255. However, some functions do not use the entire range.

If Maintenance Code is not active

Display Code -99 for four seconds and activate speed limit (if selected)

BDI Display or Blank Display (No BDI used)

Diagnostics override with fault

There are 15 numbers on the keypad and 18 functions. For the first 15 functions on the keypad we simply need to press the appropriate number. To access functions 16 through 30 we must press the CONT button and the appropriate number on the keypad at the same time.

Run Mode BDI Display or Blank Display (No BDI used)

105

Key Switch On

If Maintenance Code is active

U 05

Diagnostics override with fault

Example for function 16:

CONT and keypad #1

Example for function 18:

CONT and keypad #3

To access functions 48 and up we must close the seat switch. Then press the CONT button and the appropriate number on the keypad at the same time.

Key Switch Off

Display traction hourmeter for four seconds

Example for function 48:

CONT and keypad #1

When we are finished programming we press the ESC button when the (8888) is showing and hold it down for 1 second. The display now shows the battery state of charge. This means we are in run mode.

Display pump Hourmeter for four seconds

FIGURE 2. Start up display 2-2

HANDSET

Accessing and Clearing Fault Codes The EV 100ZX Motor Controller has function registers (31 through 47) that store the last 16 Status Codes that caused the operation of the forklift truck to stop and the battery charge at the time the fault occurred. A PMT fault is reset by turning the key to the OFF position and then to the ON position. The first of the 16 status codes will be overwritten each time a new status code occurs. The stored status can be cleared from the register by using the Handset. Use the procedure in FIGURE 3 to access and clear the fault code registers with the Handset.

The Handset can also be used to check and adjust the functions of the Control Card when it is connected to a bench power supply. You will need a power supply of from 24 to 84 volts. Four 9 volt batteries hooked up in series will give us 36 volts and work fine. The current is small enough that it will last a long time. In the programming mode the card does not care what the voltage supply is, just so it is between the card’s parameters of 24 to 84 volts. Note: When the batteries drop to a voltage level of 35 or less you will get a fault code (15) on a card set for 36 volts. The wiring harness we have to make up will require a Z plug and we only use 2 wire connections. Z Plug Pin #2 goes to battery negative and Pin #7 goes to battery positive. We also need a wire with a terminal end set up to connect to TB4 on the Card.

Key to OFF position

Push ESC and CONT at the same time

Release ESC and CONT

GE recommends a disconnect switch but there is no need for it as long as you make sure the power is not connected to the card when plugging in or unplugging the Handset.

Status Code Displayed

1) Plug in the Handset. 2) Plug in the Z plug with power supply. 3) Hook up the positive wire to TB4. 4) The Handset will now display -01 or -15 (fault codes for seat switch open or low battery). 5) Press CONT and you will get (8888) meaning you are now in the programming mode. 6) Program just like you would with the card in a truck (on the ZX card to simulate the seat switch closed and get to function 48 and up you will have to put a jumper between TB4 and TB3). 7) When done hold escape until you get out of program ming (you will get the -01 or -15 display) 8) Disconnect the wire on TB4. 9) Unplug the Z plug power supply and then the handset.

Push CONT Button Battery charge shown when fault occurred (only if equipped with BDI-otherwise zero (0) Push CONT Button

Display hour reading when fault occurred

Push ESC to erase stored data

Push CONT Button FIGURE 3. Clearing Fault Codes

Bench Checks and Adjustments

FIGURE 4. Bench Programming 2-3

HANDSET

Function Numbers (Traction) The Function Numbers are code numbers for the different parameters that can be set for the “ZX” series Control Cards. The Handset or Personal Computer must be used to adjust the parameters for the Control Card. There is a description of the code numbers for the different Control Cards in the Parameters Tables. These tables have the correct setting numbers for the parameters on each Control Card.

! WARNING If any of the parameters are changed, the operators must be told that the forklift truck will operate differently. DO NOT adjust the parameters outside the range of numbers shown in the Tables. Parameters set outside the ranges can cause damage to the components of the traction system and can cause the forklift truck to operate differently than normal.

reached. It can be set from .1 to 22.0 seconds. Each unit on the handset is equal to .084 seconds. This means that a setting of 20 would equal 1.76 seconds (remember a setting of zero = .084) since .084+20x.084=1.76. A lower number will cause the truck to accelerate faster. Function 4 Current Limit This function is determined by the match of the control components size with the motors used on the forklift truck. It must be set at factory specifications or the truck will either under perform or control component failure will take place. Function 5 Plugging Distance

FUNCTION NUMBERS 1 THROUGH 15 Push the keypad numbers for the desired register. Function 1 Stored Fault Code This function contains the last status code to identify the last fault (failure to operate properly) that the control identified. When the next fault occurs the code will be overwritten by the new code. It can only be cleared from memory by use of the Handset to adjust the value to zero, or when the battery is disconnected. NOTE that status codes on the handset will not have the minus sign in front of them like a fault does on the gauge. Function 2 Creep Speed This function sets the vehicle speed at the highest accelerator input voltage when the accelerator is depressed just enough for the start switch to close. It can be set from 5% to 15% of 1 Rec on time. Each unit on the handset is equal to .03% on time. This means since 0 is 5% then 20 would be 5.6%. A higher number will cause the truck to start up faster. Function 3 Controlled Acceleration This is the length of time it takes for the control to go from zero to 96% on time of the 1 Rec when the accelerator is fully depressed. It also effects the 1A bypass contactor operation as the control automatically closes the 1A .2 seconds after top control speed is 2-4

The distance over which a truck will travel before coming to a stop and accelerating in the other direction is adjustable with this function. The lower the number the softer the plug (greater distance traveled) and the higher the number the more severe the plug. Within reason this may be set to any value the customer desires. There is a possibility, however that you may encounter motor problems if this setting is too high. This setting is actually a plugging current adjustment with each handset unit being equal to 3.14 amps. The setting range is from 200 to 1000 amps. Therefore a value of 20 would be 200 + 20 x 3.14 or 263 amps. This value may need resetting to get the proper feel for the customer if Function 16 Pedal Position Plug is adjusted.

! WARNING Plug settings must be in accordance with control operating instructions. An excessively high setting could cause damage to control system or traction motor. Function 6 1A Drop Out If for some reason the truck is in a 1A and encounters a heavy load situation which could cause motor problems, such as pushing pallets across the floor, the control can drop out the 1A contactor. This function sets the current at which the control will do this. If operator continues to push the load, the motor could be destroyed. The benefit of 1A drop out is that it will take longer as the control now will limit the current to the setting in function 4. The setting is adjustable from 450 amps at a value of 0 and 1260 at 250. Above a setting value of 250 this feature is disabled and 1A drop out will not occur. Each unit on the handset is equal to 3.24 amps.

HANDSET

Function Numbers (Traction) Function 14 Internal Resistance Compensation

Function 7 Field Wakening Pick Up This feature is an option not yet available. Function 8 Field Weakening Drop Out This feature is an option not yet available. Function 9 Regenerative Braking Current Limit This function allows for the adjustment of the regenerative braking current limit. The higher the current limit setting, the shorter the stopping distance. The shorter stopping distance causes faster wear on the drive train and brushes of the traction motor. The setting is adjustable from 75 amps at 0 to 630 amps at 255. Each set unit is equal to 2.2 amps. Function 10 Regenerative Start This function allows for the adjustment of the percent of on time at which the control will start to regenerate. Remember that during a plug we are also pulsing the fields to help us slow down the truck. The difference being that at a slow speed the percent of on time for this pulsing is very low and the currents generated are also low. Therefore we do not open the regenerative contactor to put the motor in series with the battery we let all the current go back through the motor by way of the 4 REC. If the pulsing percent on time is high (above the value we set here) then our currents generated will be high and the control will open the regenerative contactor placing the battery in series with the motor armature. The setting ranges from 0% at 0 to 96% at 255. Each set unit is equal to .37% on time. Function 11 Speed Limit 1 This function is not used. Function 12 Speed Limit 2 This function is not used. Function 13 Speed Limit 3 This function is used with the TMM card on the 2FBC. This setting allows us to slow a truck down when either of the motors overheat or if the brush wear indicators on either of the motors are actuated. We are able to set the pulse on time from 96% at 0 to 0% at 255. A setting of 0 disables this function. 2-5

This function allows us to fine tune the low battery lift interrupt system to a much more exacting degree than most older systems could. Since every battery and forklift truck have minor variations that affect the voltage the card sees in checking the battery they can cause the system to cut out lift early or allow the battery to get too low before cutting out. This function allows us to compensate for these variations. In order to make this setting we need to find the voltage drop per amp of battery draw. This can be done without worrying about the battery state of charge (as long as it is between 80 and 20 on the dash display) by taking two readings. First we disconnect the power steering contactor coil and then bypass the brake switch so we can load the traction motor down to a specific amperage draw. We connect our voltmeter to the first connection points of the battery positive and negative cables on the control panel. Then we hook up an ammeter on the drive motor. With the brake pedal depressed so there is a 100 amp draw on the drive motor while in 1A we note the voltage drop. Then we do the same thing with the motor loaded to a 200 amp draw. We can then get the system drop by subtracting the two numbers. In other words: Voltage drop @ 100 amps - Voltage drop @ 200 amps = System voltage drop. Once we have this number we use the following table to obtain our function setting.

System Drop

Setting

System Drop

Setting

System Drop

Setting

11.44

01.90

01.04

0.780

01.76

00.99

05.72

01.63

00.95

04.57

01.52

00.91

03.81

01.43

00.88

03.27

01.34

00.85

02.86

01.27

00.82

02.54

01.20

00.79

02.28

01.14

00.76

02.08

01.09

00.74

HANDSET

Function Numbers (Traction) Function 15 Battery Volts

Function 17 Card Type Selection

The EV 100LX system is designed to work on a number of different voltages. This function tells the card what voltage battery you are using. Settings for this function are: 32 to 44 on 36 Volts

The EV100 controls offer a variety of options within each control type. To minimize cost and add versatility these optional features are built into all of the cards for each control type. The Card must be programmed to know the options on the truck’s Control System. This is done by this Function. If done incorrectly the Card, in some instances, is able to recognize this error and a Status Code indicating a fault will be displayed. However, the Card cannot recognize every possibility of error. This does not mean that any EV100 Card can be used on any type control. At the end of the GE part number of the card is a two letter card type designation. The designation of a new card must match the one required for your control. Some designations are TX, TT, TK, MK, MX, MT, FX, FT, PT, ZM, ZK, ZP, etc. NEVER set Function Number to a parameter that is not shown for your forklift truck.

45 to 69 on 48 Volts In other words 36 will be 36 volts and 48 will be 48 volts. There is also a setting which allows a truck to be used on either 36 or 48 volts. This value is from 184-250. The control may be shipped from the factory at this setting, since at the same time the control is manufactured we do not know which voltage truck it will be installed in. If you want to disable the lift interrupt function you can set this value between 251 and 255. Be aware that doing this will also eliminate the battery state of charge reading on the dash gauge.

Function 18 Steer Pump Time Delay

FUNCTION NUMBERS 16 THROUGH 30 The following functions have function numbers larger than the numbers on the Handset keyboard. To access these numbers, think of the CONT key as equal to 15. Push and hold the CONT key plus the additional key number above 15 to total the required register number.

NOTE: The Seat Switch must be OPEN for Function Numbers 16 through 30.

Function 16 Pedal Position Plug This function allows the operator to control the stopping distance during a plug by the position of the accelerator. If you want a soft plug, lift up on the pedal and if you want a rapid direction change, push down on the pedal. The variation in how soft or how severe is set with this function adjustment. It sets the plugging from 100 amps at 0 to 930 amps at 255. Each handset unit is equal to 3.2 amps. A setting of 20 would then be 164 amps. When this setting is changed you may have to reset function 5.If for some reason the customer wants to disable this function it will not cause any problems. To disable this feature set the function 16 amps the same as the function 5 amps. Example: If standard Function 5 setting is 105 or 530 amps

Set Function 16 at 530 amps or a value of 134. 2-6

The steer pump contactor pick up and time delay drop out can be set to work either on directional switch closure or seat switch closure. Card settings from 0 to 128 control seat switch operation and 129 to 255 control directional switch operation. The 2FBC utilizes steer pump contactor pick up on directional switch closure with drop out occurring 3.5 seconds after the lever is returned to neutral. The contactor will also drop out 1.5 seconds after the seat switch opens. This function can be adjusted from .5 seconds with a 129 handset value to 63 seconds with a 255 handset value. A setting of 149 would be equal to 10.5 seconds. If desirable this can also be set to pick up and drop out on seat switch closure. In some operations this may be of benefit. This is often done on other style trucks where the steer pump is also used for another function. This function can be adjusted from 1.5 seconds with a 0 handset value to 65 seconds with a 128 handset value. In both situations each unit on the handset is equal to .5 seconds. Function 19 Maintenance Code This function allows for the adjustment of time (tens and units hours–last two places in the hour meter reading card) a scheduled maintenance is required. It is only available on the ZX style control. When reading is reached the dash will illuminate a wrench shaped

HANDSET

Function Numbers (Traction) light. This light will not go out until a new hour meter reading is programmed into the card which is higher than the reading we have reached.

The FBC is equipped with a premium instrument panel, the forklift truck can be set to four performance levels by the operator. a) Low performance for handling fragile loads. b) Medium speed for less consumption of battery charge during a work shift. c) Higher performance with higher consumption of battery charge during a work shift. d) Maximum forklift truck performance with higher consumption of battery charge.

Function 20 Maintenance Code This function works with Function 19 and sets the thousands and hundreds (first two places) in the hour meter reading card. Function 21 Maintenance Speed Limit This function allows us to restrict truck speed when the maintenance hour meter reading programmed under Functions 19 & 20 are reached. Some customers may find it desirable to do this in order to force routine maintenance to be performed. We can set this from 100% battery volts (no speed limit) at 0 to 0% at 180. Each set unit is equal to a .56% speed reduction. Function 28 Fault Code Count Pointer This function allows us to determine where among the possible 16 stored fault codes the last one to occur is located. It provides us a reference number we must compare to a chart to find the stored location of the last fault code.

The register interlocks will not permit a higher performance level setting toward the slow speeds than the adjacent registers toward the faster speeds. Function 48 Controlled Acceleration Speed Mode 1 This is the same as Function 3 Controlled Acceleration except it is only utilized when the dash button has Speed 1 selected. Function 50 Speed Limit Speed Mode 1 This is the same as Function 11 Speed Limit 1 except it is only utilized when the dash button has Speed 1 selected. Function 52 Controlled Acceleration Speed Mode 2

Function 29 Hour Meter

This is the same as Function 3 Controlled Acceleration except it is only utilized when the dash button has Speed 2 selected.

We are able with the ZX control to change the hour meter reading the operator sees on the dash gauge. This function sets the tens and units (last two places) of the hour meter reading. If a new Control Card is installed, the total hours from the old Control Card must be entered so that the total operating hours of the forklift truck is correctly recorded.

Function 54 Speed Limit Speed Mode 2 This is the same as Function 12 Speed Limit 2 except is only utilized when the dash button has Speed 2 selected. Function 56 Controlled Acceleration Speed Mode 3

Function 30 Hour Meter

This is the same as Function 3 Controlled Acceleration except it is only utilized when the dash button has Speed 3 selected.

This function works with Function 29 and sets the thousands and hundreds (first two places) of the hour meter reading.

Function 58 Speed Limit Speed Mode 3 This is the same as Function 13 Speed Limit 3 except it is only utilized when the dash button has Speed 3 selected.

FUNCTION NUMBERS 48 THROUGH 60 The following functions have function numbers larger than the numbers on the Handset keyboard. To access these numbers, think of the CONT key as equal to 15. Push and hold the CONT key plus the additional key number above 15 to total the required register number.

Function 60 Controlled Acceleration Speed Mode 4 This is the same as Function 3 Controlled Acceleration except it is only utilized when the dash button has Speed 4 selected. This is usually equal to the setting we have in Function 3. If it is set higher; then Function 3 will override the setting.

NOTE: The Seat Switch must be CLOSED for Function Numbers 48 through 60. 2-7

HANDSET

Function Numbers (Traction) Function 62 Speed Limit Speed Mode 4 This is the same as Function 13 Speed Limit 3 except it is only utilized when the dash button has Speed 4 selected.

Function Settings (Traction Card) All speed mode settings must be equal to or more aggressive than the previous setting, i.e. speed 2 must be faster than speed 1 and so forth. If we try to set these speed functions outside the guidelines an error code will be displayed and we will have to correct the settings for the truck to operate. Code 80 - Setting is too slow Code 81 - Setting is too fast TRACTION CARD SETTINGS 2FBC15, 18 FUNCTION CODE

DESCRIPTION

SETTING

VALUE

Fault Code

N/A

Creep Speed

175

Controlled Acceleration

2.6 Sec

Current Limit

255

N/A

Plugging

125

595 Amps

1A Drop Out

250

1260 Amps

Field Weakening Pick Up

170 Amps

Field Weakening Drop Out

360 Amps

Regen Braking Current Limit

145

395 Amps

Regen Start

7.80%

Speed Limit 1

Speed Limit 2

Speed Limit 3 / TMM

50%

Internal Resistance Compensation

.91v

Battery Voltage

215

36/48

Pedal Position Plug

148

Card Type

Standard

Steer Pump Time Delay

135

3.5 Sec

Maintenance Tens & Units

255

Maintenance Thousands & Hundreds

200

Maintenance Speed Limit

None

28 29

N/A Hour Meter

N/A

Hour Meter

N/A

Speed Mode 1 C/A & 1A

128

10.9 Sec

Speed Mode 1 Top Speed

72%

Speed Mode 2 C/A & 1A

5.1 Sec.

Speed Mode 2 Top Speed

72%

Speed Mode 3 C/A & 1A

3.4 Sec.

Speed Mode 3 Top Speed

No Limit

Speed Mode 4 C/A & 1A

No Limit

Speed Mode 4 Top Speed

No Limit

2-8

HANDSET

TRACTION CARD SETTINGS 2FBC20, 25, 25E & 30 FUNCTION CODE

DESCRIPTION

SETTING

VALUE

Fault Code

N/A

Creep Speed

175

Controlled Acceleration

2.6 Sec

Current Limit

255

N/A

Plugging

125

595 Amps

1A Drop Out

250

1260 Amps

Field Weakening Pick Up

170 Amps

Field Weakening Drop Out

360 Amps

Regen Braking Current Limit

145

395 Amps

Regen Start

7.80%

Speed Limit 1

Speed Limit 2

Speed Limit 3 / TMM

Internal Resistance Compensation

.91v

Battery Voltage

215

36/48

Pedal Position Plug

148

50%

Card Type

Standard

Steer Pump Time Delay

135

3.5 Sec

Maintenance Tens & Units

255

Maintenance Thousands & Hundreds

200

Maintenance Speed Limit

None

N/A

Hour Meter

N/A

Hour Meter

N/A

Speed Mode 1 C/A & 1A

128

10.9 Sec

Speed Mode 1 Top Speed

72%

Speed Mode 2 C/A & 1A

2.6

Speed Mode 2 Top Speed

72%

Speed Mode 3 C/A & 1A

2.6

Speed Mode 3 Top Speed

No Limit

Speed Mode 4 C/A & 1A

No Limit

Speed Mode 4 Top Speed

No Limit

2-9

HANDSET

TRACTION CARD SETTINGS 2FB15, 18, 20, 25E & 30 EE Option FUNCTION CODE

DESCRIPTION

SETTING

VALUE

Fault Code

N/A

Creep Speed

180

Controlled Acceleration

2.6 Sec

Current Limit

220

N/A

Plugging

130

595 Amps

1A Drop Out

250

1260 Amps

Field Weakening Pick Up

170 Amps

Field Weakening Drop Out

360 Amps

Regen Braking Current Limit

150

395 Amps

Regen Start

7.80%

Speed Limit 1

Speed Limit 2

Speed Limit 3 / TMM

50%

Internal Resistance Compensation

.91 volts

Battery Voltage

215

36/48

Pedal Position Plug

148

Card Type

Standard

Steer Pump Time Delay

135

3.5 Sec

Maintenance Tens & Units

255

Maintenance Thousands & Hundreds

200

Maintenance Speed Limit

None

Hour Meter

N/A

Hour Meter

N/A

Speed Mode 1 C/A & 1A

128

10.9 Sec

Speed Mode 1 Top Speed

72%

Speed Mode 2 C/A & 1A

2.6

N/A

Speed Mode 2 Top Speed

72%

Speed Mode 3 C/A & 1A

2.6

Speed Mode 3 Top Speed

No Limit

Speed Mode 4 C/A & 1A

No Limit

Speed Mode 4 Top Speed

No Limit

2-10

HANDSET

Function Set-Up Procedures for Optional SCR Hydraulics

Function Numbers (Pump) Function 1

NOTE: THE SEAT SWITCH MUST BE CLOSED TO ACCESS ALL FUNCTIONS. With the Handset connected, hold down the CONT button while turning on the Key Switch. The Handset will now show the segment checking display. This places you in the set up mode, ready to monitor or adjust control function settings. If a fault code is displayed simply push the CONT button to clear.

This function register contains the last status code that shut down vehicle operation (PMT type fault that is reset by the key switch). This status code will be over written each time a new fault occurs and can be cleared from memory by adjusting the value to zero. This register will be cleared when the battery is unplugged.

Push down one of the function numbers on the keypad to check that setting. If for example we push down on function key ➄ we will see: Example:

U 05

After one second we will see the value which is stored under this function: Example

Stored Fault Code (Push 1)

105

If we need to reset this value, we push again on the CONT button and the value will blink. The number on the Handset will no longer be the original value but will correspond to the setting the adjustment knob was left at. We now turn the adjustment knob to the desired setting (the values will continue to blink). When we reach the desired setting we push STORE. This value will be displayed but will no longer be blinking. Next we push the ESC button and we will get the Segment Check display again. This indicates we are still in the programming mode. We can continue this process to check or set all the functions. Each time you change a value you should go back and verify that the setting is correct. The value adjustment range available on the Handset is 0 to 255. However, some functions do not use the entire range. There are 15 numbers on the keypad and 18 functions. For the first 15 functions on the keypad we simply need to press the appropriate number. To access functions 16 through 30 we must press the CONT button and the appropriate number on the keypad at the same time. Example for function 16: CONT and keypad #1 Example for function 18: CONT and keypad #3

Function 2

This function allows for the adjustment of the current level at which the internal resistance compensation feature (Function 16) will take effect. Range 0 to 1325 amps Set 0 to 255 Resolution 6.5 amps per set unit Example:

Setting of 72 = 130 amps

Function 3

Controlled Acceleration And 1A Time (Push 3)

This function allows for the adjustment of the rate of time it takes for the control to accelerate to 96% applied battery voltage to the motor on hard acceleration. The 1A contactor will automatically close .2 seconds after the controlled acceleration stops and the accelerator input is less than .5 volts or less than 50 ohms. Range .1 to 5.5 amps Set 0 to 255 Resolution .021 seconds per set unit Example:

Setting of 20 = .52 seconds C/A and .72 seconds 1A time.

Function 4

Current Limit (Push 4)

This function allows for the adjustment of the current limit of the control. The rating of the control will determine the range of adjustment for this function. Please refer to the operating instructions for the control used in your vehicle. Range See control C/L curves Set 0 to 255 Example:

2-11

Internal Resistance Compensation Start (Push 2)

0 = min. current, 255 = max. current

HANDSET

Function Numbers (Pump) Function 7

FUNCTION NUMBERS 16 THROUGH 28

Internal Resistance Compensation Rate (Push 7)

The following functions have function numbers larger than the numbers on the Handset keyboard. To access these functions, push the CONT key and the number shown in the following instructions at the same time.

This function allows for the adjustment of the rate of time it takes for the control to add the internal resistance compensation voltage that is applied to the motor. This function will add .375 volts to the motor at the rate of time adjusted until the total IR compensation voltage has been added. Range .0015 to .383 seconds Set 0 to 255 Resolution .0015 seconds per set unit Example:

NOTE: The Seat Switch must be OPEN for Function Numbers 16 through 28.

Function 16 Speed/Torque Compensation (Push CONT and 1) This function is used to stabilize pump speed at heavy loads. The voltage selected will be added to the motor at each 100 amp increment starting at the value set in Function 2. The voltage compensation selected will be added in increments of .375 volts until the entire voltage is added. For example a setting of 2 will be added in 30 steps of .375 volts each whereas, a setting of 4 will be added in 15 steps of .375 volts each.

Setting of 20 = .032 seconds

For example, if you had selected 2.08 volts from Function 16 to be added to the motor. This example would take .18 seconds to add a total of 2.08 volts. (2.08/.375).032. Function 11 Speed Limit 1 (SL1) (Push 11) This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL1 limit switch input signal is received by the control card. SL1 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit. Range 0% to 100% battery volts Set 0 to 255 Resolution .375 volts per set unit Example:

SPEED/TORQUE COMPENSATION TABLE

Setting of 50 = .18.75 volts

Function 12 Speed Limit 2 (SL2) (Push 12) Same as Function 11 except using SL2 limit switch for input. Function 13 Speed Limit 3 (SL3) (Push 13) Same as Function 11 except using SL3 limit switch for input. Function 14 Speed Limit 4 (SL4) (Push 14) Same as Function 11 except using SL4 limit switch for input.

2-12

Setting

Voltage Drop

Setting

Voltage Drop

11.44

01.34

07.60

01.27

05.72

01.20

04.57

01.14

03.81

01.09

03.27

01.04

02.86

00.99

02.54

00.95

02.28

00.91

02.08

00.88

01.90

00.85

01.76

00.82

01.63

00.79

01.52

00.76

01.43

00.74

HANDSET Function Numbers (Pump) Function 17 Card Type Selection (Push CONT and 2)

FUNCTION NUMBERS 48 THROUGH 62

This function allows for the selection of the card type used for your vehicle’s application. The table below shows the setting to select card application type depending on which control card is used.

With Pump Ctr/PMT 0 to 8 9 to 17

Without Pump Ctr/PMT 36 to 44 45 to 53

NOTE: The Seat Switch must be CLOSED for Function Numbers 48 through 62.

18 to 26

54 to 62

27 to 35

63 to 71

Function STD C/L High C/L STD C/L BDI (Lockout) High C/L BDI (Lockout)

BDI Lockout means that the BDI signal from the traction control must be present in order for the pump controlto operate. This control will stop operation when the battery state of charge reaches 10%.

The following functions (Functions 48 – 62) are mode settings that are activated from the display. Each function must be set using the logic table shown below. If you try to set the function outside these guidelines, an error code will be displayed to prompt you to enter the correct setting. If: If:

Setting for these functions should be made in between the values shown.

80 is displayed 81 is displayed

! WARNING

To determine which stored status code was the last one recorded, read the number stored in Function 28. Using the memory map for your logic card, match the fault code pointer number [the number shown in (bold italics) in the HS number column] on the memory map, with the number obtained from Function 28. This will be the last fault recorded.

Mode 2

Mode 3

Mode 4

C/A Time => Mode 2 =< Mode 1 =< Mode 2 =< Mode 3 => Mode 3 => Mode 4 SL2 => Mode 2 =< Mode 1 =< Mode 2 =< Mode 2 => Mode 3 => Mode 4 SL4 => Mode 2 =< Mode 1 =< Mode 2 =< Mode 3 => Mode 3 => Mode 4

These settings must be changed by authorized personnel only, following instructions supplied by the manufacturer. Card type selection must be made within the capabilities of the SCR control panel used and the supporting electromechanical devices. Failure to comply with proper application standards could result in misoperation or damage to the control and/or motors.

This register contains the location of the last fault recorded of the 16 stored status codes.

setting is too low setting is too high

SETTING LOGIC TABLE Mode 1

Function 28 Fault Count Pointer (Push CONT 13)

– –

Function 48 Mode 1 – Controlled Acceleration and a 1A Time (Push CONT 1) This function allows for the adjustment of the rate of time it takes for the control to accelerate to 96% applied battery voltage to the motor on hard acceleration. The 1A contactor will automatically close .2 seconds after the controlled acceleration stops and the accelerator input is less than .5 volts or less than 50 ohms. This CA and 1A time takes effect when the Mode 1 settings are called for by the interactive Dash Display.

Note: When scrolling the fault register, the register always starts as Fault 1 and scrolls to Fault 16. 2-13

Range Set Resolution

.1 to 22.0 amps 0 to 255 .084 seconds per set unit

Example:

Setting of 20 = 1.8 seconds C/A and 2.0 1A time.

HANDSET Function Numbers (Pump) Function 49 Mode 1 – Speed Limit 2 (SL2) (Push CONT 2)

Function 54 Mode 2 – Speed Limit 4 (SL4) (Push CONT 7)

This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL2 limit switch input signal is received by the control card. SL2 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit. This Speed Limit 2 (SL2) takes effect when the Mode 1 settings are called for by the interactive Dash Display. Range Set Resolution

0% to 100% battery volts 0 to 255 .375 volts per set unit

Example:

Setting of 50 = 18.75 volts

Function 57 Mode 3 – Speed Limit 2 (SL2) (Push CONT 10)

This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL4 limit switch input signal is received by the control card.. SL4 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit. This Speed Limit 4 (SL4) takes effect when the Mode 1 settings are called for by the interactive Dash Display. 0% to 100% battery volts 0 to 255 .375 volts per set unit

Example:

Setting of 50 = 18.75 volts

Function 56 Mode 3 – Controlled Acceleration and a 1A Time (Push CONT 9) Same as function 48. This CA and 1A time takes effect when the Mode 3 settings are called for by the interactive Dash Display.

Function 50 Mode 1 – Speed Limit 4 (SL4) (Push CONT 3)

Range Set Resolution

Same as function 50. This Speed Limit (SL4) value takes effect when the Mode 2 settings are called for by the interactive Dash Display.

Same as function 49. This Speed Limit (SL2) value takes effect when the Mode 3 settings are called for by the interactive Dash Display. Function 58 Mode 3 – Speed Limit 4 (SL4) (Push CONT 11) Same as function 50. This Speed Limit (SL4) value takes effect when the Mode 3 settings are called for by the interactive Dash Display. Function 60 Mode 4 – Controlled Acceleration and a 1A Time (Push CONT 13) Same as function 48. This CA and 1A time takes effect when the Mode 4 settings are called for by the interactive Dash Display.

Function 52 Mode 2 – Controlled Acceleration and a 1A Time (Push CONT 5) Same as function 48. This CA and 1A time takes effect when the Mode 2 settings are called for by the interactive Dash Display. Function 53 Mode 2 – Speed Limit 2 (SL2) (Push CONT 6) Same as function 49. This Speed Limit (SL2) value takes effect when the Mode 2 settings are called for by the interactive Dash Display.

Function 61 Mode 3 – Speed Limit 4 (SL4) (Push CONT 14) Same as function 49. This Speed Limit (SL2) value takes effect when the Mode 4 settings are called for by the interactive Dash Display. Function 61 Mode 3 – Speed Limit 4 (SL4) (Push CONT 15)

Same as function 50. This Speed Limit (SL4) value takes effect when the Mode 4 settings are called for by the interactive Dash Display. 2-14

HANDSET

Function Settings (Pump Card) (Optional SCR Hydraulics)

PUMP CARD SETTINGS HYDRAULICS SCR OPTION 2FBC15, 18, 20, 25, 25E & 30 FUNCTION CODE 1

DESCRIPTION Fault Code

SETTING 0

VALUE N/A

IR Comp Start

255

1325 Amps (Disabled)

Controlled Acceleration

1.36 Sec

Current Limit

255

Max

IR Comp Rate

Disabled

Speed Limit 1 ( Lift 1)

N/A

Speed Limit 2 (Tilt)

N/A

Speed Limit 3 (Aux 1)

N/A

Speed Limit 4 (Lift 2)

255

N/A

Speed/Torque Comp

1.63 Volts

Card Type

BDI with PMT

Speed Mode On/Off

Off

Speed Mode 1 C/A

5.04 Sec.

Speed Mode 1 Speed Limit 2

N/A

Speed Mode 1 Speed Limit 4

255

N/A

Speed Mode 1 C/A

5.04 Sec.

Speed Mode 2 Speed Limit 2

N/A

Speed Mode 2 Speed Limit 4

255

N/A

Speed Mode 1 C/A

5.04 Sec.

Speed Mode 3 Speed Limit 2

N/A

Speed Mode 3 Speed Limit 4

255

N/A

Speed Mode 1 C/A

5.04 Sec.

Speed Mode 4 Speed Limit 2

N/A

Speed Mode 4 Speed Limit 4

255

N/A

2-15

HANDSET

Function Settings (Pump Card) (Optional SCR Hydraulics)

PUMP CARD SETTINGS HYDRAULICS SCR & EE OPTION 2FBC15, 18, 20, 25, 25E & 30 FUNCTION CODE 1

DESCRIPTION Fault Code

SETTING 0

VALUE N/A

IR Comp Start

255

1325 Amps (Disabled)

Controlled Acceleration

1.36 Sec

Current Limit

205

Max

IR Comp Rate

Disabled

Speed Limit 1 ( Lift 1)

N/A

Speed Limit 2 (Tilt)

N/A

Speed Limit 3 (Aux 1)

N/A

Speed Limit 4 (Lift 2)

255

N/A

Speed/Torque Comp

1.63 Volts

Card Type

BDI with PMT

Speed Mode On/Off

Off

Speed Mode 1 C/A

5.04 Sec.

Speed Mode 1 Speed Limit 2

N/A

Speed Mode 1 Speed Limit 4

255

N/A

Speed Mode 1 C/A

5.04 Sec.

Speed Mode 1 Speed Limit 2

N/A

Speed Mode 1 Speed Limit 4

255

N/A

Speed Mode 1 C/A

5.04 Sec.

Speed Mode 1 Speed Limit 2

N/A

Speed Mode 1 Speed Limit 4

255

N/A

Speed Mode 1 C/A

5.04 Sec.

Speed Mode 1 Speed Limit 2

N/A

Speed Mode 1 Speed Limit 4

255

N/A

2-16

CHECKS & REPAIRS

General Information .......................................................................................... 3-1 Fuses ................................................................................................................... 3-2 SCR’s................................................................................................................... 3-2 Thermal Protector ................................................................................................ 3-3 Reactor Assembly................................................................................................ 3-4 Suppressors......................................................................................................... 3-4 Capacitor C1........................................................................................................ 3-5 Diodes D3, D4 & D7 ............................................................................................ 3-5 Motor Current Sensor .......................................................................................... 3-6 Thermal Protector Test ........................................................................................ 3-6 Contactors............................................................................................................ 3-7 Control Card ........................................................................................................ 3-9 Control Card Plugs .............................................................................................. 3-9 Brush Wear Indicators ......................................................................................... 3-10 Motor Thermal Switches ...................................................................................... 3-10

Electric Truck Motors and Controls .......................................................... 3-11 Truck Management Module (TMM) ..................................................................... 3-11 TMM1 Connections.............................................................................................. 3-12 Thermal Transfer ................................................................................................. 3-13 Trouble Shooting Tips .......................................................................................... 3-14

Unsatisfactory Brush Performance .......................................................... 3-15

Commutator Surfaces ...................................................................................... 3-21

Motor Winding Specifications...................................................................... 3-23

CHECKS & REPAIRS

General Information 12

14 15

7 3

6 2 4 5 FIGURE 1. EV100ZX Motor Controller

1. 2. 3. 4. 5. 6. 7. 8.

CONTROL CARD 9. CAPACITOR C1 10. BASE PLATE 11. SCR 1 12. DIODE D3 13. MOTOR CURRENT SENSOR 14. DIODE D4 15. REACTOR (INDUCTOR L1 AND 1X)

SCR 2 AND SCR 5 (NOT SHOWN) SPIDER ASSEMBLY SUPPRESSOR, SCR 2 SUPPRESSOR, SCR 5 SUPPRESSOR, D4 SUPPRESSOR, D3 THERMAL PROTECTOR

! WARNING Some adjustments in this section must be done with the battery connected and power applied to the controller. When making these adjustments, make sure the drive wheels are raised from the floor. Some voltage measurements must be made with the SRO circuit complete. Make sure the drive wheels are raised from the surface before doing troubleshooting. If you are working alone, put a weight in the seat to close the seat switch. If your forklift truck has a seat brake, use a block behind the lower actuator bar to release the seat brake when the operator is not in the seat. Put the voltmeter so that you can see it from the operator area. You can operate the controls with your hand and also make the voltage measurements. 3-1

CHECKS & REPAIRS

General Information

! WARNING

Cathode –

+ Anode

Make sure you disconnect the battery and separate the connector before you disassemble any part of the controller. The capacitor stores electrical energy and can cause injury if a person discharges a capacitor through parts of the body. Discharge the C1 capacitor with 150 ohm 150 ohm 25 Watt Resistor. 2. Check these Recs with the VOM. Hook the positive lead to the Cathode and the negative lead to the Anode. You should get a reading of 100K ohms or more.

☞ NOTICE ☞ The electronic controller in the forklift trucks can not be seen from the operator area. Some checks and adjustments are difficult to do unless another person can operate the controls.

Cathode –

☞ NOTICE ☞

+ Anode

The bolts and screws connected to the electronic components are normally metric sizes. Make sure that you use the correct fastener for the part that has been disassembled.

Fuses The fuses are found on the EV100 control panel. The power fuses for the traction circuit (500 amperes) and for the hydraulic pump (325 amperes) is found on the (+) bus bar. The condition of the fuses can normally be checked by looking at them or checked with an ohmmeter. The location of the fuses can be found in FIGURE 1.

3. Reverse the meter leads. You should get a reading of 100K ohms or more.

Cathode –

+ Anode

How to Check an SCR The following checks will indicate most SCRs with defects. The checks will not always indicate a fault that does not occur regularly during operation. 1. Disconnect the Anode and Cathode connections to the SCR. Disconnect the Gate lead to the SCR by unplugging the Z Plug at the Logic Card.

4. Check from the Gate to the Cathode. With positive on the Cathode and negative on the Gate, you should get a reading between 10 and 250 ohms.

3-2

CHECKS & REPAIRS

The SCR Assembly The SCR assembly cannot be disassembled. The SCR assembly includes an SCR fastened between two metal blocks used as heat sinks. The heat sinks are also the power connections for the SCR. A plastic case holds the complete assembly. There is a thin sheet of electrical insulation between the SCR 1 assembly and the base plate. The insulator permits heat to transfer from the heat sinks to the base plate.

! WARNING The insulator is very thin. Dirt between the surfaces of SCR 1 and the base plate can damage the insulator and cause a short-circuit.

NOTE: Silicon compound (Part No. 5P8937) is used between the heat sinks and the parts of the controller. The purpose of this compound is to fill in the micrometer size spaces between the parts to give better heat flow. Always use a very thin layer of compound between the parts. Too much compound will be an insulator and cause both electrical and heat faults. It is better to use no compound instead of too much. DO NOT USE this silicon compound on the threads of the diodes.

Thermal Protector

4. Install the new SCR 1 assembly. Make sure the heat sinks make full contact with the insulator and base plate. Check the resistance between both heat sinks and the base plate with an ohmmeter. A correct installation will indicate infinity on the ohmmeter. 5. Install the electrical connections to the SCR 1 assembly. Install the thermal protector on the heat sink. 6. Install the mount and the suppressors over the SCR 1 assembly. Make sure the connections are made correctly.

The “OFF” Circuit for SCR 1

The SCR 1 has a thermal protector fastened to the cathode heat sink. The thermal protector is a resistor that changes resistance when the temperature changes. When the temperature is greater than 85°C (185°F), the thermal protector changes the signal voltage to the control card. The control card decreases the percent of ON time to decrease the SCR 1 temperature. The normal resistance for the thermal protector is 120 to 150 ohms at 18°C (65°F) when measured between pins PZ1 and PZ5.

! WARNING Make sure you disconnect the battery and separate the connector before you disassemble any part of the controller. Make sure you also discharge capacitor C1.

The “OFF” circuit for SCR 1 has the following parts:

Replacing the SCR 1 Assembly

Reactor assembly (Inductor L1 and 1X)

1. Make notes of the positions of the suppressors and remove the suppressors from the mount over SCR 1. Disconnect the electronic connections to the SCR 1 assembly.

SCR 2

2. Remove the thermal protector from the heat sink. Remove the two capscrews that connect the power cables to the heat sinks (make a note of the cathode sensor wire). Remove the two mounting screws that hold the SCR 1 assembly to the base plate.

Capacitor C1

SCR 5 Suppressors for SCR 2 and SCR 5

The inductor and a capacitor assembly generates the reverse polarity voltage to change the SCR 1 to OFF for each pulse. SCR 2 and SCR 5 control the operation of the “OFF” circuit. The suppressors protect the SCRs from electrical noise.

3. Check the insulator between the SCR 1 assembly and the base plate. Replace the insulator if it is damaged. The insulator is also a heat conductor. Use a very thin coat of silicon compound (Part Number 5P8937 or approved equivalent) between the surfaces of the parts. Keep dirt from the surfaces.

3-3

CHECKS & REPAIRS

Check the Reactor Assembly

Check Suppressors for SCR 2, SCR 5, Diode D3, and Diode D4

The reactor assembly is in a plastic case that fastens to the base plate. The connections for the reactor are under the mount for the suppressors and are difficult to check with an ohmmeter. A fault does not often occur in the reactor assembly. Most faults that do occur at the reactor assembly are caused by loose connections. The normal repair of the reactor assembly is to replace it. This reactor assembly has two inductor windings (L1 and 1X) joined by a common connection. A good inductor winding will indicate approximately zero ohms on the R x 1 scale.

The suppressors are one or more resistors and capacitors in a small plastic block. (See items 11 and 12 in FIGURE 1). The suppressors prevent damage to the SCRs from electrical noise. Sometimes a suppressor will not indicate a defect except when in an operating circuit and will cause a fault that does not occur regularly during forklift truck operation. A bad suppressor can cause a fault similar to a bad SCR 2 or a bad SCR 5. The suppressor is a resistor/capacitor filter assembly. Using a 200 ohm scale across the two terminals, the capacitor should quickly charge. Change the meter to the 2 volt scale and you can watch the suppressor quickly discharge.

T-4

T-5

T-3

They are installed on a mount as shown.

☞ NOTE ☞ Dotted Lines Indicate Internal Connections

To check the Reactor/Choke with a VOM, connect the leads to the T3 and T4 terminals. Place the meter on 200 ohm scale. The reading should be absolute 0 ohms. The part should be replaced if the reading is anything other than 0 ohms.

T-5

T-4

T-3

After checking the Reactor/Choke, connect the leads to the T3 and T5 terminals. The reading should again be absolute 0 ohms.

Suppressor Mount

3-4

CHECKS & REPAIRS

Check SCR 2 and SCR 5

Replace SCR 2 and SCR 5

NOTE: The plastic cases for SCR 2 and SCR 5 are the same, but the part numbers are different because the electrical components inside of the case are different. An SCR 2 has a higher electrical rating than an SCR 5. An SCR 2 can be used as an SCR 5, but do not use an SCR 5 as an SCR 2. Check the part number to make sure that you are using the correct SCR.

Disconnect the electrical connections to the SCR. Remove the two screws that hold the SCR.

Use a thin layer of silicon compound (Part No. 5P8937 or approved equivalent) between the surfaces of the heat sink and the replacement SCR. Install the SCR. Connect the electrical connections.

Check Capacitor C1 Discharge C1 and disconnect the terminals before checking C1 for a short-circuit. Measure the resistance between the terminals. The ohmmeter will indicate a low resistance and increase to more than 100 000 ohms. A capacitor with a short-circuit must be replaced. The capacitor is fastened with two screws and brackets.

1 FIGURE 3. SCR2 and SCR5

Check Diodes D3, D4 and D7

! WARNING

The heat sink assembly for the diodes D3 and D4 is also the connection for the (-) power cable. The heat sink assembly for Diode D7 is also the (+) power cable connection. The heat sink assembly is connected to the base plate. A thin insulator with a silicone surface separates the heat sink assembly from the base plate. NOTE: The optional SCR controller used for the hydraulic pump only has diode D3.

Make sure you disconnect the battery and separate the connector before you disassemble any part of the controller. Make sure you also discharge capacitor C1. 1. Disconnect the Anode or Cathode connections to the SCR. Disconnect the Gate lead to the SCR by unplugging the Z Plug at the Logic Card.

You will need a digital VOM to check the diodes. Disconnect the diode pigtail (cable connection). The base can remain in the heat sink. The D3 and D4 diodes have the Anode as the base and the pigtail (cable) is the Cathode. The D7 is just the opposite. The base is the Cathode and the pigtail is the Anode.

2. Connect the Positive lead of the meter to the Anode and the Negative lead to the Cathode. The reading should be 50,000 ohms or more. 3. Reverse the meter leads. The reading should be 50,00º ohms or more. 4. Connect the Posistive lead to the Cathode and the Negative lead to the Gate. The reading should be between 10 and 250 ohms. 5. Reverse the meter leads. The reading should be at least 5 ohms or more.

3-5

Put the VOM on the diode test scale. With the positive lead on the Cathode and negative lead on the Anode, you should read OL. With the positive lead on the Anode and the negative lead on the Cathode, you should read less than one volt.

CHECKS & REPAIRS

Replacement, Diodes D3 and D4

Motor Current Sensor The motor current sensor is a short piece of the circuit bus bar with two sensor wires connected to it. All of the traction motor current flows through this power connector. The metal between the connection points of the sensor wires has a small resistance. This small resistance between the two sensor wires sends a voltage signal to the control card. The voltage signal increases as the motor current increases. The control card compares the voltage with the “C/L” current limit adjustment. The control card controls the current flow so that the traction circuit is not damaged.

! CAUTION Do not use a hammer and punch to loosen or tighten diodes.

Thermal Protector Test Read the resistance between the Black and Gray wires at the card plug (inside female connector) for each Thermal Protector. Reading should be less than 65 ohms at room temperature.

FIGURE 4. Diodes D3 and D4 Disconnect the cathode cable. Use a deep socket to remove the diodes. Put the wire through the top of the socket and use a handle or wrench to turn the socket. Use a thin layer of conductive thermal compound between the surface of the heat sink and replacement diode. Tighten the diode to a torque of 3.4 N.m (30 lbf in).

☞ NOTICE ☞ Diodes D3 and D4 have a suppressor connected in parallel to the diode. Replace the suppressor and test the operation if troubleshooting indicates that the suppressor is bad.

FIGURE 5. Motor Current Sensor

3-6

Notes:

CHECKS & REPAIRS

Contactors The FORWARD and REVERSE (direction) contactor assemblies control the direction of current flow through the traction motor. The contactor is a heavyduty switch that opens and closes the power circuit. The traction circuit has a FORWARD and REVERSE contactor assembly. Each contactor assembly has the following parts: two sets of normally open (NO) contacts, two sets of normally closed (NC) contacts, and a coil. The coil is an electromagnet that moves the NO contacts to the closed position against spring pressure. The coil is in the control circuit. The contactor tips are in the traction circuit. When a contactor coil is energized, the normally open (NO) contacts close and the normally closed (NC) contacts open. This action gives direction control to the traction motor. The contacts normally have a long service life because the current flow through the contacts is stopped before the contacts open. The SCR 1 is OFF before the contactor coil is de-energized. The only condition where the contacts open during a large current flow is a Pulse Monitor Trip (PMT).

FIGURE 7. Typical Contactor Assembly (Regenerative Braking Shown)

Contactor Repair Make an identification and disconnect the wires and cables from the contactor assembly. Remove the mounting screws and remove the contactor assembly. Contactor Contacts. The contacts in a contactor are made of special silver alloy. The contacts will look black and rough from normal operation. This condition does not cause problems with the operation of the forklift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS.

! WARNING 1. POWER TERMINALS 2. NC CONTACTS 3. NO CONTACTS

4. COIL TERMINALS 5. MOUNT BRACKET 6. COIL

FIGURE 6. Direction Contactor The other contactors used in the motor controller have one set of NO contacts. These contactors are not the same, but their operation is similar. A typical contactor of this kind is shown in FIGURE 7.

3-7

ALWAYS replace all of the contacts in a contactor at the same time. Replace the contacts in the contactor for the hydraulic pump after 1000 hours of operation. Replace the contacts in the other contactors when the thickness of any area of a contact is less than 30% of the thickness of a new contact or if there is any transfer of contact material.

CHECKS & REPAIRS

Contactor Repair Coil. Check the coil with an ohmmeter for an open circuit or a short-circuit. Replace the coil if it is damaged. Make sure the coil wires are connected again to the correct terminals. The coils in the contactors for the hydraulic pump and the regenerative braking have an external suppressor. The coil and the suppressor can be checked separately with an ohmmeter. [A suppressor diode (and sometimes a resistor in series) is part of the coil. The diode will cause the ohmmeter to indicate a difference in resistance in one direction. Reverse the probes of the ohmmeter to the opposite terminals and measure the resistance. Use the highest resistance indication].

COIL RESISTANCE TEST SPECIFICATIONS All except Hydraulic Pump Contactor Coil

10-15 ohm

Hydraulic Pump Contactor Coil

30 - 40 ohm

Hydraulic Pump Contactor Coil w/ optional SCR Hydraulics

10 - 15 ohm

1. BASE-MAGNET 2. COIL 3. BUS 4. BUS 5. BUS 6. SPACER 7. CLAMP-BUS 8. BUS

9. COVER 10. BUS 11. BUS 12. SPRING-RETURN 13. ARMATURE 14. BASE-BUS 15. CARRIER-MOVABLE TIP

16. BUSHING-PLUNGER 17. TIP-MOVABLE 18. SEAT-SPRING 19. TIP SPRING 20. INSULATION-UPPER BUS 21. NUT 22. WASHER

FIGURE 8. Direction Contactor 3-8

CHECKS & REPAIRS

Control Card NOTE: Do NOT remove the circuit board from the case when replacing a control card. There are no internal repairs that can be made by service personnel. The control card and case must be replaced as a unit.

1. Control Card (Traction or Hydraulic Pump) 2. TB Screw Terminals (6) 3. Plug Guides 4. Plug PA (6-pin) (wide guides) 5. Plug PB (6-pin) (close guides) 6. Plug PY (14-pin) 7. Plug PZ (14-pin)

Control Card Plugs All control card connections are made at plugs A, B, Y or Z or at the six screws of TB terminals. If a wire of one of the plugs must be replaced, the operation to remove a pin connector must be done carefully. A special tool (MCF-1062), must be used to remove the pin connector from the plug. How the pin connectors are held in the plug is shown in FIGURE 10. Use the tool as shown to release the lock so that the pin connector can be removed from the plug. If a pin connector must be removed, the service person must work carefully so that the pin connectors and the plug are not damaged. When a new pin connector is installed in the plug, make sure it is not damaged and is locked into the correct position in the plug. NOTE: Use Terminal Maintenance Kit Part #SE000003 on connectors.. If the pin connection becomes loose during operation of the forklift truck, the malfunction is not regular and is very difficult to find and repair.

1. Plug 2. Rubber Seal 3. Pin Connector (removed from plug) 4. Lock 5. Pin Connector (installed in plug) 6. Tool (unlocks pin connector for removal)

MCF-1062

FIGURE 9. Control Card Connections

FIGURE 10. Control Card Plug 3-9

CHECKS & REPAIRS

Brush Wear Indicators

Motor Thermal Switches

The brush wear indicators illuminate when the motor brushes must be replaced. The sensor wires for the brush wear indicators are an insert in the brush material when it is made. The sensor wires are insulated from the brush material. When the brush wears within approximately 1.5 mm (0.060 in) of the brush lead, the insulation between the sensor wire and the brush material is destroyed.The connection between the brush and the sensor wire causes the indicator to illuminate.

The thermal switch can be replaced if it is damaged. However, the motor must be disassembled to replace the thermal switch.

The operation of the brush wear indicators can be checked during periodic maintenance. The battery must be removed from the forklift truck for access to the motors. Use a jumper cable so that the battery can be connected for operation of the motors. See FIGURE 11. Disconnect the sensor wires from the outside of the motor case. Touch the ends of the sensor wires together. The warning light will illuminate if the circuit

! WARNING Prevent damage and injury if the forklift truck moves. Raise the drive wheels from the floor during these tests. Use a jumper cable so that the battery can be connected for operation of the motors. See FIGURE 11. Disconnect the sensor wires, one at a time, from outside of the motor case. Touch the end of the sensor wire to battery negative. The warning light will illuminate if the circuit is operating correctly.

1. RAISE DRIVE WHEELS 2. JUMPER 3. BATTERY

Connect the battery so that the motor can be operated. The battery must be removed for access to the motor. Use a jumper cable to connect the battery to the forklift truck. Raise the drive wheels. See “How to Raise the Drive Tires” in the GENERAL INFORMATION Section.

FIGURE 11. Connect Battery to Operate Motor

Notes:

3-10

CHECKS & REPAIRS

Motors and Controls Truck Management Module (TMM) The Truck Management Module is a multi-function accessory card or an auxiliary function of the EV100 Pump control used with the EV100ZX series Traction controls. The TMM card provides Mitsubishi the ability to provide status codes or operator warning codes that will be displayed on the dash display whenever a normally open switch or sensor wire provides a signal to the TMM accessory card. The TMM is used to display overtemperature of motors, hydraulic systems or any other device or system than can activate a thermostat type switch that closes at the desired temperature. Status codes 90 and 93 not only display the status code to the dash display but when activated can be programmed with the Handset to reduce the speed of the truck from 100% to 0% percent on time. The TMM is also used to monitor and display motor brush wear warnings when the motor brushes require replacement.

Operation of TMM1 Card The TMM card utilizes up to 9 input points and 3 output points. The 3 output points connect to the “Y” plug on the EV100 logic card. Due to the low level signal value of this output, shielded wire should always be used to insure proper operation. The input to the TMM card is either switch or sensor wire closure to battery negative or positive. The table below outlines the status code displayed for each input point when that point is closed to battery negative or positive as indicated.

WIRE HARNESS CONNECTIONS TO TMM1 (P5) or PUMP CONTROL (P5) Pin Error # TMM1

TB1

Description

☞ NOTE ☞ The microprocessor only checks for TMM status codes 93, 94 and 95 when a neutral signal is present (i.e. open start switch or open F/R switch), the status code is displayed and the speed limit enabled when the control is returned to the run mode. Do not use status code 93 speed limit for applications requiring immediate speed limit on switch closure. Figure 12 outlines the typical wiring for the TMM with all switch closure inputs. The TMM can also be used as a Brush Wear Indicator (BWI). The Brush Wear Indicator is designed to detect a worn-out brush and display a fault code on the dash display to warn maintenance personnel that the motor brushes need to be replaced before they wear to the point of causing destructive damage to the motor commutator surface. The BWI is compatible with any sensor that short circuits to the motor armature to signal limits of brush wear.

NOTE: Motor armature must be in the positive side of the battery circuit.

Installation

Wire # Pump Control

Traction Thermal

None

Pump Thermal

None

TB8

Traction BWI

TB10

Traction BWI

PA5

TB11

Pump BWI

PB1

TB12

Pump BWI

PB2

TB4

The instructions for adjustment of the speed limit function of status codes 90 and 93 are described in detail in the instructions for the Handset. The speed limit function will be enabled when the input switch supplies a negative signal to either TB1, TB5 or TB6.

! WARNING

PA3

Before adjusting, servicing or making contact with working components, raise the truck wheels off the floor, disconnect the battery and discharge the capacitor in the traction and pump controls.

PB6

PA4

3-11

CHECKS & REPAIRS

Motors and Controls Truck Management Module Connections (TMM1)

FIGURE 12. TMM1 Connections

3-12

CHECKS & REPAIRS

Motors and Controls Thermal Transfer

Insuring proper Thermal Transfer

Why is Thermal Transfer important? Solid-state electronic devices are often considered “lossless” as compared to their electro-mechanical counterparts. However, these devices are not entirely 100% efficient and losses exist in the form of generated heat which must be dissipated properly to insure long-term reliability and performance. The SCR Control incorporates solid-state devices throughout. It also incorporates heat sinking to provide proper dissipation of the generated heat through these heat sinks to the control base to be eventually dissipate in the vehicle control mounting structure (i.e. bulkhead). The SCR Control heat sinks are designed to provide short-term thermal peak overloads, but long-term cooling is dependent on proper thermal transfer from the heat sink to the vehicle frame.

Proper consideration must be given to the 3 factors for ensuring “good” thermal transfer to insure continued performance and reliability of the SCR Control and the vehicle it controls. SCR Controls are thermally rated using a 12” x 24” x 1/2” thick steel heat sink. Maximum vehicle sinking of the control is obtained by mounting it to the vehicle bulkhead or counterweight. Other locations can be used, but it is recommended they provide thermal capacity similar to the above. The vehicle surface for control mounting should be reasonably flat, without ridges, cast mold lines, voids, weld splatter, or paint. Care should be taken to insure the Control is clamped (bolted) down evenly and securely. A thermal transfer grease should be used between the control base and the truck mounting surface to provide optimum thermal conductivity. This should be applied to the control base in a thin, smooth, consistent coat.

What determines “Good” Thermal Transfer? The primary factor for insuring “good” thermal transfer is good mechanical surface-to-surface interfacing and applies to flat and threaded surface mating. The effectiveness of the thermal transfer then becomes a function of the amount of actual surface contact of the heat “source” to a properly selected heat “sink”.

Most heat sink suppliers have their own recommendations, but generally should be equivalent to Dow Corning 340 or 342, a non-conductive transfer grease. Threaded devices require a conductive grease similar to Dow Corning 44.

While most commercially prepared surfaces appear flat and smooth, good thermal transfer of the heat generated in solid-state devices requires the optimum in surface contact. The smallest amount of surface irregularity can be detrimental as it adds to the thermal resistivity between the two surfaces and limits thermal transfer. “Good” thermal transfer is thus dependent on 3 factors: 1. Proper heat sinking. 2. Proper mechanical mating (mounting). 3. Optimum surface contact.

3-13

CHECKS & REPAIRS

Trouble Shooting Tips SUCCESSFUL ☞ COMMUTATION ☞ REQUIREMENTS

☞ INSULATION SYSTEM ☞ • Insulation resistance - 0.10 Mega-ohm (or greater)

• Good contact between commutator and brush

• Less than 0.10 Mega-ohm, investigate: – Excessive dirt – Moisture – Insulation breaK down

• Mechanically true commutator • Brushes free to move in holders • Copper-Oxide-Carbon film (as opposed to pure copper surface) noted by color variations

For moisture, bake in an oven at 90 degrees C (190F)

• Commutator surface should be clean and smooth

• 600V - 60HZ - 1 minute • Test old motors at 75% of above values

• Clean commutator

☞ ARMATURE WINDING PROBLEMS ☞

NOTE: Refer to the next following pages for charts on “Unsatisfactory Brush Performance” and illustrations of “Commutator Surfaces” which show the main patterns of film build-up on commutators, and indicate the type of brush/commutator interaction which give rise to each pattern.

☞

• Open Circuit – Thin red sparks encircling commutator – Blackens or flattens commutator bars, especially at edges

☞

• Short Circuit – Blue spark in vicinity of brush holder – Commutator bars oxidize or burn

SPARKING AT BRUSHES • Commutator in poor condition

• Grounded – High current draw – Rapid brush wear

• Eccentric or rough commutator • Excessive vibration • Broken or sluggish spring • Brushes to short • Machine overloaded

Notes:

3-14

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE ONE Primary Sources of Unsatisfactory Brush Performance

Preparation and Care of Motor

Mechanical Fault in Motor

Electric Fault in Motor

Load or Service Condition

Disturbing External Condition

• Poor operation of commutator surface • High mica • Side mica • Need for periodic cleaning • Clogged ventilating ducts • Brushes tight in holders • Brushes too loose in holders • Brush holders loose at mounting • Loose pole pieces • Loose or worn bearings • Dynamic imbalance • Variable angular velocity • Open or high resistance connection at commutator • Connection at series terminal • Short circuit in field or armature winding • Ground in field or armature winding • Reversed polarity on main pole • Overload • Dynamic braking • Low average current density in brushes • Contaminated atmosphere • “Contact positions” • Oil on commutator or oil mist in air • Abrasive dust in air • Humidity too high • Humidity too low • Silicone contamination • Loose or damaged motor mounting • External source of vibration • External short circuit • Contact drop of brushes too high • Contact drop of brushes too low • Lack of film-forming properties in brush • Lack of polishing action in brush • Brushes too abrasive • Lack of carrying capacity 3-15

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE TWO Indications Appearing at Brushes INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Sparking

Commutator surface condition

• Poor operation of commutator surface • High mica • Side mica • Low average current density in brushes • Contaminated atmosphere • Contact positions • Oil on commutator or oil mist in air • Humidity too low • Lack of film-forming properties in brush • Lack of polishing action in brush

Mechanical fault in motor

• Clogged ventilating ducts • Brushes tight in holders • Brushes too loose at mounting • Loose pole pieces • Loose or worn bearings • Dynamic unbalance • Incorrect spring tension

Electrical fault in motor

• Open or high resistance connection at commutator

• Short circuit in field or armature winding (see Motor Winding Specifications page 3-23)

• Ground in field or armature winding • Reversed polarity on main pole Bad load condition

• Overload • Rapid change of load

Vibration

• Loose or damaged motor mountings • External source of vibration

Chattering of brushes

• See Chattering or Noisy Brushes

Wrong brush grade for

• Lack of film-forming properties in brush application

Other

• Silicone contamination

Etched or Burned Bands on Brush Face

Embedded copper

• See Copper in Brush Face

Rapid Brush Wear

Commutator surface condition

• See specific surface fault in evidence • Silicone contamination

Severe sparking

• See Sparking 3-16

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE TWO (cont’d) Indications Appearing at Brushes INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Rapid Brush Wear (cont’d)

Imperfect contact w/commutator

• Incorrect spring tension • Brushes tight in holders • Brushes too loose in holders • Brushes holders loose at mounting • Loose or damaged motor mountings • External source of vibration

Wrong brush grade f/application

• Lack of film-forming properties in brush

Commutator surface condition

• High mica • Side mica

Bad service condition

• Oil on commutator or oil mist in air • Abrasive dust in air • Humidity too high • Humidity too low

Wrong brush grade f/application

• Lack of film-forming properties in brush • Brushes too abrasive

Commutator surface condition

• Raised Commutator Bars

Looseness in motor

• Brushes too loose in holders • Brushes holders loose at mounting • Incorrect spring tension

High friction

• Clogged ventilating ducts • Contact poisons • Humidity too low • External source of vibration

Wrong brush grade f/application

• Lack of film-forming properties in brush

Copper in Brush Face

Chattering or Noisy Brushes

3-17

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE THREE Indications Appearing as Heating INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Heating in Windings (Field or Armature)

Severe load condition

• Overload • External short circuit • Stalled motor

Unbalanced magnetic field

• Loose or worn bearings • Short circuit in field or armature winding

Lack of ventilation

Heating at Commutator

Heating at Brushes

Severe load condition

• Overload

Severe sparking

• Contact positions • See Sparking

High friction

• Incorrect spring tension • Contact poisons • Humidity too low • Lack of film-forming properties in brush

Poor commutator surface

• See specific surface fault in evidence

Depreciation

• Clogged ventilating ducts

High contact resistance

• Contact drop of brushes too high

Severe load condition

• Overload

Faulty motor adjustment

• Incorrect spring tension

Severe sparking

• See Sparking

Raw streaks on commutator

• See Streaking or Threading of Surface

Embedded copper

• See Copper in Brush Face

Wrong brush grade f/application

• Contact drop of brushes too low • Lack of film-forming properties in brush • Brushes too abrasive • Lack of carrying capacity

3-18

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE FOUR Indications Appearing at Commutator Surface INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Brush Chipping or Breakage

Commutator surface condition

• See specific surface fault in evidence

Looseness in motor

• Brushes too loose in holders • Brushes holders loose at mounting

Vibration

• External source of vibration

Chattering

• See Chattering or Noisy Brushes

Sluggish brush movement

• Brushes tight in holders

Rough or uneven surface

• Poor operation of commutator surface • High mica • Side mica

High Commutator Bar

Sparking

• Stalled motor

Low Commutator Bar

Sparking

• High mica • Open or high resistance connection •

at commutator Stalled motor

Sparking

• Low average current density in brushes • Contaminated atmosphere • Contact positions • Oil on commutator or oil mist in air • Humidity too low • Lack of film-forming properties in brush

Copper or foreign material in brush face

• High mica • Side mica • Oil on commutator or oil mist in air • Abrasive dust in air • Humidity too high • Brushes too abrasive

Bar Etching or Burning

Sparking

• High mica • Side mica

Bar Marking at Pole Pitch Spacing

Sparking

• Open or high resistance connection

Streaking or Threading of Surface

at commutator

3-19

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE FOUR (cont’d) Indications Appearing at Commutator Surface INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Bar Marking at Slot Pitch Spacing

Sparking

• Lack of polishing action in brush • Lack of film-forming properties in brush

Flat Spot

Sparking

• Open or high resistance connection at commutator

• Stalled motor Discoloration of Surface

Raw Copper Surface

Rapid Commutator Wear with Blackened Surface

High temperature

• See Heating at Commutator

Atmospheric condition

• Contaminated atmosphere • Oil in commutator or oil mist in air

Wrong brush grade f/application

• Lack of polishing action in brush • Lack of film-forming properties in brush

Embedded copper

• See Copper in Brush Face

Bad service condition

• Contact positions • Abrasive dust in air • Humidity too low

Wrong brush grade f/application

• Lack of film-forming properties in brush • Brushes too abrasive

Burning

• High mica • Side mica • Incorrect spring tension • Brushes tight in holders • See Sparking

Severe sparking

Rapid Commutator Wear with Bright Surface

Copper Dragging

Foreign material in brush face

• Contact positions • Abrasive dust in air • Humidity too low • Brushes too abrasive

Wrong brush grade f/application

• Brushes too abrasive • Lack of film-forming properties

Brush Vibration

• External source of vibration • Lack of film-forming properties in brush 3-20

CHECKS & REPAIRS

Commutator Surfaces GOOD CONDITION

UNSATISFACTORY CONDITION

LIGHT FILM

UNEVEN FILM

Uniform coloring indicates satisfactory operation of machine and brushes. Film color is largely an effect of thickness, therefore provided the film is uniform it is perfectly acceptable.

Patchy colors of varying densities and shape. Due to unclean operating conditions or incorrect physical condition of commutator.

SATISFACTORY CONDITION

UNSATISFACTORY CONDITION

LIGHT AND DARK PATTERN This is not a good condition but in our experience it is known that machines having this commutator pattern have operated with satisfactory results for long periods of time. This condition can appear in alternating bars as shown or every 3rd or 4th bar, etc. This is related to the winding design of the armature. Difficulty caused from split windings crossing in the same slot.

FILM WITH DARK AREAS

UNSATISFACTORY CONDITION

STREAKY FILM WITH NO COMMUTATOR WEAR

EXAMPLE OF POOR COMMUTATOR MACHINING

These areas can be isolated or regular. Commutator out of round. This can be caused by vibration or mechanical deficiencies in equipment operation, bearings, couplings, etc.

Frequently due to under-loaded operation, machine grossly over-brushed or brush grade incorrect for particular machine application. Atmosphere and environmental conditions can contribute.

Bars are low on entry and leaving edges giving rise to the brushes riding on the middle of the bars.

3-21

CHECKS & REPAIRS

Commutator Surfaces UNSATISFACTORY CONDITION

UNSATISFACTORY CONDITION

EXAMPLE OF POOR COMMUTATOR MACHINING

BRUSH CONTACT MARK Storage of machines, for lengthy periods, with brushes in position. This can also result from operation of machine in prolonged stall conditions.

Bars are low in the middle giving rise to the brushes riding on entry and leaving bar edges. This and the previous illustration indicate the need for better maintenance.

UNSATISFACTORY CONDITION

STREAKY FILM WITH COMMUTATOR WEAR

BAR EDGE BURNING CAUSE HIGH MICA

This is a further development of the third example, previous page. Brush grade, machine applications and working environment all suspect. Earlier corrective action should have been taken.

Illustration shows high mica in every slot. Same effect can occur on one bar only. Similar conditions can be caused by a high or low bar.

UNSATISFACTORY CONDITION

DOUBLE POLE PITCH

SMALL BRIGHT SPOTS

Darkening of commutator in sequences two pole pitches apart is due to armature fault, defective coil, riser bars or equalizer connections.

Related to over-loaded machines and low brush pressure. Due to sparking under brush which gives rise to spots being of a random distribution. If not corrected, will result in scored commutator.

3-22

CHECKS & REPAIRS

Motor Winding Specifications MOTOR WINDING SPECIFICATIONS 36/48 APPLICATIONS PART NUMBER

ARMATURE RESISTANCE OHMS (SPAN)

SERIES FIELD RESISTANCE (OHMS)

SHUNT FIELD RESISTANCE (OHMS)

TYPE & SIZE

97121-01600

0.007 (1 - 12)

0.010

---

9” Traction

97121-11600

0.007 (1 - 12)

0.010

---

9” Traction

97121-21600

0.007 (1 - 12)

0.010

---

9” Traction

97220-04900

0.005 (1 - 13)

0.002

---

11” Traction

97220-14900

0.005 (1 - 13)

0.002

---

11” Traction

97220-24900

0.005 (1 - 13)

0.002

---

11” Traction

97121-01900

0.120 (1 - 9)

---

Power Steering Motor

97121-11900

0.120 (1 - 9)

---

Power Steering Motor

97121-21900

0.120 (1 - 9)

---

Power Steering Motor

97121-02200

0.006 (1 - 10)

0.007

---

6 5/8” Pump

97121-12200

0.006 (1 - 10)

0.007

---

6 5/8” Pump

97121-01800

0.008 (1 - 9)

0.005

---

7.5” Pump

97220-09300

0.005 (1 - 11)

0.004

---

9” Pump

97220-19300

0.005 (1 - 11)

0.004

---

9” Pump

97220-29300

0.005 (1 - 11)

0.004

---

9” Pump

3-23

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Main Logic Card .................................................................................................. 4-1

Component Locations...................................................................................... 4-2

Terminal Connections for ZX Logic Cards ............................................ 4-3

EV100ZX Logic Card Specifications ......................................................... 4-4

EV100ZX Current Limit Curves ................................................................... 4-6

Secondary Troubleshooting ......................................................................... 4-7 Table 1 Failures that cause reduced or no motor torque with SCR Control........ 4-7 Table 2 Failures that cause full or no motor torque with SCR Control ................ 4-9 Table 3 Mis-operation of Other Features. ............................................................ 4-10

Hydraulic Pump Control Troubleshooting ............................................ 4-12 Table 4 Failures that cause reduced or no motor torque with SCR Control........ 4-12 Table 5 Failures that cause no motor torque with SCR Control .......................... 4-14

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Main Logic Card Terminals 1–6

Y Plug

Z Plug

A and B Plugs Mounting Screw

These troubleshooting instructions are intended as a method to check all outside devices and eliminate them as the source of the problem in order to conclude that the Control Card (Main Logic Card) is faulty. Instructions for Removal of Control Card 1. Remove control wires on the screw terminals 1 through 6 as required. 2. Unplug A, B, and Z plugs by pressing down on tab with wide blade screwdriver and rotating 90 degrees. 3. Remove the two mounting screws and lift Card Box free. NOTE: Do not attempt to remove circuit board from Card Box. Reverse procedures to install new Control Card. 4-1

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Component Locations

Card Connection Terminals

Oscillator Card

Thermal Protector

Charging SCR (5 REC) Filter (22 REC)

Filter (23 REC) Turn-off SCR (2 REC)

Commutation Capacitor Main SCR (1 REC)

Filter (25 REC) Filter (24 REC) Reactor/Choke

Motor Current Sensor

Flyback Diode (3 REC)

Plugging Diode (4 REC)

4-2

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Terminal Connections For ZX Logic Cards INPUT

TRACTION STANDARD

TRACTION SL /FW

TRACTION REGEN /FW

PUMP

TB1

Accel Pot Input

TB2

Start Switch Input

SL2

TB3

Seat Switch Input

SL2

TB4

Key Switch Input

TB5

Forward Switch Input

SL3

TB6

Reverse Switch Input

SL4

PA1

Plug Signal

Status Code 93 Input

PA2

BDI Interrupt

Status Code 93 Input

PA3

Hourmeter Input

Status Code 90 Input

PA3 (Opt) C/L Reduction Input (Opt)

C/L Reduction Input (Opt)

PA4

Not Used

SL2

Sensor 2 Yellow Wire

Status Code 94 Input

PA5

Not Used

SL3

Sensor 2 Green Wire

Status Code 94 Input

PA6

Not Used

SL1

Mtr A2 Input

Status Code 91 Input

PB1

FW Coil Driver

Status Code 94 Input

PB2

Not Used

Regen Coil Driver

Status Code 95 Input

PB3

SP Coil Driver

BDI Enable Signal Input

PB4

F Coil Driver

Pump (PMT) Coil Driver

PB5

R Coil Driver

1A Coil Driver

PB6

1A Coil Driver

Status Code 92 Input

PY1

Dash Display 4 Input

PY2

Dash Display 3 Input

PY3

Dash Display 1 Input

Dash Display 4 Input

PY4

Dash Display 2 Input

PY5

Dash Display 5 Input

Not Used

PY6

Handset Store

PY7

Not Used

PY8

TMM / Pump-PY12

Not Used

PY9

TMM / Pump-PY11

Not Used

PY10

TMM / Pump-PY10

Traction PY10

PY11

Not Used

Traction Py9

PY12

MPH Input

Traction PY8

PY13

Serial Receive

PY14

Serial Transmit

PZ6

+5 VDC Output

+5 VDC Output 4-3

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

EV100ZX Logic Card Specifications CONTROL FEATURES

TRACTION

PUMP

On-Board Diagnostics

Standard Displayed to Handset or Dash Display

Hourmeter

1-Displayed to Dash 1-Secure (Handset Read)

Stored Status Codes

16 Codes with BDI and Hourmeter reference

Card Type Selection

Standard Enable / Disable features

Creep Speed

Adjustable 2% to 15% On Time

Not applicable

Current Limit

Adjustable. See C/L Curves Standard/High Performance

Plugging

Adjustable 200 to 930 amps

Not applicable

Pedal Position Plug

Adjustable. 100 to 930 Amps Can be disabled

Not applicable

Ramp Start

Standard

Not applicable

Full Power Transition

Standard with 1A Ctr

Controlled Acceleration

Adjustable .1 to 22 seconds

Adjustable .1 to 5.5 seconds

1A Timed Pick-Up

Follows CA by .2 seconds with Accel Volts is <.5V or Accel Ohms is <200

1A Thermal Hold-Off

Standard at 90°C Cutback at 20%

1A Plugging Hold-Off

Standard

Not applicable

Delay to First Pulse

Standard

PMT (Fault Shut Down)

Standard Look ahead and reset two count

Thermal Protection

Standard 90°C Cutback

Static Return to Off

Standard 2 second delay

Not applicable

Voltage Range

24 - 80 VDC

Accelerator Input

3.5-0 VDC

Low Battery Operation

Standard 50% at 36-80 VDC 75% at 24 VDC

Reverse Battery Protection

Standard

Ambient Temperature

-30 to +50°C

Approximate Weight

5.5 Kg

5.5 K

Coil Drivers F / R or Line

On-Board

Not applicable

Regen

Standard

Not applicable

On-Board

Not applicable

4-4

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

EV100ZX Logic Card Specifications CONTROL FEATURES

TRACTION

PUMP

Shorted Driver Protection

Standard

Shorted 3 REC Protection

Standard

F/R and Speed Input Switch Loading

Logic Current

1A Switch

Not Required

Not required

1A Current dropout

Adjustable 450 to 1260 amps

Not applicable

Regenerative Braking

Adjustable Regen C/L - 75A to 630A Regen Start - 15% to 96%

Not applicable

Field Weakening

Adjustable Pick-up - 52A - 466A Drop-out - 65A to 895A

Not applicable

Speed Limit Three Ranges Creep to Full Speed

Standard Adjustable Input by Limit Switch

Steer Pump Time Delay

Seat - .5 to 63 sec Neutral - .5 to 63 sec

Not applicable

Accelerator Volts Lockout Accel Volts > 2.5V

Standard

Battery Volts Check

Standard

C/L Reduction Input

Standard

Four Function Mode Registers selectable by Interactive Dash Display

4 - C/A Modes 4 - FW Pickup Modes 4 - SL1 Modes

4 - C/A Modes 4 - SL2 Modes 4 - SL4 Modes

RS-232 Communication Port

Standard

Battery Discharge Indication

Optional

Full Load Level Running Mtr Current at 50% 1A duty

150 Amps plus

Continuous Duty Mtr Current with 0.3°C/Watt Heatsink at 40°C ambient

103 Amps plus

330/950 Amps 330/650 Amps

Not applicable

Min-Max @ 30% On Time

405/640 Amps (STD)

475/690 Amps (H/P)

Min-Max @ 50% On Time

320/565 Amps (STD)

455/685 Amps (H/P)

Min-Max @ 70% On Time

230/495 Amps (STD)

435/680 Amps (H/P)

Plug Current Limit Min-Max @ 1 Sec Min-Max @ 3 Sec

Average Motor C/L with Typical Mtr Inductance

4-5

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

EV100ZX Current Limit Curves 100 200 300 400 500 600 700 800 900 1000

EV100ZX Traction STD Curve

Av era ge in

Min imu m

100

EV100ZX SCR Pump H/P Curve

100 200 300 400 500 600 700 800 900 1000

Average in Maximum

Average in Minimum

50 4-6

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Secondary Troubleshooting The primary method of diagnosing EV100ZX Control System faults is to use the diagnostic features of the display and handset. These, along with the preceding fault code tables, aid in the resolution of the majority of faults encountered.

If a problem is readily identified through the built-in diagnostics feature, use the following tables as a secondary guide to aid in the identification of the fault.

TABLE ONE Failures that Cause Reduced or No Motor Torque with SCR Control

☞ NOTE ☞ Conduct all testing with truck jacked up.

Symptom

Probable Cause

1a. Contactors do not pick up. No control voltage from positive to negative.

• Check power and control fuses. • Check battery for low specific gravity and connections for looseness or broken fittings.

1b. Contactors do not pick up. [For troubleshooting regen braking (RB) contactor problems, refer to “Table 3” j to q.]

• Plug in the battery with the key switch OFF. Voltage on TB4 should be less than 4 volts.

• Close key switch and check volts at T2; voltage should be about 50% battery volts. If above 85% of battery volts, check for shorted 1A tips or shorted 1 REC.

• Close brake, start switches (all switches needed to close F or R contactor except the directional switch). Voltage on TB4, TB3 and TB2 should be at battery volts. Voltage on TB5 and TB6 should be near zero volts. Wait one second, then close the forward directional switch. Voltage at TB6 should remain at zero. Voltage at TB5 and the TB5 side of the F contactor coil should be battery volts. If not, check the wiring and switches.

• With key switch and seat switch closed, check for battery volts at TB4. If low or zero, check control fuse, wiring or faulty key switch.

• With key switch and seat switch closed, check for battery volts at TB3. If low or zero, check control wire #10 between key switch and seat switch and control card or fault seat switch.

• Static Return to Off Fault. If warning light on OK monitor (!) comes on, once the key switch and seat switch are closed:

• Check for fault in directional control switch or switch adjustment.

• Check for fault in wiring to directional control switch. 4-7

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Secondary Troubleshooting TABLE ONE (cont’d) Failures that Cause Reduced or No Motor Torque with SCR Control

☞ NOTE ☞ Conduct all testing with truck jacked up.

Symptom

Probable Cause

1c. Contactors close. NO power and NO SCR hum with accelerator in SCR range.

• Check power fuse at SCR positive. Should be battery volts. If not, check power fuse.

• Check to see if RB contactor is closed. If not, see “Table 3” l. • Check voltage at T2. Should be zero. If not, check volts at S1, S2, A1 and A2 to locate open circuit.

• Check voltage at TB1. Should be 3-4 volts with accelerator at creep speed, reducing to 0.5 volts or less as the accelerator is pressed down toward top speed. If TB1 remains at about 4 volts, check brake switch, start switch and accelerator. Start switch and accelerator potentiometer.

• Check for an open thermal protector (refer to pg. 4). • Check 1C volts at the orange wire, If more than 0.125 times the battery volts, verify that 1 REC will gate ON (refer to pg. 4). Check the green lead on the current sensor for a good connection to card input pin 4.

• Check 23FIL for short (refer to pg. 5). • Replace the Control Card. 1d. Contactors close. Little or no power. Normal SCR hum.

• Check 3 REC for open circuit (refer to pg. 4).

1e. Contactors close. Little or no power. Abnormal SCR hum.

• Check 2 REC for short circuit (refer to pg. 4).

• Check 4 REC for short circuit (refer to pg. 4). • Check 5 REC for short circuit (refer to pg. 4). • Check 22 REC and 25 REC. NOTE: A 25 REC which checks good with an ohm meter can cause a mis-operation of 5 REC under load.

1f. Contactors close. Little power. No SCR hum.

• Check 1C for low resistance (refer to pg. 4).

4-8

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Secondary Troubleshooting TABLE ONE (cont’d) Failures that Cause Reduced or No Motor Torque with SCR Control

☞ NOTE ☞ Conduct all testing with truck jacked up.

Symptom

Probable Cause

1g. One contactors closes with normal operation, but opposite contactor will not close.

• Close key, brake & start needed to close F or R switches

1h. PMT trips after operating in 1A and accelerator is returned to SCR range.

• Check for cause of long 1A drop-out time, i.e., low

(all switches contactor expect the directional switch). Voltage on TB5 and TB6 should be near zero volts. Wait one second, then close the directional switch of the contactor that will not close. Voltage at the other direction input (TB5 or TB6) should remain at zero volts. Volts at the non-closing direction (TB5 or TB6) and top of the contactor coil should be battery volts. If not, check wiring and switches.

resistance in 1A filter, shorted turns in 1A coil, or low voltage coil.

TABLE TWO Failures that Cause Full or No Motor Torque with SCR Control

☞ NOTE ☞ Conduct all testing with truck jacked up.

Symptom

Probable Cause

2a. Contactors close. Full SCR speed immediately with audible hum. No PMT trip.

• Key switch on. Check volts at TB1. Should be 3-4 volts

2b. Contactors close once or twice, then remain open. PMT trips.

with accelerator output check open circuit.

• Replace Control Card. • Check 5 REC for open circuit or open gate (refer to pg. 4). • Check 1C for open and loose connections (refer to pg. 4). • Check 1C for short (refer to pg. 4). • Check 2 REC for short (refer to pg. 4). • Check 5 REC for short (refer to pg. 4). • Check 22 REC for short (refer to pg. 4). • Check 25 REC for short (refer to pg. 4). • Check 1X choke and reactor T3-T4 (refer to pg. 5). • Check PA3 wire for open (regen circuit only). • Replace Control Card. 4-9

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Secondary Troubleshooting TABLE TWO (cont’d) Failures that Cause Full or No Motor Torque with SCR Control

☞ NOTE ☞ Conduct all testing with truck jacked up.

Symptom

Probable Cause

2c. Contactors close. Stall currents, under SCR operation, higher than normal and uncontrollable with C/L trimpot. Contactors may open once or twice and then remain open.

• Check current sensor yellow lead from negative end of sensor to card input pin 3.

• Replace Control Card. TABLE THREE Mis-operation of Other Features

☞ NOTE ☞ Conduct all testing with truck jacked up.

Symptom

Probable Cause

3a. 1A or FW contactors close with key.

• Replace Control Card.

3b. F or R contactor will close without returning the directional switch to OFF.

• Check location of TB2. Any open switch between TB2 and the directional switch will satisfy the SRO function.

• Close the key switch only. Voltage at TB4 should be battery volts. Voltage at TB2, TB3, TB5 and TB6 should be near zero. Close the seat, brake and start switches. Voltage at TB3 and TB2 should be battery volts.

• Replace Control Card. 3c. 1A contactor will not close.

• Check coil voltage. • Check the voltage at TB1. Should reduce to less than 0.2 volts at top speed. If over 0.2 volts, check accelerator switch.

• Replace Control Card. 4-10

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Secondary Troubleshooting TABLE THREE (cont’d) Mis-operation of Other Features

☞ NOTE ☞ Conduct all testing with truck jacked up.

Symptom

Probable Cause

3d. 1A contactor will not close at SCR stall.

• Check voltage at gray lead to thermal protector (TP). If above 3.4 volts, the control is in thermal cutback. Allow control to cool and recheck 1A function.

• Replace Control Card. 3e. 1A will not open until start switch is opened.

• Check voltage at TB1. Should be near 3 volts when

3f. FW contactor will not close after 1A pickup.

• Check voltage across FW coil. • Check card settings.

3g. FW contactor will not drop out with increasing load.

• Check drop-out setting on Control Card. • Replace Control Card.

3h. Stiff plug (severe reversal).

• Check plug adjustment setting on Control Card. • Check yellow wire on current sensor for open. • Check 4 REC for open circuit (refer to pg. 4). • Replace Control Card.

3i. Hour meter feed faults.

• [Not applicable to this truck.]

3j. Regen contactor does not close.

• Check voltage on coil.

3k. Stiff reversal during regen braking mode.

• Check for proper adjustment of regen. • Check for open connection between sensor-2 green

accelerator is released. If not, check accelerator output.

lead and control card PA5.

• Replace Control Card. 3l. Very soft reversal during regen braking mode. Normal plug.

• Check for proper adjustment of regen. • Replace Control Card. 4-11

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Secondary Troubleshooting TABLE THREE (cont’d) Mis-operation of Other Features

☞ NOTE ☞ Conduct all testing with truck jacked up.

Symptom

Probable Cause

3m. RB contactor remains open after reversal.

• Check for open connection between sensor-2 yellow lead and control card PA4.

• Replace Control Card. 3n. Failure to transition to regen braking mode.

• Check for proper adjustment of regen. • Replace Control Card.

3o. RB contactor does not open during regen braking mode.

• Check coil voltage. • Replace Control Card.

3p. Very soft reversal.

• Check plug adjustment setting on Control Card. • Replace Control Card.

3q. Blown power fuse.

• Check 3 REC for short (refer to pg. 4). Very hot power cables. (Also, possible damage to 1 REC).

Hydraulic Pump Control Troubleshooting Troubleshooting is based on using the voltmeter to determine if the proper voltages are available to permit the control to operate properly.

TABLE FOUR Failures that Cause Reduced or No Motor Torque with SCR Control Symptom

Probable Cause

4a. Hydraulic pump will not operate when any hydraulic hand lever is moved from neutral position. No control voltage from positive to negative.

• Check power and control fuses.

4b. Hydraulic pump will not operate. Control volts present from positive to negative with proper polarity.

• Plug in the battery with the key switch OFF. Voltage on

• Check battery for low specific gravity and connections for looseness or broken fittings.

TB4 should be less than 4 volts.

• Close key switch and check volts at T2; voltage should be about 50% battery volts. If above 85% of battery volts, check for shorted 1A tips or shorted 1 REC. 4-12

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Hydraulic Pump Control Troubleshooting TABLE FOUR (cont’d) Failures that Cause Reduced or No Motor Torque with SCR Control Symptom

Probable Cause

4b. Hydraulic pump will not operate. Control volts present from positive to negative with proper polarity.

• Check voltage at TB2, TB3 or TB6 when the hand lever

4c. Hydraulic pump will not operate and control voltage present. No power and no SCR hum.

• Check power fuse at SCR positive. Should be battery

is moved for that function. Voltage should read 8.0 volts and decrease to zero volts when the switches are activated. If not, check the wiring and switch.

volts. If not, check power fuse.

• Check voltage at T2. Should be zero. If not, check volts at S1 and A2 to locate open circuit.

• Check for an open thermal protector (refer to pg. 4). • Check 1C voltage at the orange wire. If more than 0.125 times the battery volts, check if 2 REC will gate ON (refer to pg. 4). If less than 0.125 times the battery volts, check if 1 REC will gate ON. Check the green lead on the current sensor for a good connection to card input pin 4.

• Check 23 FIL for short (refer to pg. 5). • Replace Control Card. 4d. Hydraulic pump will not operate. Little or no power. Normal SCR hum.

• Check 3 REC for open circuit (refer to pg. 4).

4e. Hydraulic pump will not operate. No power. Abnormal SCR hum.

• Check 3 REC for short circuit (refer to pg. 4). • Check 5 REC for short circuit (refer to pg. 4). • Check 22 REC and 25 REC. NOTE: A 25 REC which checks good with an ohm meter can cause a mis-operation of 5 REC under load.

4f. Hydraulic pump will not operate. Little power. No SCR hum.

• Check 1C for low resistance (refer to pg. 4).

4-13

LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Hydraulic Pump Control Troubleshooting TABLE FIVE Failures that Cause No Motor Torque with SCR Control Symptom

Probable Cause

5a. Full SCR speed immediately with audible hum.

• Key switch on. Check voltage at TB1. Should be 3-4 volts with pump switch in neutral position. If near zero volts, check pump switch for welded tips.

• Check lift potentiometer for short circuit. • Replace Control Card.

5b. Full speed immediately with no hum and control can be shut off only by disconnecting the battery.

• Check 5 REC for open circuit or open gate (refer to pg. 4). • Check 1C for open and loose connections (refer to pg. 4).

• Check 1C for short (refer to pg. 4). • Check 2 REC for short (refer to pg. 4). • Check 5 REC for short (refer to pg. 4). • Check 1X choke and reactor T3-T4 (refer to pg. 4). • Replace Control Card.

4-14

THEORY OF OPERATION

Electronic Speed Controls............................................................................. 5-1 Silicon Controlled Rectifier (SCR) ....................................................................... 5-1 Motor Circuit that Operates with Pulses .............................................................. 5-1 Traction Circuit..................................................................................................... 5-3 Hydraulic Pump Motor ......................................................................................... 5-3 SCR 1 “OFF” Circuit ............................................................................................ 5-4

Flyback Current from the Motor ................................................................. 5-6

Control Cards ....................................................................................................... 5-6 Pulse Monitor Trip (Traction Circuit only) ............................................................ 5-6 SRO Circuit (Traction Circuit only) ...................................................................... 5-7

Sequence of Operation .................................................................................... 5-7 Control Card Adjustments (Traction Circuit) ........................................................ 5-8 Accelerator Control .............................................................................................. 5-11

SCR Control (Hydraulic Pump Motor) ..................................................... 5-11

Contactors .............................................................................................................. 5-12

Circuit Protection .............................................................................................. 5-13 Traction Circuit Fuse............................................................................................ 5-13 Current Limit ........................................................................................................ 5-13 Thermal Protection .............................................................................................. 5-13

Truck Management Module (TMM1) .......................................................... 5-13

Instrument Panel Display ............................................................................... 5-14 Fault Code Memory ............................................................................................... 5-16 Brush Wear Indicators ........................................................................................... 5-16

THEORY OF OPERATION

Electronic Speed Controls NOTE: The description of the current flow in the electrical circuits in this section uses the “Conventional Theory of Current Flow.” This theory describes the current as flowing from positive to negative. An electric forklift truck uses a two-wire electrical system. There is no common ground through the frame. Both the positive and negative supply return current flow through wires and cables. There must be a minimum resistance of 50,000 ohms between the electrical circuits and the frame of the forklift truck.

The Silicon Controlled Rectifier (SCR)

The EV100 series of motor controllers have solid-state electronic circuits that control the operation of a DC motor. The speed of DC motors is controlled by the average applied voltage. The higher the average applied voltage, the faster the motor will rotate. If a switch is put in the traction motor circuit, and the switch is changed to OFF and ON quickly, the traction motor will rotate. See FIGURE 1. The speed of rotation increases as the time the switch is ON increases. The speed of rotation will decrease if the switch is OFF for a longer time than it is ON. The speed of the motor can be controlled using this principle.

500 Amp

1 REC

A silicon controlled rectifier (SCR) is a solid-state device that operates like a very fast switch. Rectifiers and diodes are electronic devices that permit electricity to flow in only one direction. See FIGURE 2. A rectifier or diode permits electricity to flow easily from the anode to the cathode. An SCR is a rectifier that has an additional element called a gate. An SCR will only permit electricity to flow when a positive signal voltage is applied momentarily to the gate. An SCR will permit electricity to flow from the anode to the cathode after the signal to the gate is removed. The following conditions stop the flow of electricity through an SCR: a. The signal voltage to the gate must be removed and the current flow through the SCR must be momentarily stopped. b. The voltage at the anode and the cathode must be equal so that there is no current flow. The current flow can be changed momentarily to charge a large capacitor so that the current flow through the SCR is momentarily interrupted. When the SCR is used as a switch:

Forward

a. The SCR is ON when electric current flows through it.

Reverse

b. The SCR is OFF when electric current cannot flow through it.

S1 Forward

Reverse

A Motor Circuit that Operates with Pulses

7 REC

Part of a schematic that shows an SCR in a traction circuit is shown in FIGURE 2. (This main SCR that is in series with the motor is called “SCR 1” in this manual). An SCR controller is also used to control the speed of the hydraulic motor in some forklift trucks. The operation of an SCR controller is the same for a traction circuit and a hydraulic motor. The controller for a traction circuit has more functions which are described in the section for the traction circuit.

RB Contactor

FIGURE 1. Basic Motor Circuit An electronic switch called an SCR is used to generate the rapid ON and OFF times. It has no moving parts. (An SCR in some countries is called a thyristor). NOTE: In the following illustrations: Indicates Positive Voltage.

////////

Indicates Battery Negative. 5-1

THEORY OF OPERATION

Electronic Speed Controls The frequency of the pulses also changes the average motor voltage. As the frequency of the pulses increases, the average motor voltage increases. The controller for the motor circuit has an oscillator that controls the ON time by sending a gate signal to the SCR (begin the pulse).

SCR ON 500 Amp

1 REC 1A

Forward

Reverse

100%

ON Low Speed

OFF

Reverse

Forward

OFF

50%

Average Motor Voltage (Speed) 10%

Battery Voltage

RB Contactor

➪

TIME LOW FREQUENCY

SCR OFF 500 Amp

1 REC OFF

100%

Forward

OFF

Average Motor Voltage (Speed)

Reverse

50%

Battery Voltage

Reverse

Forward

50% SCR Speed

➪

TIME HIGHEST FREQUENCY

A2 RB Contactor

OFF

100%

FIGURE 2. SCR Control

When a signal is momentarily applied to the gate, the SCR permits current flow from the battery through the motor. When the gate signal is removed and the current flow is momentarily interrupted the SCR is changed to OFF. The battery voltage is applied to the motor in pulses. The pulses of energy through the SCR to the motor are very fast. The motor cannot follow each pulse, but the motor runs smoothly on the average voltage generated by the ON and OFF times. The average motor voltage applied to the traction motor is shown in FIGURE 3.

OFF ON

OFF

Maximum SCR Speed 96%

Average Motor Voltage (Speed)

50% Battery Voltage

0% TIME

➪

LOW FREQUENCY FIGURE 3. Average Motor Voltage 5-2

THEORY OF OPERATION

Electronic Speed Controls The oscillator sends another signal to the special circuit that changes the SCR to OFF (end of the pulse). The controller has a variable ON time and variable OFF time and is controlled by the position of the accelerator pedal.

FREQUENCY

300 Hz

A potentiometer on the accelerator pedal sends a signal (5 volts decreasing to 0 volts) to the controller. The controller has a voltage controlled oscillator that increases in frequency when the voltage decreases from the accelerator potentiometer. The oscillator controls the ON time by sending a gate signal to SCR 1 (begin the pulse). The oscillator sends another signal to the special circuit that changes SCR 1 to OFF (end of the pulse). The position of the accelerator pedal causes a variation in the 0 to 5 volts supplied to the oscillator and controls the pulse rate and the speed of the motor.

150 Hz

50 Hz 5% ON TIME CREEP SPEED

50% ON TIME HALF SCR SPEED

96% ON TIME MAXIMUM SCR SPEED

FIGURE 4. SCR Oscillator Frequency

Traction Circuit The control card supplies approximately 5.0 volts to the accelerator control for the traction circuit. When the accelerator is connected and correctly adjusted, the voltage is 3.5 to 3.7 colts when measured between the accelerator and battery negative. This voltage is measured at the slowest speed (CREEP speed) of the forklift truck and the accelerator potentiometer is at its highest resistance. The accelerator potentiometer decreases this voltage by decreasing the resistance between the control card and battery negative. This accelerator voltage controls the oscillator in the control card when the accelerator potentiometer is moved by the operator. The oscillator controls the ON time of SCR 1 and controls the travel speed of the forklift truck. When the accelerator pedal is pushed farther down, the control voltage to the control card decreases. The maximum ON time (fast travel speed) occurs when the control voltage is 0.0 to 0.2 volts. Most forklift trucks are equipped with a by-pass circuit (1A) that is energized when the accelerator voltage decreases to less than 1.0 volts. The 1A by-pass circuit disables the SCR control and applies battery voltage directly to the traction motor.

A low average voltage applied to the motor is the result of a short ON time and a long OFF time. See FIGURE 3. The minimum pulse that the controller can give is one millisecond ON and 45 milliseconds OFF. This minimum pulse occurs at the slowest speed of forklift truck travel. The pulse rate is also least. When the oscillator frequencies give equal ON and OFF times (approximately 1.7 milliseconds each), the pulse rate is the greatest. Approximately 50% of the average battery voltage is available to the motor. The maximum average voltage to the motor gives the highest operating speed. This voltage occurs when the ON time is long compared to a short OFF time. The pulse rate is again least. At the maximum speed, the ON time is approximately 20 milliseconds and the OFF time is approximately 0.8 milliseconds. This maximum speed sends approximately 96% of the battery voltage to the motor. Many EV100 controllers for the traction motor use a 1A by-pass contactor and a field weakening contactor to increase the maximum travel speed of the forklift truck. These functions are described later in this section.

Hydraulic Pump Motor

See FIGURE 4. The pulse rate is approximately 50 Hertz at a low average motor voltage. When the pulse rate increases to a maximum of 300 Hertz, the average motor voltage increases. This increase in voltage is caused by an increase in the ON time and a decrease in the OFF time. The continued increase in ON time causes the pulse rate to decrease again toward a minimum of 50 Hertz when the average motor voltage is greater than 50%.

Some forklift trucks are equipped with an SCR controller to control the speed of the hydraulic pump motor. The switches fastened to the linkage for the main control valve change the resistance in the control circuit. These changes in the resistance change the voltage that controls the oscillator in the control card. The changes in motor speed is controlled in three steps instead of the continuous variation when the voltage is controlled with a potentiometer. 5-3

THEORY OF OPERATION

Electronic Speed Controls because there is no electrical path to C1. C1 will slowly charge to battery voltage in approximately four minutes because there is a high resistance path through the control card. The SCRs are not ON.

The SCR 1 “OFF” Circuit A special circuit is necessary to generate a momentary interruption in current flow to change SCR 1 to OFF. The parts of this circuit are the capacitor C1, Reactor, SCR 2, and SCR 5. SCR 2 discharges the capacitor C1 to the cathode of SCR 1. This discharge changes SCR 1 to OFF. SCR 5 and the Reactor are used to charge the capacitor C1 with the correct polarity.

+ _C1

An SCR controller uses the principle of self-induction in its operation. It is important to remember that selfinduction is like a flywheel in a mechanical device. When the torque is increased or decreased in a mechanical device, the flywheel gives a resistance to any change in speed. Self-induction does the same function in an electric circuit and resists any change in current flow.

SCR 1 SCR 2

+ _

Reactor SCR 5

The current flow through the motor circuit creates a magnetic field around the power cables. When SCR 1 is changed to OFF, this magnetic field decreases rapidly and creates an induction voltage that is proportional to the current flow. At maximum current flow, this induction voltage can be greater than 300 volts when measured across the capacitor C1.

To Motor Circuit

FIGURE 5. (Step 2) Operation of the SCR 1 “OFF” Circuit Step Step22 A signal is sent to SCR 2 to go ON, which closes the electrical path to C1. This action leaves C1 equal to battery negative and C1 is charged to battery voltage. When C1 is charged, SCR 2 goes OFF because there is no current flow.

+ C1 SCR 1 SCR 2 + _

+ _

Reactor

+ _C1

SCR 1

SCR 5

To Motor Circuit

SCR 2

+ _ A

FIGURE 5. (Step 1) Operation of the SCR 1 “OFF” Circuit

Reactor SCR 5

To Motor Circuit

Step Step11 When the battery is first connected, the top plate of C1 is connected to battery positive. The direction contactor is closed in preparation to operate the lift truck. C1 can not charge immediately to battery voltage

FIGURE 5. (Step 3) Operation of the SCR 1 “OFF” Circuit 5-4

THEORY OF OPERATION

Electronic Speed Controls Step Step13 _

A signal is sent to SCR 1 and SCR 5 to go ON. Current flows through SCR 1, the motor circuit and returns to battery negative. The polarity at point A is now positive compared to C1 because SCR 1 is ON.

_ C1 +

SCR 1 + B _

_ +

_ C1 +

Reactor SCR 5

SCR 1

To Motor Circuit

SCR 2 + SCR 5

SCR 2

FIGURE 5. (Step 5) Operation of the SCR 1 “OFF” Circuit

Reactor

To Motor Circuit

+ _

+ _ C1

SCR 1

FIGURE 5. (Step 4) Operation of the SCR 1 “OFF” Circuit +

Step Step44

SCR 2

When SCR 5 is ON, the positive charge at point A now moves through SCR 5 to change the charge on C1. The momentary current flow through the Reactor creates a magnetic field. When C1 is charged, the current flow through SCR 5 stops and SCR 5 goes OFF. The magnetic field decreases and the induction voltage causes a current flow from the Reactor to C1. This action of the Reactor charges C1 to a voltage higher than battery voltage, making the battery side of the capacitor (+) to appear (-) when compared to the charge on the other side of C1. This action leaves the other side of C1 negative compared to the other side, and C1 now has a “reverse charge”. This action takes less than one millisecond.

Reactor SCR 5

To Motor Circuit

FIGURE 5. (Step 6) Operation of the SCR 1 “OFF” Circuit Step Step66 When SCR 1 is OFF, the magnetic field around the power cables begins to decrease. This decrease generates a voltage that causes the other side of C1 to become more negative than battery negative. The voltage across C1 can now be as high as 150 volts. When the current flow through SCR 2 stops, SCR 2 goes OFF. This action leaves C1 charged at a much higher voltage. C1 is now charged for the next cycle. The fast pulse times and the necessary signals to the SCRs require a special electronic control. These control cards can not be repaired except by the manufacturer. A service person must replace a bad control card with a new or rebuilt control card.

Step Step15 The current flows through SCR 1 until a signal is sent to SCR 2 to go ON. When SCR 2 goes ON, the higher positive voltage moves from C1 and momentarily makes point B more positive than the battery. This momentary positive voltage makes SCR 1 go OFF. 5-5

THEORY OF OPERATION

Flyback Current from the Motor When a DC motor is controlled by a pulsed circuit, the magnetic field in the armature and field is continuously expanding and decreasing. This expansion and decrease of the magnetic field is lost energy for doing work unless the controller is designed to use this energy. A The inductor L2 shown Stepfor 4 this of FIGURE 5 is not diode D3 is added to the in circuit purpose. a component in the motor controller. The inductor L2 The inductor L2 shown step 4 is caused not a compois the symbol for the in inductance by the power nentcables in the when motorelectric controller. L2 flows is thethrough symbolthem for as current the inductance by paragraph. the power cables when described incaused the above 2 electric current flows through them.

☞

The graph in FIGURE 6 shows the typical induction current during equal ON and OFF times of SCR 1.

1 +

Control Cards The Control Cards for the traction circuit and the hydraulic circuit will be described separately in the following paragraphs.

3 5

NOTE: The configuration of the controller divides the base plate into three groups:

1. Battery 2. SCR 1 (OFF) 3. Diode D3

100%

OFF

a. Traction Controller group b. Contactor group c. Controller group for the hydraulic pump motor

4. Motor Field 5. Motor Armature 6. Motor Current Sensor

OFF

The three groups of components are fastened to the rear plate of the battery compartment. Typical controller configurations are shown on page 6 of the “GENERAL INFORMATION & FEATURES” section of this manual. (If the SCR controller for the hydraulic pump motor is not used, a single contactor for the hydraulic pump motor is installed in that position).

Maximum Motor Current

Average Battery Current

The control card makes checks as part of the logic sequence. The control card only permits forklift truck operation during the correct conditions. The control card checks and controls the functions described in the following paragraphs.

Battery Current

0% TIME

Diode D3, often called the “flyback diode”, permits the current to flow through the field and armature again to do work. At slower speeds motor torque is high without a high current draw from the battery. (High current drawn from the battery is to be avoided if possible, because it is less efficient). At higher speeds, the torque requirement is less, but SCR 1 OFF time is also less, so that less induction current (“flyback current”) is generated. Most of the motor current comes from the battery at high speeds.

➪

FIGURE 6. Flyback Current

Pulse Monitor Trip (PMT) (Traction Circuit Only)

When SCR 1 goes OFF, the decreasing magnetic field generates a voltage and current in the motor. Diode D3 permits the current to flow through the field and armature again to do work. See FIGURE 6. The torque of a DC motor is directly proportional to the amount of current flow through it. At slower speeds, the motor torque is high, and SCR OFF time is relatively long. When SCR 1 is OFF, the decreasing magnetic field generates a voltage and current in the motor. (This current is often called the “flyback current”).

The PMT circuit is part of the control card function. When the SRO checks are complete, the control card senses the voltage across SCR 1. If the voltage across SCR 1 stays at a low voltage, there is a fault in the traction circuit. If the control card senses a shortcircuit (low voltage) across SCR 1, it will not permit a direction contactor to close. The PMT circuit also checks the traction circuit for faults during forklift truck operation. 5-6

THEORY OF OPERATION

Control Cards The control card must sense battery voltage at terminals TB4 and TB3, then at TB2, then at TB6 (seat switch closed) or the control card will not permit a direction contactor to close.

Pulse Monitor Trip (PMT) (Traction Circuit Only) (cont’d) If SCR 1 stays ON for greater than 32 milliseconds, the PMT circuit opens the direction contactor. The control card immediately closes the contactor again. If the fault occurs again, the control card opens the contactor until the fault is corrected or the PMT circuit is reset. The circuit is reset when the key switch is turned to OFF and then to ON again.

Sequence of Operation The sequence of operation describes a complete cycle of the SCR traction circuit. See FIGURE 7. Seat Switch Closed.

When the Control Card senses a fault across SCR 1, it removes the signal that closes a direction contactor. A loss of signal from the control card will de-energize and open the direction contactors. A PMT occurs when the control card senses a malfunction in the operation of SCR 1 and stops sending a signal to the direction contactors.

Key Switch to the ON Position.

Control Card checks for battery voltage across SCR 1.

SRO Circuit (Traction Circuit Only)

Control Card energizes so the direction contactors can close.

The forklift truck is equipped with a safety circuit, called the “Static Return to OFF” (SRO) circuit, that prevents the operation of the forklift truck if the starting sequence is not correct. The function of the SRO circuit is to make sure the operator is in the seat and ready to operate the controls.

Operator closes the FORWARD direction switch. The SRO circuit checks that the START switch and a direction switch are not closed before the key switch.

The starting sequence: FORWARD contactor closes.

a. The operator must be on the operator’s seat and the seat switch closed. (Seat switch closes with the weight of the operator).

PMT check.

b. Turn the key switch to the ON position. The key switch supplies the battery voltage to the control circuits.

Control card sends gate signal to SCR 2. SCR 2 goes ON and connects capacitor C1 to the battery. SCR 2 goes OFF when C1 is charged.

c. Move the direction lever to FORWARD or REVERSE. Move the accelerator pedal to close the START switch after steps 1 and 2 are complete. The operator’s foot must be removed from the brake pedal so that the brake switch is closed.

Control card sends gate signal to change SCR 1 and SCR 5 to ON. Power pulse to traction circuit.

If step 3 is done before steps 1 and 2, the forklift truck will not travel in either direction. The seat switch and key switch each send a signal voltage to a timer circuit. Both voltages must be sent to the timer circuit before the timer will send a voltage signal to terminal TB3 on the control card. The timer circuit has a six second delay if the seat switch is opened. This delay permits the operator to change position in the seat without causing the forklift truck to stop. The voltages from the parts to the SRO circuit are sent to the control card. The SRO circuit is reset when the START switch or a direction switch is momentarily opened.

C1 fully charged with reverse voltage. SCR 5 goes OFF.

Control card sends gate signal to SCR 2. SCR 2 goes ON and discharges C1 to cathode of SCR 1.

SCR 1 goes OFF. Control card repeats cycle.

FIGURE 7. Sequence of Operation 5-7

THEORY OF OPERATION

Sequence of Operation Control Card Adjustments (Traction Circuit) The control card checks the current in the traction circuit and controls the current to prevent damage. The control card has several control adjustments. The control card for the traction circuit has a control adjustment called “CREEP”. This adjustment controls the minimum current level in the traction circuit when the direction contactors are closed. This adjustment can be changed to meet the needs of a specific application. The CREEP adjustment controls how far the accelerator pedal moves between the closing of the START switch and the application of enough power to move the forklift truck. This adjustment is only made after the adjustment between the accelerator pedal and the accelerator control is correct.

FIGURE 8. Motor Current Sensor The 1A or By-Pass Circuit permits the battery to be connected directly to the traction motor. This circuit disconnects the control of the SCR circuit and is used for maximum power from the traction motor. When the battery is connected to the traction motor through the 1A circuit, the maximum voltage available to the traction motor is increased by approximately 10%.

The “C/A” (Controlled Accelerator) adjustment controls the maximum rate that the average voltage is increased by the controller to accelerate the traction motor. This maximum rate is not controlled by the rate that the accelerator pedal is pushed down for maximum acceleration. A high rate of acceleration increases the wear on the brushes of the traction motor. The acceleration time can be adjusted for the operating conditions of the user. The acceleration rate can be adjusted to give a smooth acceleration for better load handling.

2 7

3 5 6

The “C/L” (Current Limit) adjustment will control the pulse rate if the current flow reaches the limit set by the adjustment. The traction circuit has a current sensor in the power circuit in series with the traction motor. All of the current that flows through the traction motor flows through the current sensor. The current sensor is a shunt with two sensor wires connected. See FIGURE 8. The metal of the shunt has a small resistance between the two sensor wires. This small resistance sends a signal voltage to the control card. This signal voltage increases as the motor current increases. The control card compares the signal voltage with the C/L current limit adjustment. When the signal voltage reaches the limit set on the C/L, the control card reduces the pulse rate. The current sensor is found connected between the heat sink for D3 and D4 and the terminal for a power cable.

1. Battery 2. SCR 1 (OFF) 3. Diode D3 4. Motor Field

5. Motor Armature 6. Motor Current Sensor 7. Contactor 1A

FIGURE 9. 1A By-Pass Circuit The control card controls the operation of the 1A circuit. A 1A TIME adjustment permits the SCR control to begin the operation of the traction motor before the 1A contactor closes. This time delay prevents full battery current being applied across the traction motor when it is not rotating. (Full battery voltage applied across a stalled traction motor causes a large current draw. This large current draw causes a large amount of heat in the motor and wastes battery energy.) 5-8

THEORY OF OPERATION

Sequence of Operation Control Card Adjustments (Traction Circuit) (cont’d) This adjustment also permits smooth operation of the forklift truck. The control card begins 1A TIME when the accelerator voltage is decreased to less than 1.0 volts. 1A TIME is normally one to three seconds. The full battery power is available to the traction motor through the 1A circuit after the time delay 1A TIME. “PLUG”. Plugging uses the traction motor as a brake to slow or stop a forklift truck. When a forklift truck is being stopped, the motion of the forklift truck causes the traction motor to rotate and operate like a generator. Plugging uses a current flow from the battery to be opposite the current flow generated by the traction motor. Plugging generates heat in the traction motor.

2 7

1 +

8 5 6

The Control Card for the traction circuit has a PLUG adjustment. This adjustment controls the maximum application of the plugging current. The position of the accelerator pedal controls the plugging distance up to the maximum application. This adjustment can be changed as needed for an operator. The shorter the plugging distance, the faster is the wear on the traction motor brushes. “REGENERATIVE BRAKING”. When a forklift truck is being stopped, energy is generated by the traction motor. The forklift truck causes the traction motor to rotate and operate like a generator. Plugging uses battery energy in opposition to the energy generated by the traction motor. This energy generates heat in the traction motor. Lift trucks used in heavy duty operations can generate enough heat to damage the traction motors and cause the motor brushes to wear rapidly. Regenerative braking returns the energy generated by the traction motor to the battery. The regenerative braking contactor opens during regenerative braking. When the voltage generated by the traction motor is less than the battery voltage, the forklift truck will be moving slowly. The contactor for regenerative braking then closes and plugging is used to stop the slowly moving forklift truck. Regenerative braking generates less heat in the traction motor and reduces brush wear. Another electric circuit must be added to the motor controller to control this operation. The energy generated during regenerative braking must be controlled within limits so that the parts of the electric circuit are not damaged. The adjustments used to control regenerative braking are: REGEN C/L (Regenerative Braking Current Limit)

1. Battery 2. SCR 1 (OFF) 3. Diode D3 4. Motor Field

5. Motor Armature 6. Motor Current Sensor 7. Contactor 1A 8. Diode D4

FIGURE 10. Plugging Circuit

REGEN D.O. (Regenerative Braking Drop Out) The “regenerative braking current limit” controls the maximum application of regenerative braking during operation. The position of the accelerator pedal by the operator controls the plugging distance up to the limit set by the REGEN C/L adjustment.

Plugging is energized when the direction switches in The “regenerative braking drop out” adjusts the voltage the direction control lever is moved to the opposite level where the regenerative braking contactor closes direction from which the forklift truck is traveling. The during regenerative braking. The regenerative braking direction contactors will change to their opposite contactor closes when the key switch is turned to ON. positions and reverse the current flow through the During regenerative braking, the contactor opens and motor field. The induction current generated in the the energy generated by the traction circuit is sent to traction motor now flows opposite to the current flow the battery. When the voltage level is less than the from the battery. The forklift truck will stop very quickly level set by the REGEN D.O., the regenerative braking if the induction current is not controlled. A diode D4 contactor closes and the remainder of the forklift truck permits part of the induction current from the armature speed is decreased by plugging. When the plugging to flow with the battery current through the armature function is in operation, the voltage generated by the again. This reduction of the opposite induction current traction motor is normally less than battery voltage. permits the forklift truck to stop more smoothly. 5-9

THEORY OF OPERATION

Sequence of Operation Control Card Adjustments (Traction Circuit) (cont’d)

“FIELD WEAKENING”. Some forklift trucks have a “field weakening” circuit. The field weakening circuit permits a faster travel speed than the 1A circuit. The traction motor must be operating during 1A conditions of high speed and small load before the field weakening circuit is used.

2 7 1 +

R 4

5 3

8 9 6

1. Battery 8. Diode D4 2. SCR 1 (OFF) 9. Regenerative Braking 3. Diode D3 (RB) Contactor 4. Motor Field 10. Diode D7 5. Motor Armature 11. Current Sensor, 6. Motor Current Sensor Regenerative Braking 7. Contactor 1A

FIGURE 11. Regenerative Braking When the regenerative braking function is started, the controller begins the plugging function first. The controller checks the voltage in the plugging circuit during three pulses of SCR 1. If the voltage in the plugging circuit is greater than the battery voltage, the controller opens the regenerative braking contactor. The current generated in the traction motor flows through diode D7. SCR 1 continues to operate as selected by the operator (accelerator position). When SCR 1 is ON, the current flows through SCR 1 and then through the field and armature again.

The field weakening contactor connects a by-pass shunt around the motor field. This shunt gives a second path for the current flow and weakens the magnetic field in the motor field. The increased current flow through the armature causes the motor to turn faster. See FIGURE 12. This increased speed caused by field weakening is only possible when the traction motor has a small load. For example, high speed travel on a flat surface. The field weakening decreases the power available from the traction motor to increase the travel speed. The field weakening contactor is controlled by two adjustments on the Control Card: F.W.P.U. (Field Weakening Pick Up) F.W.D.O. (Field Weakening Drop Out) When the forklift truck is operating at high speed with a small load, the armature current will decrease to a minimum current of approximately 185 amperes. The F.W.P.U. is adjusted to close the field weakening contactor at approximately 1.3 times this minimum armature current. The field weakening shunt is a strip of metal that connects the field weakening contactor to the FORWARD and REVERSE contactors. The field weakening shunt is calibrated at less than 1.0 ohm and is parallel to the field of the traction motor in the circuit. The field weakening contactor closes after the 1A contactor closes. The 1A contactor closes after the accelerator potentiometer voltage is less than 1.0 volts and the 1A TIME function has occurred.

If the forklift truck begins to travel up a ramp, the armature current will increase. When the armature current increases 2.75-3.0 times the minimum armature current, the F.W.D.O. will open the field When SCR 1 is OFF, the current flows through the weakening contactor. If the accelerator pedal is moved battery, diodes D3 and D4 and then to the fields and to a slower speed, the control card will open the field armature again. The energy generated during weakening contactor. regenerative braking is used to change the battery. 5-10

THEORY OF OPERATION

Sequence of Operation Control Card Adjustments (Traction Circuit) (cont’d)

The voltage signal from the accelerator control is 0-5 volts. The voltage is normally adjusted to 3.5-3.7 volts. At 3.50-3.7 volts, the forklift truck will move at CREEP speed. The 1A TIME will begin its cycle at 1.0 volts so that the 1A contactor can close. The maximum speed of the forklift truck when operating in the SCR range occurs when the voltage is 0.0-0.2 volts. The 1A contactor applies battery voltage directly to the traction motor.

2 7

1 +

R 4

FW RES

9 R

3 8

5 6

1. Battery 2. SCR 1 (OFF) 3. Diode D3 4. Motor Field 5. Motor Armature 6. Motor Current Sensor

7. Contactor 1A 8. Field Weakening (FW) Contactor 9. Field Weakening (FW) Resistor

FIGURE 12. Field Weakening Circuit “RAMP START” is a function of the EV100ZX Control Card for the traction circuit. This function permits an operator to stop a forklift truck with a load when going up a slope. If the operator does not change the direction controls, the forklift truck can be started again on the slope. A forklift truck will often roll backward a little distance when starting again on a slope. If the operator does not change the direction controls, the control card will not sense the reverse operation of the motor armature and will apply enough power to go up the slope. If the operator has changed the direction controls, the control card will sense that the expected operation is PLUGGING when the forklift truck rolls backward. The control card will not apply enough power during PLUGGING to make the forklift truck go up the slope.

Accelerator Control

SCR Control (Hydraulic Pump Motor) The control card for the hydraulic pump motor is not the same as the control card for the traction circuit. This control card has a different label. The SCR function for speed control is the same, but the many functions necessary for control of a traction circuit are not needed for the hydraulic pump motor. The 325 ampere fuse for the hydraulic pump circuit is found between the (+) bus bar and the SCR 1 anode of the controller. This control card does not have an SRO check nor a PMT check. If SCR 1 has a short-circuit, the hydraulic control card will open the pump contactor. The main control valve is an open center valve and the hydraulic function will stop when the hand lever is returned to the NEUTRAL position. The SCR controller for the hydraulic pump motor controls the motor at three speeds: SPEED 1 is for the TILT function and for optional functions that require the third or fourth spool of the main control valve (slow speed for some attachments). SPEED 2 is for the low speed LIFT function and high speed operation of an optional function that requires the third spool of the main control valve.

The Control Card supplies approximately 5.0 volts at terminal TB1 of the control card. The accelerator SPEED 4 control decreases the voltage between TB1 of the control card and battery negative. This voltage controls the frequency of the oscillator which controls the SCR speed of the forklift truck. 5-11

is only for the high speed LIFT function. This speed applies full SCR 1 voltage across the hydraulic pump motor. The SPD 3 adjustment is not used.

THEORY OF OPERATION

SCR Control (Hydraulic Pump Motor) The Control Card sends three reference voltages to the switches controlled by the linkage to the main control valve. When a contact on a switch is closed, the reference voltage is connected with battery negative and the control card senses the change in the reference voltage. The voltage controlled oscillator in the control card causes SCR 1 to operate at a certain frequency. The speeds of operation can be adjusted for an operating application.

Contactors Contactors are switches, controlled by electromagnets, that close and open a power circuit. The control card has internal electronic drivers and the electronic drivers controls the current to the coils of the electromagnets for the contactors. The electromagnetic field in the coil moves the armature against spring pressure to close the contact. When the coil is de-energized, the spring pressure moves the armature and opens the contacts. When a spring holds the contacts of a switch open, the switch is called normally open (NO). If a spring holds the contacts of a switch closed, the switch is called normally closed (NC).

1. Power Terminals 2. Contacts 3. Suppressor 4. Coil Terminals 5. Mount Bracket 6. Coil FIGURE 13. Typical Contactor Assembly (Regenerative Braking shown)

Some forklift trucks have an SCR control for the hydraulic pump motor. Some forklift trucks also have an electronic driver that energizes the coil for the hydraulic pump contactor. Forklift trucks equipped with regenerative braking, 1A, and field weakening circuits have contactors with one set of normally open contacts. See FIGURE 13. When the forklift truck does not have an SCR controller for the hydraulic pump motor, the hydraulic pump contactor also has one set of NO contacts. 1. Power Terminals 2. NC Contacts 3. NO Contacts 4. Coil Terminals 5. Mount Bracket 6. Coil (the Suppressor is added to the outside of the Coil)

A typical set of direction contactors are shown in FIGURE 14. The direction contactors (FORWARD and REVERSE) each have two sets of NC and NO contacts. When a coil for a direction contactor is energized, the NO contact close and the NC contacts open. This design prevents the contacts from being closed in the wrong sequence.

FIGURE 14. Direction Contactor 5-12

THEORY OF OPERATION

Truck Management Module (TMM1)

Circuit Protection Traction Circuit Fuse The 500 ampere fuse for the traction circuit is found on the motor controller between the (+) bus bar and the anode of 1 REC. If the current flow becomes great enough to damage the traction circuit because of a short-circuit or electrical overload, the fuse will fail.

Current Limit SCR 1 will become damaged from heat unless the current flow has limits. A current sensor is installed in the traction circuit between the armature and battery negative. The current sensor sends a voltage signal to the control card. The control card compares the adjustment C/L with the signal from the current sensor. If the current flow reaches the limit, the control card overrides the other signals to the oscillator. The pulse width and frequency are decreased to decrease the average motor current.

The Truck Management Module is a multi-function accessory card that can be used to give additional status codes or operator warnings on the instrument panel display. If a forklift truck has brush wear indicators and motor temperature switches and does not have an SCR controller for the hydraulic pump motor, a TMM1 card is added to the controller. The TMM1 receives the signals from the brush wear sensors and motor temperature switches and sends the signals through the traction controller to the instrument panel display.

Thermal Protection The parts in the traction circuit will be damaged by too much heat. A heat sensor is connected to the 1 REC heat sink. When the temperature increases towards the design limit [85°C (185°F)], the resistance in the sensor increases. The increase in resistance decreases the 1 REC ON time by decreasing the pulse width and frequency to 1 REC. The average motor current is decreased to prevent damage. When the heat sink cools, the thermal protection will return the control to normal operation. This input signal overrides all other input signals (except the 1A signal) to the oscillator during forklift truck operation.

Notes

5-13

FIGURE 15. Truck Management Module (TMM1)

THEORY OF OPERATION

Instrument Panel Display

FIGURE 16. Instrument Panel Display When the key switch is turned to ON, a start program will cause a warning light to illuminate at the same time in order to show that function is operating. The Display consists of (4) seven segment LED’s that will display the truck Hours, Battery state of charge, and Fault Codes.

key switch is turned to the START position and must go OFF after one second. If the warning light is ON during operation, the brake fluid level in the reservoir is too low. 4.

This instrument panel has the following functions: 1. Hourmeter - The hourmeter display shows the operating time of 0000 to 9999 hours. The time for the traction circuit is shown for four seconds after the forklift truck has been operating and the key is turned to the OFF position. 2. Warning Light, Parking Brake Indicator The “Symbol” is ON when the parking brake is applied and the seat switch is closed and goes OFF when the parking brake is released. 3. Warning Light, Brake Fluid Reservoir is Low The “Symbol” is ON for one second when the 5-14

Battery Charge Indicator with Lift Interrupt The battery charge indicator uses the traction control shunt to measure the current during operation. This current and battery voltage are checked at the same time for an accurate reading of battery voltage with a load (during use). This method can make operation of the forklift truck different when the battery is low or a different battery is connected. This method permits better use of the battery charge. The controller also checks the battery voltage each time a battery is connected. The traction control will prevent forklift truck operation if the battery voltage is not correct as set by traction function 15. A status code of - 16 (voltage too high) or -15 (voltage too low) will indicate on the

THEORY OF OPERATION

Instrument Panel Display instrument panel display. The battery can have a voltage that is too high or too low. A battery with the correct voltage can also be deeply discharged from use or other reason and have a voltage that is less than the minimum of the voltage range. Batteries having different ampere hour ratings or are of different ages can sometimes be used in the same forklift truck. It can be necessary to adjust traction function 14 so that the weaker battery is not damaged. Follow the procedure for adjusting traction function 14 in the “Handset Section” under Function Numbers.

5. Status Code Indicator - The status codes and the hourmeter values are shown on this fourdigit LED display. When a fault occurs, the status code will be shown. The warning “Symbol” (!) will also be illuminated when a fault occurs. When it is time for periodic maintenance, the (Wrench) warning “Symbol” will be illuminated and a status code 99 will be indicated. The register in the controller card must be reset by the service person before this warning light will go OFF. The hourmeter display shows the operating time of 0000 to 9999 hours. The time for the traction circuit is shown for four seconds after the lift truck has been operating and the key is turned to the OFF position. If there is an SCR control card for the hydraulic pump motor this time will then be shown on the hourmeter for another four seconds.

8. Warning Light, Motor Brushes are Worn When the sensor for brush wear closes, this warning light and the Fault Code for the motor that has the problem will both illuminate.

9. Warning Light, Motor Temperature Over Limit The traction motor and the hydraulic pump motor have thermal switches inside the motors. When the temperature increases to the limit set by the manufacturer of the motor, the thermal switch closes and the warning light on the instrument panel display illuminates. The Fault Code for traction motor (8) or for the hydraulic motor (9) will show which motor has the problem.

10. Set Forklift Truck Performance - The forklift truck can be set to four performance levels by the operator.(If the customer does not want this functionavailable to the operator, a service person can set all four levels to the same setting). Each time the operator pushes the button (14), perfor mance level will increase by one step. At the maximum (#4) level, the performance levels will begin at the lowest (#1) level again. The four performance levels set by the manufacturer are:

➀ Low Performance for handling fragile loads. ➁ Medium Speed for less consumption of battery charge during a work shift.

➂ Higher Performance with higher consumption of battery charge during a work shift.

➃ Maximum forklift truck performance with maximum consumption of battery charge.

6. Warning Light, Brake Fluid Reservoir is Low The “Symbol” is ON for one second when the key switch is turned to the START position and must go OFF when the motor is running. If the warning light is ON when the motor is running, the brake fluid level in the reservoir is too low.

7. Warning Light, Parking Brake Indicator The “Symbol” is ON when the parking brake is applied and the seat switch is closed, and goes OFF when the parking brake is released. 5-15

The performance settings can be made with the Handset (Function 11, 12, and 13). The four performance levels can be set to any level up to the maximum limits. Two or more adjustment performance levels can be set to the same limits. The performance levels must be set at the same or in ascending order (from #1 to #4). The register interlocks will not permit a higher performance level setting toward the #1 setting than the adjacent registers toward the #4 setting.

THEORY OF OPERATION

Instrument Panel Display Notes

Fault Code Memory The control cards for the traction motor controller and hydraulic pump motor each have memory registers in which the last 16 status codes can be stored. Each status code is stored with the hourmeter time and the battery charge at the time of the fault. The status code for the last fault will be indicated on the Status Code Indicator (2). If the key switch is turned to OFF, the status code will be removed from the four digit display. The left Mode Change button (1) will cause the status codes for the faults to be shown on the Status Code Indicator (2). When the button is pushed and held down. The status codes in memory for the detected faults will be displayed, starting with the most recent fault. The hourmeter time and the battery charge at the time of the fault will be shown. A Handset must be used to clear the status code from the register. If the right Mode Change button is pushed and then held down, the indicator light for the hydraulic pump motor (9) will illuminate. The status codes in memory for the detected faults will be displayed, starting with the most recent fault. The hourmeter time and the battery charge at the time of the fault will be shown. A Handset must be used to clear the code from the register.

Brush Wear Indicators The brush wear indicators illuminate when the motor brushes must be replaced. The sensor wires for the brush wear indicators are an insert in the brush material when it is made. The sensor wires are insulated from the brush material. When the brush wears within approximately 1.5mm (0.060 in) of the brush lead, the insulation between the sensor wire and the brush material is destroyed. The connection between the brush and the sensor wire causes the indicator to illuminate. The operation of the brush wear indicators can be checked during periodic maintenance. The battery must be removed from the forklift truck for access to the motors.

5-16

WIRING

Power Cable Connections ............................................................................. 6-1 Standard Control.................................................................................................. 6-1 Optional SCR Hydraulic Control .......................................................................... 6-1

Traction Control Card Wire Harness Connections ........................... 6-2 A & B Plugs.......................................................................................................... 6-2 Y Plug .................................................................................................................. 6-3 Z Plug .................................................................................................................. 6-4 Truck Management Module 1 .............................................................................. 6-5 TB Connections ................................................................................................... 6-6

Control Card Wire Harness Connections for Optional Hydraulic Pump SCR .................................................................. 6-7 Panel Connector .................................................................................................. 6-7 TB Connections ................................................................................................... 6-8 A & B Plugs.......................................................................................................... 6-9 Y Plug for use on Option Card ............................................................................ 6-10 Z Plug for use on Option Card............................................................................. 6-11

Pump Driver........................................................................................................... 6-12

Pump Time Delay ................................................................................................ 6-13

WIRING

Power Cable Connections Standard Control

A1 S1

Negative

Positive

PA1

ST1

12 14 33

Optional SCR Hydraulic Control PS2

PA1

Positive

Negative

6-1

WIRING

Traction Control Card Wire Harness Connections A & B Plugs A Plug

B Plug B

A 1

Rear View of Terminals from wire side toward Control Card

PLUG A PIN NO.

WIRE #

PA1

–

PA2

PA3

–

PA4

RB Sensor #2 Negative Signal

All Modes

PA5

RB Sensor #2 Positive Signal

All Modes

PA6

Regenerative Braking Input Signal

DESCRIPTION

CONDITION

VOLTAGE

Not Presently Used BDI Pump Interrupt

Battery < 90% Discharged

Battery > 90% Discharged

Not Presently Used BV (NOTE: Voltage drop PA5-PA4 during regen only.)

BV Varies with Motor Current

SCR Run Mode (RB Closed)

Regen Mode (RB Open)

PLUG B PIN NO.

WIRE #

PB1

FW Contactor Drive (optional)

PB2

RB Contactor Drive

PB3

Power Steering Contactor Drive

PB4

FWD Contactor Drive

PB5

REV Contactor Drive

PB6

1A Contactor Drive

BV = Battery Volt

DESCRIPTION

CONDITION

6-2

VOLTAGE

Contactor Open Contactor Closed

0V 18V

Contactor Open Contactor Closed Contactor Open Contactor Closed Contactor Open Contactor Closed Contactor Open Contactor Closed Contactor Open Contactor Closed

0V 18V 0V 18V 0V 18V 0V 18V 0V 18V

WIRING

Traction Control Card Wire Harness Connections Y Plug Y Plug

Y Plug 8

View of Terminals from wire side toward Control Card

PLUG #

WIRE #

Display Common

Display +5V

–

Not Used

DESCRIPTION

Display Data

6 7 8

TMM1 or SCR Hydraulic Output

11 12 –

Not Used

13 14

6-3

WIRING

Traction Control Card Wire Harness Connections Z Plug Z Plug

Z Plug 8

View of Terminals from wire side toward Control Card

PLUG #

WIRE COLOR

FUNCTION or CIRCUIT

Black

Thermal Cutback Protector Circuit

Brown

Negative Supply to Card

Yellow

Current Sensor Circuit

Green

Gray

–

White

White/Blue

1 REC – G

Blue

1 REC – C

White/Red

2 REC – G

Red

2 REC – C

White/Violet

5 REC – G

Violet

5 REC – C/Reactor T4

Orange

Reactor T3

Thermal Cutback Protector Circuit Not Used Positive Supply to Card

6-4

WIRING

Traction Control Card Wire Harness Connections TMM1 (Truck Management Module 1)

CONNECTOR WIRE TERMINAL #

DESCRIPTION

CONDITION No Fault

Traction Motor Over Temperature

PY 10 Traction Card

–

Not Used

–

Not Used

PY 9 Traction Card

Traction Motor BWI

PY 8 Traction Card

Traction Motor BWI

Pump Motor BWI

– Not Used

Pump Motor Over Temperature

No Fault

Traction Motor Over Temperature

– No Fault

Traction Motor Brushes Worn

– No Fault

Traction Motor Brushes Worn

No Fault

Pump Motor Brushes Worn

No Fault

Pump Motor Brushes Worn

13 14

NOMINAL VOLTAGE

–

Not Used

6-5

WIRING

Traction Control Card Wire Harness Connections TB Connections TB Connections

Wire Connections looking at Control Card

PIN #

WIRE #

DESCRIPTION

CONDITION Key Switch Off

VOLTAGE 4-5V

Key Switch On and Accelerator Start Switches On: TB1

Accelerator Input

• Creep Speed • Top Speed 15 TB2

TB3

TB4

TB5

SRO; Accelerator Start Switch and Brake Switch Inputs must be High after TB3, 4 are at BV and TB5, 6 are Low

Key, Seat, Start or Brake Switch Open Key, Seat, Start or Brake Switch Closed

3-4.0V 0.5-0V 0V BV

Key Closed and Seat Open

Key Closed and Seat Closed

Key Switch Open

Key Switch Closed

Seat Switch Input

Key Switch Input (must be Open to reset PMT)

Forward directional switch input

Key, Seat, Start and Brake Switch Closed and:

• Forward in neutral (or reverse) • Forward selected (F closed)

0V BV

Key, Seat, Start and Brake Switch Closed and: TB6

Reverse directional switch input

BV = Battery Volt 6-6

• Reverse in neutral (or forward) • Reverse selected (R closed)

0V BV

WIRING

Control Card Wire Harness Connections For Optional Hydraulic Pump SCR Panel Connector

Panel Connector CONNECTOR WIRE TERMINAL #

CONNECTOR WIRE TERMINAL #

DESCRIPTION

P1-1

Key Switch Output

P3-6

P1-2

Seat Switch Output

P4-1

P1-3

Accelerator Switch Output

P4-2

P1-4

Forward Directional Switch Output

P4-3

P1-5

Reverse Directional Switch Output

P4-4

P1-6

Battery Negative

P5-1

P1-7

Accelerator Output

P5-2

Not Used

P5-3

P1-8

DESCRIPTION

Battery Negative

SCR Hydraulic Display

Traction Motor Over Temperature Not Used

Pump Motor Over Temperature

P5-4

Not Used

P5-5

Not Used

P2-1

P2-2

P2-3

P5-6

Traction Motor BWI

P2-4

P5-7

Traction Motor BWI

P3-1

Tilt Switch Output

P5-8

Pump Motor BWI

P3-2

Aux 1 Switch Output

P5-9

Pump Motor BWI

P3-3

Aux 2 Switch Output

P5-10

Battery Negative

P3-4

Lift Switch Output

P5-11

Not Used

P3-5

Lift Potentiometer Output

P5-12

Not Used

SCR Traction Display

6-7

WIRING

Hydraulic Pump SCR Control Card Wire Harness Connections TB Connections TB Connections

Wire Connections looking at Control Card

PIN #

WIRE #

DESCRIPTION

CONDITION Key Switch Off

VOLTAGE 0V

Key Switch On and ACC at: TB1

Lift Potentiometer Input

• Creep Speed • Top Speed

3-4.0V 0.5-0V

Switch Open TB2

Lift Switch Input Switch Closed

TB3

TB4

TB5

TB6

BV = Battery Volt

Switch Open

Switch Closed

Key Switch Open

Key Switch Closed

Switch Open

Switch Closed

Switch Open

Switch Closed

Tilt Switch Input

Key Switch Input (Must go Low to Reset PMT)

Aux 1 Switch Input

Aux 2 Switch Input

6-8

WIRING

Hydraulic Pump SCR Control Card Wire Harness Connections A & B Plugs A Plug

B Plug B

A 1

Rear View of Terminals from Wire Side toward Control Card

PLUG A PIN NO.

WIRE #

PA1

–

Not Presently Used

PA2

–

Not Presently Used

PA3

Traction Motor Thermal Switch

Switch Closed

PA4

Traction Motor BWI Input

Brushes Worn

PA5

Traction Motor BWI Input

Brushes Worn

PA6

–

DESCRIPTION

CONDITION

VOLTAGE

Not Presently Used

PLUG B PIN NO.

WIRE #

PB1

Pump Motor BWI Input

Brushes Worn

PB2

Pump Motor BWI Input

Brushes Worn

Battery <90% Discharged

PB3

BDI Pump Interrupt Battery >90% Discharged

PB4

PB5

PB6

BV = Battery Volt

DESCRIPTION

CONDITION

On Off

Pump Coil Output

VOLTAGE

10-13V 0V

Not Presently Used Pump Motor Thermal Switch 6-9

Switch Closed

WIRING

Hydraulic Pump SCR Control Card Wire Harness Connections Y Plug for use on Option Card Y Plug

Y Plug 8

View of Terminals from Wire Side toward Control Card

PLUG #

WIRE #

DESCRIPTION

1 2

–

Not Used

Display Common

Display Data

–

Not Used

6 7 8 9 10

Display Data

Traction Card Input

6-10

WIRING

Hydraulic Pump SCR Control Card Wire Harness Connections Z Plug for use on Option Card Z Plug

Z Plug 8

View of Terminals from wire side toward Control Card

PLUG #

WIRE COLOR

FUNCTION or CIRCUIT

Black

Thermal Cutback Protector Circuit

Brown

Negative Supply to Card

Yellow

Current Sensor Circuit

Green

Gray

–

White

White/Blue

1 REC – G

Blue

1 REC – C

White/Red

2 REC – G

Red

2 REC – C

White/Violet

5 REC – G

Violet

5 REC – C/Reactor T4

Orange

Reactor T3

Thermal Cutback Protector Circuit Not Used Positive Supply to Card

6-11

WIRING

Pump Driver FUNCTION: Controls the power supply to the contactor coil according to the control signal input.

TERMINAL #

WIRE #

DESCRIPTION

CONDITION Not Activated

Activated

Always

Contactor Not Activated

Control Signal Input

Battery Negative

Contactor Coil Input Contactor Activated

VOLTAGE ON TERMINAL

N/A

Not Used

BV = Battery Volt

6-12

0 - 0.5V

WIRING

Pump Time Delay FUNCTION: Controls the power supply to the pump driver according to the control signal input.

TERMINAL #

WIRE #

DESCRIPTION

CONDITION

VOLTAGE ON TERMINAL

Not Activated

Activated

Always

Contactor Not Activated

12V

Contactor Activated

11V

Not Activated

12V

Activated

12V

Control Signal Output

Battery Negative

Control Card Input to Delay

Battery Positive

BV = Battery Volt

6-13

EV100ZX DIAGNOSTIC STATUS CODES

Basic Checks ........................................................................................................ 7-1

On Board Diagnostics ...................................................................................... 7-2

Status Codes......................................................................................................... 7-4

EV100ZX DIAGNOSTIC STATUS CODES

Basic Checks The biggest mistake technicians can make is to assume they know the problem before starting to work on a truck. Unfortunately while making our life easier self-diagnostics also make us more susceptible to this type of mistake. Never start to fix a truck based solely on the number on the dash or handset display. Always follow the basic troubleshooting steps.

Talk to the operator •

Confirm their description of the problem with an operational check.

•

Visually inspect cables, connectors, contactor tips, etc.

•

Perform basic battery cables to frame resistance tests. You should have at least 20,000 ohms.

and hour meter reading. This will keep us from getting confused trying to count to the proper fault code storage location and the information may later prove helpful. I would suggest that these codes only be zeroed out after the truck is repaired and running properly. Now we can utilize the Status Codes in the following pages to find the component or area to check for our fault. A bad card can cause virtually any problem imaginable, yet it is the one part we cannot test. Therefore any Status Code could be the result of a card failure. If all the pertinent areas to check are in proper operating condition then check all the card inputs and if they are good then we have no choice but to replace the card. Some discretion here is advisable as approximately 70% of the control cards replaced have nothing wrong with them. Ironically enough this is about the same ratio as is found in the automotive industry for computers on cars.

Notes •

Check the battery condition.

Now we are ready to allow the self-diagnostics to give us a starting point to repair the truck. Turn the key switch on and check when the 8 88 8 is displayed to be sure all of the LED’s are functional. At this time note the status (fault) code (if any) and then turn the key switch off so you can note the hours on the meter. Disconnect the battery and discharge the capacitor. Remove the Y plug which connects the dash gauge to the card and insert the handset plug connector. Plug in the battery. While holding the CONT button down on the handset turn on the key switch to enter the programming mode. When you get the 8 8 88 push down on the Function I button to double check the Status Code stored in the memory which should be the same as the dash gauge (if it showed one). Before proceeding we need to check the card’s programming. Always check each function and always write down the reading. Nobody has a perfect memory and you may not get a second chance to know how the card was programmed. If the programming fails to match the specifications, reprogram the card and check the truck operationally before going any further. If repairs are required, turn the key switch off, then push the CONT and ESC keys at the same time to enter the scrolling mode 7-1

EV100ZX DIAGNOSTIC STATUS CODES

On-Board Diagnostics

7-2

EV100ZX DIAGNOSTIC STATUS CODES

On-Board Diagnostics

7-3

EV100ZX DIAGNOSTIC STATUS CODES TABLE OF CONTENTS STATUS CODE Blank -00 -01 -02 -03 -04 -05 -06 -07 -08 -09 -11 -15 -16 -17 -21 -23 -24 -25 -26 -41

DESCRIPTION

PAGE

No input voltage to control card or display ................................................................ 7-5 Battery is extremely discharged ................................................................................. 7-6 No input signal from seat switch ................................................................................ 7-6 Forward switch closed on initial start ......................................................................... 7-7 Reverse switch closed on initial start ......................................................................... 7-7 Start switch - low voltage after start........................................................................... 7-8 Start or Brake switch did not close ............................................................................ 7-8 Accelerator depressed, no direction selected ............................................................ 7-9 Accelerator input voltage too high.............................................................................. 7-9 Accelerator input voltage too low or power to control card after key in ON position 7-10 Both Forward and Reverse switches closed at same time...................................... 7-10 Start switch is closed when the key switch is closed and voltage is applied to the control card .7-11 Battery volts too low ................................................................................................. 7-11 Battery volts too high ............................................................................................... 7-12 Wrong control card installed..................................................................................... 7-12 Accelerator input is less than 0.25 volts .................................................................. 7-13 Coil current low, Forward or Reverse contactor ..................................................... 7-13 Voltage at T2 too low ............................................................................................... 7-14 1A contactor does not open or opens too slowly ..................................................... 7-14 Shorted coil driver for 1A, RB, or PS contactor ....................................................... 7-15 Open thermal protector or motor control temperature too high .............................. 7-15 NOTE: Motor speed is decreased when code -41 is indicated -42 Motor sensor input missing (green wire).................................................................. 7-16 -43 Motor sensor input missing (yellow wire) ................................................................. 7-16 -44 1 REC did not turn OFF correctly ............................................................................ 7-17 -45 1 REC did not turn ON correctly .............................................................................. 7-17 -46 T2 voltage too high .................................................................................................. 7-18 -47 2 REC does not turn ON correctly ........................................................................... 7-18 -48 T2 voltage too low .................................................................................................... 7-19 -49 5 REC does not turn ON correctly ........................................................................... 7-19 -50 C1 voltage too low ................................................................................................... 7-20 -51 C1 voltage too high with high motor current ............................................................ 7-20 -52 C1 voltage too high with low motor current ............................................................. 7-21 -53 1 REC does not go OFF during plugging ................................................................ 7-21 -54 Short-circuit, Forward, Reverse or 1A contactor coil driver ..................................... 7-22 -57 Polarity check, current sensor input voltage ............................................................ 7-22 -70 Current sensor input missing (wire #22) .................................................................. 7-23 -71 Current sensor input missing (wire #21) .................................................................. 7-23 -72 Regenerative braking contactor does not energize ................................................. 7-24 -73 Regenerative braking contactor does not de-energize or de-energizes slowly ....... 7-24 -74 Regenerative braking contactor energizes too slowly ............................................. 7-25 -75 1 REC does not go OFF during regenerative braking ............................................. 7-25 -76 C1 voltage too high during regenerative braking ..................................................... 7-26 -90 Voltage at terminal 1 of the TMM at zero volts ........................................................ 7-26 -92 Voltage at terminal 4 of the TMM at zero volts ........................................................ 7-27 -94 Voltage at terminal 8 and 10 of the TMM at zero volts ............................................ 7-27 (*) Not used on all models of forklift trucks. Status Codes in this group will flash on the display. 7-4

EV100ZX DIAGNOSTIC STATUS CODES TABLE OF CONTENTS STATUS DESCRIPTION PAGE CODE -95 Voltage at terminal 11 and 12 of the TMM at zero volts ......................................... 7-28 -99 Maintenance Alert Code........................................................................................... 7-28 -117 Wrong control card installed (*)................................................................................ 7-29 -123 Pump PMT contactor coil current is too low (*) ....................................................... 7-29 -124 Voltage at T2 too high (*) ......................................................................................... 7-30 -125 1A contactor does not de-energize or opens too slowly (*) ..................................... 7-30 -141 Open thermal protector or motor control temperature too high (*) .......................... 7-31 -142 Motor sensor input missing (green wire) (*)............................................................. 7-31 -143 Motor sensor input missing (yellow wire) (*) ............................................................ 7-32 -144 1 REC did not go OFF correctly (*).......................................................................... 7-32 -145 1 REC did not go ON correctly (*) ........................................................................... 7-33 -146 T2 voltage too low (*) ............................................................................................... 7-33 -147 2 REC did not go ON correctly (*) ........................................................................... 7-34 -148 Voltage at T2 too low (*)........................................................................................... 7-34 -149 5 REC does not go ON correctly (*) ........................................................................ 7-35 -150 C1 volts low (*) ......................................................................................................... 7-35 -151 C1 volts high with high motor current (*) ................................................................. 7-36 -152 C1 volts high with low motor current (*) ................................................................... 7-36 Short-circuit in electronic driver for the hydraulic pump contactor or 1A contactor (*) ....... 7-37 -154 -157 Polarity check, current sensor input voltage (*) ....................................................... 7-37 (*) Not used on all models of forklift trucks. Status Codes in this group will flash on the display.

MEMORY RECALL

Circuits valid for Traction Controller & Pump Controller

CAUSE OF STATUS INDICATION

Segments do not illuminate on the Dash Display and/or the Handset.

No input voltage to the Logic Card or the display unit.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Display screen on Dash Display and/or Handset is blank. POSSIBLE CAUSE Positive or negative control voltage is not present. • Insure that the key switch is closed and voltage is present between PZ7 & PZ3 control negative. Also check for voltage between TB4 and PZ3 control negative.

Open circuit between logic card Plug Y & the Dash Display or Handset. • Check for an open circuit or loose connection going from the “Y” plug and the Dash Display or Handset.

CONTROL FUSE

➤

POWER FUSE

TB4

➤

CAP

PZ7

➤

Defective Dash Display or Handset. • Replace Dash Display or Handset.

KEY SWITCH

➤

NONE

DESCRIPTION OF STATUS

➤

TRACTION STATUS CODE

7-5

EV100ZX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-00

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION Battery extremely discharged.

Truck does not operate. Key on in direction.

CORRECTIVE ACTIONS MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Battery connected. Key on in direction. Truck will not move. POSSIBLE CAUSE Battery extremely over discharged.

-01 MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

No seat switch or deadman switch input.

This status code will be displayed when TB3 is less than 50% battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or Reverse contractor will not close. POSSIBLE CAUSE Mis-adjusted or defective seat or deadman switch. • Check to see that the seat switch closes properly.

KEY SWITCH

SEAT SWITCH

➤

TRACTION STATUS CODE

Charge Battery overnight.

➤

Circuits valid for Traction Controller & Pump Controller

Open circuit between battery positive and TB3. • Check for loose connections or broken wires: -Between the seat switch and TB3. -Between the key switch and the battery positive side of the seat switch. -Between the seat switch and TB4.

7-6

➤

TB4

TB3

EV100ZX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-02

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Forward directional switch is closed on initial power up.

This status code will be displayed when TB5 is greater than 60% of battery voltage at initial key switch on.

CORRECTIVE ACTIONS NO

Circuits valid for Traction Controller

SYMPTOM Forward contactor will not close because of Static Return to Off (SRO) lock out. POSSIBLE CAUSE Forward directional switch is closed on initial start up (i.e. closure of battery, key switch or seat/deadman switch). • Return directional switch lever to neutral and then return lever to forward position.

SEAT SWITCH

BRAKE SWITCH

➤

MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

Forward directional switch is welded closed or mis-adjusted to be held closed. • Replace or adjust directional switch to insure that it opens when the directional switch is returned to neutral.

TB4

ACCEL START SWITCH

TB3

TB2

Short circuit between TB3 and TB5. • Disconnect the wire from the TB5 and check for a short circuit between TB3 and the wire that was connected to TB5.

FWD TB5

Defective logic card. • Disconnect wire at TB5 and measure voltage. It should be less than 60% of battery volts.

TRACTION STATUS CODE

-03

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Reverse directional switch is closed on initial power up.

This status code will be displayed when TB6 is greater than 60% of battery voltage at initial key switch on.

CORRECTIVE ACTIONS NO

Circuits valid for Traction Controller

SYMPTOM Reverse contactor will not close because of Static Return to Off (SRO) lock out. POSSIBLE CAUSE Reverse directional switch is closed on initial start up (i.e. closure of battery, key switch or seat/deadman switch). • Return directional switch lever to neutral and then return lever to reverse position.

Reverse directional switch is welded closed or mis-adjusted to be held closed. • Replace or adjust directional switch to insure that it opens when the directional switch is returned to neutral. Short circuit between TB3 and TB6. • Disconnect the wire from TB6 and check for a short circuit between TB3 and the wire. Defective logic card. • Disconnect wire at TB6 and measure voltage. It should be less than 60% of battery volts.

7-7

SEAT SWITCH

BRAKE SWITCH

➤

MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

TB4

TB3

ACCEL START SWITCH

TB2 REV TB6

EV100ZX DIAGNOSTIC STATUS CODES

-04 MEMORY RECALL

CAUSE OF STATUS INDICATION

Start switch input low after initial start up.

This status code is displayed when TB2 voltage is less than 60% of battery volts at initial start-up (seat switch closure).

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will not pick-up. POSSIBLE CAUSE Forward or reverse directional switch closed on initial start up. • Depress accelerator to close start switch. Status code will change to 03 if reverse directional switch or to 02 if forward directional switch is closed. If either of these codes appear, return directional switch to neutral and then select the desired direction.

BRAKE SWITCH

ACCEL START SWITCH

➤

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

➤

TRACTION STATUS CODE

Excessive leakage from TB2 to battery negative. • Check voltage at TB2 with key and seat switches closed and directional switch in neutral. Voltage should be greater than 60% of battery voltage. • If less than 60% battery voltage. Remove wire and measure ohmic value from wire to SCR negative. Value should be less than 22k ohms.

CAUSE OF STATUS INDICATION

Start switch or brake switch fails to close.

This status code will be displayed when TB1 is less than 2.5 volts and TB2 is less than 60% of battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will not pick up. SEAT SWITCH

POSSIBLE CAUSE Defective brake switch circuit. • Check brake switch to insure closure with brake pedal released. • Check for open circuit or loose connection in wiring from brake switch to seat switch and TB3, and from brake switch to start switch.

ACCEL START SWITCH

TB1

Defective start switch circuit. • Check start switch to insure closure when accelerator is depressed. • Check for open circuit or loose connections in wiring from brake switch to start switch and from TB2 to start switch.

7-8

BRAKE SWITCH ACCEL

TB4 TB3 TB2

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

➤

TB2

➤

MEMORY RECALL

➤

-05

➤

TRACTION STATUS CODE

➤

EV100ZX DIAGNOSTIC STATUS CODES

This status code will be displayed when TB5 & TB6 are less than 60% of battery volts, and TB1 is less than 2.5 volts.

Accelerator depressed with no direction selected.

CORRECTIVE ACTIONS NO

Circuits valid for Traction Controller

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will not pick up. POSSIBLE CAUSE Accelerator pedal is depressed before closing forward or reverse directional switch. • Status code will disappear when directional switch is closed or when accelerator pedal is released.

Circuits valid for Traction Controller

DIR SWITCH

FWD REV

FOOT DIR SWITCH

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Accelerator input voltage too high.

This status code will be displayed when the accelerator input voltage at TB1 is higher than 3.7 volts, and a directional contactor is picked up.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

-07 MEMORY RECALL

FWD REV

Defective directional switch. • Check forward or reverse switch to insure closure when direction is selected. Open circuit between directional switch(es) and battery positive or between directional switch(es) and TB5 or TB6. • Check all control wires and connections shown in Trouble Shooting Diagram.

TRACTION STATUS CODE

ACCEL CONTROL ➤

MEMORY RECALL

CAUSE OF STATUS INDICATION

SYMPTOM Forward or reverse contactor picks up but control will not operate when accelerator pedal is depressed or status code -07 is displayed then disappears when the vehicle starts to accelerate.

ACCEL CONTROL

POSSIBLE CAUSE Accelerator input mis-adjusted or defective. • Input voltage at TB1 should be less than 3.7 volts. Adjust or replace accelerator unit to insure that the voltage at TB1 will vary from 3.5 volts to less than .5 volts when the pedal is depressed.

Open circuit between battery negative and TB1 in accelerator input circuit. • Check for broken wires or loose connections or open potentiometer / voltage supply in the circuit shown in trouble-shooting diagram. Short circuit from battery positive to wiring in accelerator input circuit. • Disconnect wire from TB1 and measure voltage at wire to negative. Should ne zero volts for potentiometer type and less than 3.7 volts for solid state type accelerator input.

7-9

TB1

-06

DESCRIPTION OF STATUS

TB5 TB6 TB1

TRACTION STATUS CODE

EV100ZX DIAGNOSTIC STATUS CODES

MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

Accelerator input voltage too low on power up after initial key switch closure.

This status code will be displayed when the accelerator input voltage at TB1 is less than 3.0 volts, and any of the following connections are opened & closed: battery plug, seat switch or key switch.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor does not pick up. POSSIBLE CAUSE Accelerator input mis-adjusted or defective. • Input voltage at TB1 should be more than 3.0 volts. Adjust or replace accelerator unit to insure that the voltage at TB1 is more than 3.0 volts before depressing pedal.

Short circuit between battery negative and TB1 in accelerator input circuit. • Disconnect wire from TB1. Check for short circuit from wire to battery negative. Resistance should be greater than 4.7 ohms. Defective Card. • Disconnect wire from TB1. Measure voltage from TB1 to negative. Voltage should be greater than 4.5 volts, if not, replace card.

TRACTION STATUS CODE

-09 MEMORY RECALL

Circuits valid for Traction Controller

ACCEL CONTROL

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Both the forward and reverse directional switches are closed at the same time.

This status code will be displayed when TB5 & TB6 are greater than 60% of battery volts at the same time.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will not pick up. POSSIBLE CAUSE Forward or reverse directional switch welded closed or mis-adjusted to be held closed. • Replace or adjust directional switches to insure that they open when directional switch is returned to neutral.

➤

-08

DESCRIPTION OF STATUS

TB1

TRACTION STATUS CODE

➤ TB2 FORWARD

Short circuit between battery positive and TB5 and / or TB6. • Disconnect wires from TB5 and TB6 and check wire for short circuit to positive side of directional switch. Defective card. • Disconnect wires and measure voltage at TB5 and TB6. Voltage should be less than 60% of battery volts.

7-10

TB5

TB6

REVERSE

Directional Switches

EV100ZX DIAGNOSTIC STATUS CODES

-11 MEMORY RECALL

CAUSE OF STATUS INDICATION

Start switch closed on power up after initial key switch closure.

This status code will be displayed when TB2 is greater than 60% of battery voltage when the key switch is closed.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will not pick up. POSSIBLE CAUSE Start switch input mis-adjusted or defective. • Input voltage at TB2 should be less than 60% battery volts at key switch closing. Adjust or replace accelerator unit to insure that the voltage at TB2 is less than 60% battery volts before closing the start switch pedal.

BRAKE SWITCH

ACCEL START SWITCH

➤

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

➤

TRACTION STATUS CODE

Short circuit between battery positive and TB2 in start switch input circuit. • Disconnect wire from TB2. Check for short circuit from wire to battery positive. Resistance should be greater than 4.7K ohms. Defective card. • Disconnect wire from TB3. Measure voltage from TB3 to negative. Voltage should be zero, if not, replace card. • Check for JP1 Jumper in card on wrong pins.

-15 MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Battery voltage is too low or control card is mis-adjusted.

This status code will be displayed when the battery volts are less than 1.95 volts per cell at initial key switch on. See table below.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will not pick up. POSSIBLE CAUSE Discharged battery. • Check battery for proper open circuit voltage as outlined in the Figure and charge battery, if required.

Defective battery. • Check each battery cell for proper voltage (greater than 1.95 volts at cell). Replace or repair battery.

7-11

BATTERY

➤

Incorrect control card adjustment. • Check function 15 for proper adjustment for battery being used. See Handset instruction sheet for details. Adjust to proper settings.

BATTERY CONNECTION

➤

TRACTION STATUS CODE

TB2

BATTERY CONNECTION

MINIMUM NOMINAL LIMIT VOLTS BATTERY AT 1.95 VDC VOLTS PER CELL 24 36 48 72 84

23.4 35.1 46.8 70.2 81.9

EV100ZX DIAGNOSTIC STATUS CODES

MEMORY RECALL

Battery voltage is too high or control card is mis-adjusted.

This status code will be displayed when the battery volts are greater than 2.40 volts per cell at initial key switch on. See table below.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward and reverse contactor will not pick up. POSSIBLE CAUSE Incorrect control card adjustment. • Check function 15 for proper adjustment for battery being used. See Handset instructions for details. Adjust to proper setting.

BATTERY CONNECTION

BATTERY

➤

• Defective accelerator.

BATTERY CONNECTION

TRACTION STATUS CODE

DESCRIPTION OF STATUS

CORRECTIVE ACTIONS NO

Circuits valid for Traction Controller

YEL

7 REC

PA4

MAXIMUM NOMINAL LIMIT VOLTS BATTERY AT 2.40 VDC VOLTS PER CELL 24 36 48 72 84

28.8 43.2 57.6 86.4 100.5

CAUSE OF STATUS INDICATION This status code will be displayed when the card type selection value is set to an invalid number.

“Card Type” selection is invalid.

-17 MEMORY RECALL

➤

Battery over-charged or incorrect battery used. • Check battery for proper open circuit voltage per table in trouble-shooting diagram. If voltage excessive-check battery for proper output voltage.

SENSOR #2

➤

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

➤

-16

DESCRIPTION OF STATUS

➤

TRACTION STATUS CODE

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactors will not close. POSSIBLE CAUSE Invalid card type selection. • Review function 17 in the “Handset” section. Adjust and set card type value as instructed by the Service Manual.

Verify that the correct logic card catalog number is installed in the controller.

7-12

EV100ZX DIAGNOSTIC STATUS CODES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Accelerator input is less than .25 volts.

This status code will be displayed when the voltage at TB1 is less than .25 volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

-21

ACCEL CONTROL

POSSIBLE CAUSE Accelerator input needs adjustment or is damaged. • Input voltage at TB1 must be greater than .25 volts when the accelerator pedal is fully released. Adjust or replace accelerator unit.

Short-circuit between battery negative and TB1 in accelerator input circuit. • Disconnect wire from TB1 and check for short-circuit from end of wire to battery negative. Resistance must be greater than 4.7K ohms.

MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

Forward and reverse contactor coil current is low.

This status code will be displayed when the current draw in the forward or reverse contactor coil circuit is less than 100 milliamps.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will not pick up. Status code may alternate between code 23 and code 24. Complete check for code 23, if the problem is not found, perform check for code 24. POSSIBLE CAUSE Defective F and R contactor coil circuit. • Check for open circuit or loose connection between PB4 and positive side of F contactor coil and between PB5 and positive side of R contactor coil. • Remove plug B. Check ohmic value from PB4 to positive side of F coil. Value should be 10 to 14 ohms. Make same check for R coil.

Defective 1A, FW, RB, or PS contactor coil. • Remove plug B. Check ohmic value from positive side of each coil to its respective plug connection. Value should be 10 to 14 ohms.

7-13

➤

-23

DESCRIPTION OF STATUS

➤

TRACTION STATUS CODE

TB1

Defective Card. • Disconnect wire from TB1. Measure voltage from TB1 to negative. Voltage should be greater than 4.5 volts, if not, replace card.

➤

Circuits valid for Traction Controller

SYMPTOM Controller will not operate.

➤

MEMORY RECALL

➤

TRACTION STATUS CODE

+ F

+ R

PB4 PB5 PB6 PB2 PB3 PB1

+ 1A

+ RB

+ PS

+ FW

EV100ZX DIAGNOSTIC STATUS CODES

T2 voltage is too high. (Greater than 12% This status code will be displayed when T2 volts is greater than 12% of battery volts and the “F” & “R” battery volts). driver is energized.

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control does not operate. Status code may alternate between code 23 and code 24. Complete checks for 24, if the problem is not found, perform code 23 check. POSSIBLE CAUSE Defective F or R contactor. • F or R power tips fail to close because: 1) Welded normally closed power tips. 2) Binding contactor tip assembly. 3) Defective F or R contactor coil. (See status code 23)

Defective RB contactor. • Check RB contactor power tips for closure and proper pick up. • Check for open circuit or loose connections between positive side of RB contactor coil and PB2.

➤

ARMATURE A2 RB A2

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

1A contactor does not drop out or drops out slowly.

This status code will be displayed when 1A contactor drop out time exceeds .060 seconds.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Short tip life on F and R or 1A contactor. Status code 46 displayed and no fault found.

➤

YES

➤

MEMORY RECALL

R S1 S2 FIELD

Defective 1A, RB, PS or FW contactor. • Perform checks as outlined in status 23. • Loose Terminal on 3 REC.

-25

Note: This status code can only be found by using the handset and looking at function 1. This status code is furnished as a troubleshooting aid for status code 46. Defective 1A contactor. • Check 1A contactor for binding or slow operation when dropping out.

➤ ➤

POSSIBLE CAUSE

➤

Circuits valid for Traction Controller

➤

Open Motor Circuit. • Check for open circuit or loose connection in motor circuit from the A1 connection to the A2 connection on the SCR control panel.

TRACTION STATUS CODE

➤

-24

DESCRIPTION OF STATUS

➤

TRACTION STATUS CODE

➤

7-14

➤

EV100ZX DIAGNOSTIC STATUS CODES

This status code will be displayed when there is a shorted PS, RB, or FW coil driver.

Shorted coil driver for PS or FW contactor.

CORRECTIVE ACTIONS MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

SYMPTOM PS or FW contactor picks up immediately when key switch is closed.

➤

CAUSE OF STATUS INDICATION

Circuits valid for Traction Controller

➤

-26

DESCRIPTION OF STATUS

➤

TRACTION STATUS CODE

POSSIBLE CAUSE Defective coil driver internal to logic card. • Replace logic card.

+ RB

+ PS

PB6

+ FW

PB2 PB3

TRACTION STATUS CODE

-41

DESCRIPTION OF STATUS

This status code will be displayed when the voltage between PZ1 and PZ5 is greater than 1.8 volts.

Open thermal protector (TP) or control over temperature.

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Reduced or no power to traction motor in SCR range. POSSIBLE CAUSE Open thermal protector circuit. • Check for loose connection or broken wire between: -Black wire - Thermal protector and PZ1 -Gray wire - Thermal protector and PZ5

Defective thermal protector. • Disconnect wires from PZ1 and PZ5. At room temperature (25° C or 75° F) measure resistance between Black and Gray wire. Replace TP if ohmic value is greater than 300 ohms. SCR is in thermal cut-back. • Allow control to cool, status code should disappear.

7-15

Black

PZ1

THERMAL PROTECTOR Gray

PZ5

EV100ZX DIAGNOSTIC STATUS CODES

-42

DESCRIPTION OF STATUS

This status code will be displayed when the voltage between PY7 and Negative is greater than 1.6 volts with no current flowing in the motor circuit.

Controller “motor current sensor” input is missing.

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM No power to traction motor in SCR range. POSSIBLE CAUSE Open sensor wire circuit to PZ4. • Check for loose connection or broken wire (green wire) from current sensor to PZ4 on the logic card.

➤

TRACTION STATUS CODE

A2 Green

SCR CURRENT SENSOR

PZ4

➤

➤ NEG

MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

Controller “motor current sensor” input is missing.

This status code will be displayed when the voltage between PY7 and Negative is less than .84 volts with no current flowing in the motor circuit.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM No power to traction motor in control range. POSSIBLE CAUSE Open sensor wire circuit to PZ3. • Check for loose connections to broken wire (yellow wire) from current sensor to PZ3 on the logic card.

➤

-43

DESCRIPTION OF STATUS

➤

SCR CURRENT SENSOR

Yellow

➤

TRACTION STATUS CODE

➤ NEG

7-16

PZ3

EV100ZX DIAGNOSTIC STATUS CODES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION This status code will be displayed when, during SCR operation, 1 REC fails to turn off.

1 REC did not turn off properly.

-44 CORRECTIVE ACTIONS

➤ ➤

2 REC

Defective 2 REC circuit. • Check for shorted 2 REC. • Check for shorted 2 REC snubber (22 REC).

➤

CAUSE OF STATUS INDICATION This status code will be displayed when 1 REC fails to gate “on”.

1 REC did not turn on properly.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will open and close, then open and then can only be closed by opening and closing the key switch.

➤

POSSIBLE CAUSE Defective 2 REC circuit. • Check for shorted 2 REC.

1 REC

Wht/Blu

• Check for shorted 2 REC snubber (22 REC).

Blu

PZ8 PZ9

➤

Defective 1 REC circuit. • Check for open circuit or loose connections between 1 REC and PZ8. (white/blue wire).

➤

Circuits valid for Traction Controller

25 REC

DESCRIPTION OF STATUS

-45

YES

22 REC

5 REC

Defective 1 REC. • Turn off time for 1 REC out of specification. No field test is possible. Replace 1 REC after above checks, show no problem found.

MEMORY RECALL

CHOKE

Open choke (1X). • Check for open circuit between T5 and T3. Ohm meter should read zero ohms.

TRACTION STATUS CODE

➤

REC

➤

POSSIBLE CAUSE Defective 5 REC circuit. • Check for shorted 5 REC. • Check for shorted 5 REC snubber (25 REC). • Power cables switched.

➤

Circuits valid for Traction Controller

SYMPTOM Forward or reverse contactors open and close, then can only be closed by opening and closing the key switch.

➤

YES

➤

MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

➤

TRACTION STATUS CODE

2 REC

• Check for open circuit or loose connection between 1 REC (3 REC snubber) and PZ9. (blue wire).

Defective 1 REC. • Intermittent or open 1 REC gate. Field test may or may not show defect. Replace 1 REC after above checks show no problem found.

7-17

22 REC

➤

EV100ZX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-46 MEMORY RECALL

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

“Look Ahead” test for T2 volts. (greater than 85% of battery volts).

This status code will be displayed when the voltage at T2 is greater than 85% of battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will not pick up. POSSIBLE CAUSE Defective 1 REC. • Check for shorted 1 REC.

➤

Circuits valid for Traction Controller

➤

1 REC

• Check for defective 1 REC insulator (co-therm) that may short 1 REC heat sink to base plate.

➤

Defective 1A contactor. • Check for welded 1A contactor power tips.

➤ ➤ T2

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION This status code will be displayed when the 2 REC fails to turn on.

2 REC does not turn properly.

-47

2 REC

7-18

CHOKE

➤

22 REC

5 REC

➤

F or R contactor or power tips bouncing open. • Check that power tips on F and R contactor power tips do not bounce open during operation (ie: travel over speed bumps or dock plates).

Defective 5 REC circuit. • Check for shorted 5 REC. • Check for shorted 5 REC snubber (25 REC) Open Choke (1X). • Check for open circuit between T5 and T3. Ohm meter should read zero ohms.

➤

➤ ➤

➤

REC

➤

POSSIBLE CAUSE Defective 2 REC circuit. • Check that 2 REC will gate on. • Check for open circuit or loose connection between 2 REC gate and PZ10 (white/red wire). • Check for open circuit or loose connection 1 REC and 1 C through the 2 REC circuit.

➤

Circuits valid for Traction Controller

SYMPTOM Forward or reverse contactor will open and close, then open and then can only be closed by opening and closing the key switch.

➤

YES

TROUBLE-SHOOTING DIAGRAM

➤

CORRECTIVE ACTIONS MEMORY RECALL

➤

TRACTION STATUS CODE

25 REC

EV100ZX DIAGNOSTIC STATUS CODES

MEMORY RECALL

“Look Ahead” test for T2 volts (less than 12% of battery volts.

This status code will be displayed when the voltage at T2 is less than 12% of battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will not pick up. POSSIBLE CAUSE Defective forward or reverse contactor. • Check for welded forward or reverse contactor power tips.

F S1

FIELD

• Check for sluggish operation of forward or reverse contactor.

Defective 3 REC circuit. • Check for shorted 3 REC.

➤ 23FL

➤

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

➤

-48

DESCRIPTION OF STATUS

➤

TRACTION STATUS CODE

ARMATURE

3 REC

• Check for shorted 3 REC snubber (23 REC).

A2 SCR CURRENT SENSOR

➤ ➤

➤ NEG

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION This status code will be displayed when the 5 REC circuit fails to turn on.

5 REC does not turn on properly.

-49 CORRECTIVE ACTIONS YES

➤

PZ12

PZ14 ➤

White/Violet

➤

Circuits valid for Traction Controller

POSSIBLE CAUSE Defective 5 REC circuit. • Check for shorted 5 REC. • Check for shorted 5 REC snubber (25 REC). • Check that 5 REC will gate on. • Check for open circuit or loose connection between 5 REC gate and PZ12 (white/violet wire).

White/Violet

Orange

1X ➤

MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor will open and close, then open and then can only be closed by opening and closing the key switch.

➤

TRACTION STATUS CODE

5 REC

2 REC

CHOKE REACTOR T4

Defective capacitor circuit. • Check for open capacitor. • Check for loose connection at capacitor terminals. Defective reactor circuit. • Check for open reactor circuit. • Check for high resistance in reactor circuit.

7-19

➤

Shorted 2 REC circuit. • Check 2 REC and 2 REC snubber (22 REC) for short circuit.

Orange Wire

2 REC

➤ T5 T3 REACTOR

25 REC

EV100ZX DIAGNOSTIC STATUS CODES

DESCRIPTION OF STATUS

This status code will be displayed when 2 REC circuit fails to turn on at initial key switch on.

Capacitor volts low.

-50 CORRECTIVE ACTIONS NO

SYMPTOM Forward or reverse contactor picks up. Control does not operate.

BUS A SPIDER

POSSIBLE CAUSE Defective 2 REC circuit. • Open circuit or loose connection between spider assembly and 5 REC (BUS A).

BUS B

• Open circuit or loose connection between 5 REC and 2 REC.

White/Red Wire

➤

Circuits valid for Traction Controller

TROUBLE-SHOOTING DIAGRAM

5 REC ➤ ➤

MEMORY RECALL

CAUSE OF STATUS INDICATION

➤

TRACTION STATUS CODE

Red Wire

2 REC PZ10 ➤

• Check 2 REC to insure that it will gate on.

➤

• Open circuit or loose connection between 2 REC and PZ11 (red wire) and between 2 REC gate and PZ10 (white/red wire).

White/Red

1 REC

1C T5

This status code will be displayed when capacitor volts exceed 225 volts and motor current is greater than 300 amps.

Excessive capacitor voltage when motor current is high.

Circuits valid for Traction Controller

SYMPTOM Forward or Reverse contactors open and close, then can only be closed by opening and closing the key switch.

POSSIBLE CAUSE Excessive source inductance. • Tag lines without filters are being used.

FIELD F

• Battery cables are too long.

R A1

High peak current in motor. • Check for shorted field winding.

ARMATURE A2

• Check for shorted armature winding.

A2 SCR CURRENT SENSOR

➤ ➤

➤

YES

TROUBLE-SHOOTING DIAGRAM ➤

CORRECTIVE ACTIONS MEMORY RECALL

CAUSE OF STATUS INDICATION

➤

-51

DESCRIPTION OF STATUS

➤

2 REC

➤

TRACTION STATUS CODE

NEG

7-20

EV100ZX DIAGNOSTIC STATUS CODES

This status code will be displayed when capacitor volts exceed 225 volts and motor current is less than 200 amps.

Excessive capacitor voltage when motor current is low.

CORRECTIVE ACTIONS MEMORY RECALL

YES

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactors open and close, then can only be closed by opening and closing the key switch.

➤

-52

DESCRIPTION OF STATUS

➤

TRACTION STATUS CODE

POSSIBLE CAUSE Excessive source inductance. • Tag lines without filters are being used. • Battery cables are too long.

FIELD F

Defective 4 REC circuit. • Check for shorted 4 REC. • Check for open circuit, or loose connection in 4 REC circuit. Defective 3 REC circuit. • Check for open circuit or loose connection in 3 REC circuit.

A1 ARMATURE

3 REC

A2 A2

4 REC

SCR CURRENT SENSOR

➤ ➤

➤

NEG

YES

Circuits valid for Traction Controller

1 REC fails to turn off during plugging operation.

This status code will be displayed when any failure of 1 REC to turn off during plug cycle occurs.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor opens and closes, then opens and can only be closed by opening and closing the key switch. Severe plugging. POSSIBLE CAUSE 1 REC turn off failure not related to plugging. • Stall vehicle in both directions and note any status codes displayed that may more closely define the failure mode. Troubleshoot per new status code.

Defective motor circuit. • Check motor circuit for open or loose connections. • Check motor brushes for proper seating.

SCR CURRENT SENSOR

7-21

1 REC turn off related to plugging. • Check 4 REC circuit for open 4 REC, loose or open cable/bus connections. • Check current sensor for loose or open connection in power circuit. Check yellow and green wire from sensor to logic card for open and loose connection. Check yellow and green wires for correct pin location on control.

F or R contactor power bouncing open. • Insure that F and R contactor does not bounce open during vehicle operation (ie: traveling over speed bumps and dock plates).

➤

MEMORY RECALL

CAUSE OF STATUS INDICATION

➤

-53

DESCRIPTION OF STATUS

A1 ARMATURE A2

4 REC Green Yellow

➤

TRACTION STATUS CODE

➤ NEG

PZ4 PZ3

EV100ZX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-54

DESCRIPTION OF STATUS

This status code will be displayed when any of the Forward, Reverse or 1A contactor coil driver is shorted internal to the logic card.

Shorted Forward, Reverse, or 1A contactor coil driver.

CORRECTIVE ACTIONS MEMORY RECALL

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Defective logic card. • Replace logic card.

Circuits valid for Traction Controller

MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

Controller “motor current sensor” input voltage polarity check.

This status code will be displayed when the voltage input to PZ4 and PZ3 is the wrong polarity.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactors open and close, then can only be closed by opening and closing the key switch. POSSIBLE CAUSE Reversed yellow and green current sensor wires. • Insure that the green wire connects to PZ4 with no open circuits and that the yellow wire connects to PZ3 with no open circuits or loose connections.

Reversed power cable connection. • Insure that the battery positive cable connects to SCR negative and the motor A2 cable connects to SCR A2.

➤

-57

DESCRIPTION OF STATUS

A1 A2 A2 Green

SCR CURRENT SENSOR

Yellow

➤

TRACTION STATUS CODE

NEG

7-22

PZ4 PZ3

EV100ZX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-70

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION This status code will be displayed when the input signal at PA4 is missing.

Regenerative current sensor input missing (wire #22).

CORRECTIVE ACTIONS YES

POSSIBLE CAUSE Defective regenerative sensor input circuit. • Check sensor wire #22 for open circuit or loose connection between sensor (welded connection) and PA4.

POS

SENSOR 2

➤

Circuits valid for Traction Controller

SYMPTOM Control does not operate.

➤

MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

Wire #22

Wire #21

PA4

PA5

7 REC

➤

TRACTION STATUS CODE

-71

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION This status code will be displayed when the input signal at PA5 is missing.

Regenerative current sensor input missing (wire #21).

CORRECTIVE ACTIONS YES

POSSIBLE CAUSE Defective regenerative sensor input circuit. • Check sensor wire #21 for open circuit or loose connection between sensor (welded connection) and PA5.

POS

SENSOR 2

➤

Circuits valid for Traction Controller

SYMPTOM Control does not operate.

➤

MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

Wire #22

Wire #21

PA4

PA5

7 REC

➤

7-23

EV100ZX DIAGNOSTIC STATUS CODES

YES

Circuits valid for Traction Controller

Regenerative contactor (RB) does not pick up.

This status code will be displayed when the logic card is in the run mode and 2.5 volts or greater is present at PA6.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Regenerative control does not operate. POSSIBLE CAUSE Open connection in the PA6 circuit. • Check for open circuit of loose connection between PA6 and the A2 connection of the RB contactor.

➤

MEMORY RECALL

CAUSE OF STATUS INDICATION

➤

-72

DESCRIPTION OF STATUS

RB COIL 7 REC

➤

TRACTION STATUS CODE

• Check for open circuit or loose connection between 7 REC and the A2 connection of the RB contactor.

DRIVE MOTOR

PB2

PA6

A2 17 RB CONTACTOR TIPS

➤

MEMORY RECALL

YES

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

Regenerative contactor (RB) does not drop out or drops out slowly.

This status code will be displayed when the RB contactor power tips fail to open after 100 milliseconds after power is removed from the RB contactor coil.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor opens and closes, then opens and can only close by opening and closing the key switch. POSSIBLE CAUSE Defective RB contactor. • Check RB contactor for smoothness of operation and excessive wear on moving parts.

➤

-73

DESCRIPTION OF STATUS

7 REC

➤

TRACTION STATUS CODE

DRIVE MOTOR

PA6 A2

Intermittent PA6 input. • Check for loose connections in PA6 circuit from PA6 to RB contactor A2 connection.

17 RB CONTACTOR TIPS

➤

7-24

EV100ZX DIAGNOSTIC STATUS CODES

YES

Circuits valid for Traction Controller

Regenerative contactor (RB) picks up too slowly.

This status code will be displayed when the RB contactor power tips do not close within 100 milliseconds after power is applied to the RB contactor coil.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

➤

MEMORY RECALL

CAUSE OF STATUS INDICATION

➤

-74

DESCRIPTION OF STATUS

RB COIL 7 REC

➤

TRACTION STATUS CODE

DRIVE MOTOR

PB2

Intermittent PA6 input. • Check for loose connections in PA6 circuit from PA6 to RB contactor A2 connection.

PA6

A2 17

Defective RB contactor coil circuit. • Check RB contactor coil for proper ohmic value. It should be 10-14 ohms.

RB CONTACTOR TIPS

➤

• Check coil connection from PB2 to RB coil (-) for loose connection. • Check coil connection from battery positive to RB coil (+) for loose connection.

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

1 REC fails to turn off during regen.

This status code will be displayed when any failure of 1 REC to turn off during regen cycle.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL

YES

DRIVE MOTOR

SENSOR 2

Wire #22

Wire #21

PA4 PA5

7 REC

PA6

17 RB CONTACTOR TIPS

➤

7-25

POS

➤

Circuits valid for Traction Controller

SYMPTOM Forward or reverse contactor opens and closes, then opens and can only close by opening and closing the key switch. POSSIBLE CAUSE 1 REC turn off failure not related to regen. • Stall vehicle in both directions and note any status codes displayed that may more closely define the failure mode. Trouble shoot per new status code. 1 REC turn off related to regen. • Check for loose connections on all regen power circuits from battery positive to RB contactor A2 connection. • Check for loose connection on regen input circuits. • Wire #22 from sensor 2 to PA4. • Wire #21 from sensor 2 to PA5. • Wire #17 from RB contactor to PA6. Defective motor circuit. • Check motor circuit for open or loose connections. • Check motor brushes for proper seating. F or R contactor power bouncing open. • Insure that F and R contactor does not bounce open during vehicle operation (ie: traveling over speed bumps and dock plates). • Power cables switched.

➤

-75

➤

TRACTION STATUS CODE

EV100ZX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-76

DESCRIPTION OF STATUS

This status code will be displayed when capacitor voltage is greater than 225 volts during the regen cycle.

Capacitor voltage too high during regen.

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Forward or reverse contactor opens and closes, then opens and can only close by opening and closing the key switch. POSSIBLE CAUSE Intermittent connection in battery power circuit. • Check battery power circuit, both positive and negative for loose connections.

LINE CTR

FUSE

CAPACITOR

➤

• Check power fuse, battery connectors, line contactors and etc., for possible opening during regen cycle.

BATTERY CONNECTION

➤

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

BATTERY

BATTERY CONNECTION

Excessive source inductance. • Check for unfiltered tag lines.

➤ NEGATIVE

• Check for long battery cables.

DESCRIPTION OF STATUS

This status code will be displayed when the voltage at terminal 1 of the TMM is at zero volts.

Drive Motor Thermostat.

-90 CORRECTIVE ACTIONS MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status Code flashes “on and off”.

POSSIBLE CAUSE Indicates Drive Motor has overheated and thermostat switch is closed.

Circuits valid for Truck Management Module

CAUSE OF STATUS INDICATION

TRUCK MANAGEMENT MODULE (TMM1)

Other causes for status code: • Terminal 1 is shorted to Negative. • Defective input switch (shorted). • Defective TMM card.

SW1 NOTE: When SCR Pump Control is used with internal TMM function, input terminal is PA3 on Pump Logic Card.

BATTERY NEGATIVE

7-26

➤

TRACTION STATUS CODE

EV100ZX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

DESCRIPTION OF STATUS

This status code will be displayed when the voltage at terminal 4 of the TMM is at zero volts.

Pump Motor Thermostat.

-92 CORRECTIVE ACTIONS MEMORY RECALL

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status Code flashes “on and off”. POSSIBLE CAUSE Indicates Pump Motor has overheated and thermostat switch is closed. Other causes for status code:

TRUCK MANAGEMENT MODULE (TMM1)

• Terminal 4 is shorted to Negative. • Defective input switch (shorted). • Defective TMM card.

SW4 SW1

NOTE: When SCR pump control is used with internal TMM function, input terminal is PB6 on pump logic card.

BATTERY NEGATIVE

TRACTION STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Drive Motor Brush Wear Indicators.

This status code will be displayed when the voltage at terminal 8 and 10 of the TMM is at zero volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

-94 MEMORY RECALL

➤

Circuits valid for Truck Management Module

SYMPTOM Status Code flashes “on and off”. POSSIBLE CAUSE Indicates Drive Motor Brushes have worn through the sensing wires.

6 10

• Terminal 8 and 10 is shorted to Negative. • Defective input switch (shorted). • Defective TMM card.

SW8 SW5 NOTE: When SCR pump control is used with internal TMM function, input terminal is PA4 and PA5 on pump logic card.

7-27

BATTERY NEGATIVE

➤

Circuits valid for Truck Management Module

TRUCK MANAGEMENT MODULE (TMM1)

Other causes for status code:

SW10 SW6

EV100ZX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Pump Motor Brush Wear Indicators.

This status code will be displayed when the voltage at terminal 11 and 12 of the TMM is at zero volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

-95 MEMORY RECALL

SYMPTOM Status Code flashes “on and off.” POSSIBLE CAUSE Indicates Pump Motor Brushes have worn through the sensing wires.

TRUCK MANAGEMENT MODULE (TMM1)

Other causes for status code:

SW11 SW5 NOTE: When SCR pump control is used with internal TMM function, input terminal is PB1 and PB2 on pump logic card.

TRACTION STATUS CODE

-99 MEMORY RECALL

Circuits valid for Traction Controller

11 5

6 12

• Terminal 11 and 12 is shorted to Negative. • Defective input switch (shorted). • Defective TMM card.

BATTERY NEGATIVE

SW12 SW6

➤

Circuits valid for Truck Management Module

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

USER DEFINED STATUS CODE Maintenance Alert Code.

This status code will be displayed when the “normal” hourmeter reading exceeds the “maintenance alert hours” setting for the truck.

CORRECTIVE ACTIONS

NO DIAGRAM

SYMPTOM Status Code flashes on and off. “Maintenance alert hours” have been reached. User should perform required maintenance and reset maintenance alert hours. See Functions 19 and 20 in the Handset Section.

7-28

USER SHOULD PERFORM THE DESIRED MAINTENANCE FUNCTION.

EV100ZX DIAGNOSTIC STATUS CODES

DESCRIPTION OF STATUS

This status code will be displayed when the card type selection value is set to an invalid number.

“Card Type” selection is invalid.

-117 CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Pump Controller

HYDRAULIC STATUS CODE

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump contactor will not close. POSSIBLE CAUSE Invalid card type selection. • Review function 17 in the Handset Instruction sheets. Adjust and set card type value as instructed by Service Manual.

Verify that the correct logic card catalog number is installed in the controller.

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Pump contactor coil current is low.

This status code will be displayed when the current draw in the pump contactor coil circuit is less than 100 milliamps.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

-123 MEMORY RECALL

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION

SYMPTOM Pump contactor will not pick up. Status code may alternate between code 123 and code 124. Complete check for code 123, if the problem is not found, perform check for code 124.

➤

TRACTION STATUS CODE

POSSIBLE CAUSE Defective Pump contactor coil circuit. • Check for open circuit or loose connection between PB4 and positive side of Pump contactor coil. • Remove plug A. Check ohmic value from PB4 to positive side of F coil. Value should be between 10 and 14 ohms.

Defective P1A contactor coil. • Remove plug A. Check ohmic value from positive side of coil to its plug connection. Value should be between 10 and 14 ohms.

7-29

+ P PB4

EV100ZX DIAGNOSTIC STATUS CODES

MEMORY RECALL

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION

T2 voltage is too high (greater than 12% battery volts).

This status code is displayed when T2 voltage is greater than 12% of battery volts and the Pump driver is energized.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control does not operate. Status code may alternate between code 123 and code 124. Complete checks for 124; if the problem is not found, perform code 123 check.

POSSIBLE CAUSE Defective Pump contactor. • Pump power tips fail to close because: 1) Welded normally closed power tips 2) Binding contactor tip assembly 3) Defective Pump contactor coil 4) Incorrect pump contactor coil resistance. 5) Defective pump contactor coil snubber.

+ P A1 A2

Open motor circuit. • Check for open circuit or loose connection in pump motor circuit from the A1 connection to the A2 connection on the control panel.

NEG

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Pump contactor does not drop out or drops out slowly.

This status code is displayed when Pump contactor drop out time exceeds .060 seconds.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Short tip life on Pump contactor. Status code 46 displayed and no fault found.

➤

MEMORY RECALL

➤

Defective 1A contactor. • Perform checks as outlined in status 123.

-125

PB4

ARMATURE

(See status code 123)

HYDRAULIC STATUS CODE

➤

-124

DESCRIPTION OF STATUS

➤

HYDRAULIC STATUS CODE

➤

POSSIBLE CAUSE

Circuits valid for Pump Controller

➤

1 REC Note: This status code can only be found by using the handset and looking at function 1. This status code is furnished as a troubleshooting aid for status code 146. Defective Pump contactor. • Check Pump contactor for binding or slow operation when dropping out.

PUMP CONTACTOR

➤ ➤

7-30

EV100ZX DIAGNOSTIC STATUS CODES

HYDRAULIC STATUS CODE

-141

DESCRIPTION OF STATUS Open thermal protector (TP) or control is over temperature (greater than 194ºF).

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION This status code is displayed when the voltage between PZ1 and PZ5 is greater than 1.8 volts.

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Reduced or no power to pump motor in SCR range. POSSIBLE CAUSE Open thermal protector circuit. • Check for loose connection or broken wire between: Black wire-Thermal protector and PZ1. Gray wire-Thermal protector and PZ5.

Defective thermal protector. • Disconnected wires from PZ1 and PZ5. At room temperature (25° C or 75° F) measure resistance between Black and Gray wire. Replace TP if ohmic value is greater than 300 ohms.

Black

PZ1

THERMAL PROTECTOR Gray

PZ5

SCR is in thermal cut-back. • Allow control to cool, status code should disappear.

MEMORY RECALL

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION

Control “motor current sensor” input is missing.

This status code is displayed when the voltage between PY7 and Negative is greater than 1.6 volts with no current flowing in the motor circuit.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM No power to pump motor in SCR range.

➤

-142

DESCRIPTION OF STATUS

POSSIBLE CAUSE Open sensor wire circuit to PZ4. • Check for loose connection or broken wire (green wire) from current sensor to PZ4 on the logic card.

A2 Green

SCR CURRENT SENSOR

➤

HYDRAULIC STATUS CODE

➤ NEG

7-31

PZ4

EV100ZX DIAGNOSTIC STATUS CODES

MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

Control “motor current sensor” input is missing.

This status code is displayed when the voltage between PY7 and Negative is less than .84 volts with no current flowing in the motor circuit.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Stall currents in SCR range higher than normal and uncontrollable with C/L adjustment.

➤

-143

DESCRIPTION OF STATUS

POSSIBLE CAUSE Open sensor wire circuit to PZ3. • Check for loose connection or broken wire (yellow wire) from current sensor to PZ3 on the logic card.

➤

SCR CURRENT SENSOR

Yellow

➤

HYDRAULIC STATUS CODE

➤

PZ3

NEG

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION This status code is displayed when, during SCR operation, 1 REC fails to turn off.

1 REC did not turn off properly.

-144

➤ ➤

2 REC

➤

REC

➤

POSSIBLE CAUSE 5 REC circuit defective. • Check for shorted 5 REC. • Check for shorted 5 REC snubber (25 REC).

➤

Circuits valid for Pump Controller

SYMPTOM Pump contactor opens and closes, then can only be closed by opening and closing the key switch.

CHOKE 1X

2 REC circuit defective. • Check for shorted 2 REC. • Check for shorted 2 REC snubber (22 REC). Open Choke (1X). • Check for open circuit between T5 and T3. Ohm meter should read zero ohms.

7-32

22 REC

5 REC

➤

1 REC defective. • Turn off time for 1 REC is out of specification. No field test is possible. Replace 1 REC after above checks show no problem.

➤

YES

➤

MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

➤

CORRECTIVE ACTIONS

➤

HYDRAULIC STATUS CODE

25 REC

EV100ZX DIAGNOSTIC STATUS CODES

HYDRAULIC STATUS CODE

DESCRIPTION OF STATUS

This status code is displayed when 1 REC fails to turn on.

1 REC did not turn on properly.

-145 CORRECTIVE ACTIONS MEMORY RECALL

YES

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump contactor will open and close, then open and then can only be closed by opening and closing the key switch.

P ➤

1 REC

Wht/Blu Blu

PZ8 PZ9

2 REC

Defective 1 REC. • Intermittent or open 1 REC gate. Field test may or may not show defect. Replace 1 REC after above checks show no problem found.

HYDRAULIC STATUS CODE

-146 MEMORY RECALL

Circuits valid for Pump Controller

➤

Defective 1 REC circuit. • Check for open circuit or loose connections between 1 REC and PZ8 (white/blue wire). • Check for open circuit or loose connection between 1 REC (3 REC snubber) and PZ9 (blue wire).

➤

Circuits valid for Pump Controller

POSSIBLE CAUSE Defective 2 REC circuit. • Check for shorted 2 REC. • Check for shorted 2 REC snubber (22 REC).

➤

22 REC

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

“Look Ahead” test for T2 volts (greater than 85% of battery volts).

This status code will be displayed when the voltage at T2 is greater than 85% of battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump contactor will not pick up. POSSIBLE CAUSE Defective 1 REC. • Check for shorted 1 REC. • Check for defective 1 REC insulator (co-therm) that may short 1 REC heat sink to base plate.

➤

1 REC

➤

Defective 1A contactor. • Check for welded 1A contactor power tips.

➤ ➤ T2 P CONTACTOR

➤

7-33

PS2

EV100ZX DIAGNOSTIC STATUS CODES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION This status code will be displayed when the 2 REC fails to turn on.

2 REC does not turn properly.

-147 CORRECTIVE ACTIONS

2 REC

➤

➤ ➤

➤

REC

➤

Circuits valid for Pump Controller

SYMPTOM Pump contactor will open and close, then open and then can only be closed by opening and closing the key switch.

Defective 5 REC circuit. • Check for shorted 5 REC. • Check for shorted 5 REC snubber (25 REC)

22 REC

5 REC

Open Choke (1X). • Check for open circuit between T5 and T3. Ohm meter should read zero ohms.

➤

Pump contactor or power tips bouncing open. • Check that Pump contactor power tips do not bounce open during operation (ie: travel over speed bumps or dock plates).

CHOKE 1X

➤

YES

➤

MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

➤

HYDRAULIC STATUS CODE

T2 25 REC

• Replace 2 REC

MEMORY RECALL

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION

“Look Ahead” test for T2 volts (less than 12% of battery volts.

This status code will be displayed when the voltage at T2 is less than 12% of battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump contactor will not pick up.

➤

-148

DESCRIPTION OF STATUS

POSSIBLE CAUSE Defective Pump contactor. • Check for welded Pump contactor power tips. • Check for sluggish operation of Pump contactor.

Defective 3 REC circuit. • Check for shorted 3 REC. • Check for shorted 3 REC snubber (23 REC).

A1 23FL

ARMATURE A2 A2 SCR CURRENT SENSOR

➤ ➤

➤

HYDRAULIC STATUS CODE

NEG

7-34

3 REC

EV100ZX DIAGNOSTIC STATUS CODES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION This status code will be displayed when the 5 REC circuit fails to turn on.

5 REC does not turn on properly.

-149 CORRECTIVE ACTIONS YES

➤

PZ14

White/Violet

➤

Orange

1X 2 REC

5 REC

CHOKE REACTOR

Orange Wire

2 REC

➤ T5

➤

Shorted 2 REC circuit. • Check 2 REC and 2 REC snubber (22 REC) for short circuit.

PZ12 ➤

➤

Circuits valid for Pump Controller

SYMPTOM Pump contactor will open and close, then open and then can only be closed by opening and closing the key switch.

➤

MEMORY RECALL

TROUBLE-SHOOTING DIAGRAM

➤

HYDRAULIC STATUS CODE

T3 REACTOR 25 REC

Defective capacitator circuit. • Check for open capacitor. • Check for loose connections at capacitor terminals. • Replace 5 REC

DESCRIPTION OF STATUS

This status code will be displayed when 2 REC circuit fails to turn on at initial key switch on.

Capacitor volts low.

-150

TROUBLE-SHOOTING DIAGRAM

BUS A SPIDER

5 REC ➤

BUS B White/Red Wire

Red Wire

2 REC PZ10 ➤

➤

Circuits valid for Pump Controller

POSSIBLE CAUSE Defective 2 REC circuit. • Open circuit or loose connection between spider assembly and 5 REC (BUS A). • Open circuit or loose connection between 5 REC and 2 REC. • Open circuit or loose connection between 2 REC and PZ11 (red wire) and between 2 REC gate and PZ10 (white/red wire). • Check 2 REC to insure that it will gate on.

➤

SYMPTOM Pump contactor picks up. Control does not operate. ➤

➤

CORRECTIVE ACTIONS MEMORY RECALL

CAUSE OF STATUS INDICATION

➤

HYDRAULIC STATUS CODE

White/Red

1 REC

1C T5

➤

7-35

2 REC

EV100ZX DIAGNOSTIC STATUS CODES

-151 MEMORY RECALL

YES

Circuits valid for Pump Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Excessive Capacitor voltage when motor current is high.

This status code will be displayed when capacitor volts exceed 225 volts and motor current is greater than 300 amps.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump contactors open and close, then can only be closed by opening and closing the key switch.

➤

HYDRAULIC STATUS CODE

T2 P

POSSIBLE CAUSE Excessive source inductance. • Tag lines without filters are being used. • Battery cables are too long.

High peak current in motor. • Check for shorted field winding. • Check for shorted armature winding.

A1 ARMATURE A2 A2 SCR CURRENT SENSOR

➤ ➤

NEG

-152

DESCRIPTION OF STATUS

This status code will be displayed when capacitor volts exceed 225 volts and motor current is less than 200 amps.

Excessive capacitor voltage when motor current is low.

CORRECTIVE ACTIONS YES

Circuits valid for Pump Controller

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump contactors open and close, then can only be closed by opening and closing the key switch. POSSIBLE CAUSE Excessive source inductance. • Tag lines without filters are being used. • Battery cables are too long.

T2 P

Defective 3 REC circuit. • Check for open circuit or loose connection in 3 REC circuit.

A1 23FL

ARMATURE A2 A2 SCR CURRENT SENSOR

➤ ➤

➤

MEMORY RECALL

CAUSE OF STATUS INDICATION

➤

HYDRAULIC STATUS CODE

NEG

7-36

3 REC

EV100ZX DIAGNOSTIC STATUS CODES

HYDRAULIC STATUS CODE

-154 MEMORY RECALL

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Shorted Pump or 1A contactor coil driver.

This status code will be displayed when either the Pump or 1A contactor coil driver is shorted internal to the logic card.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Defective logic card. • Replace logic card.

Circuits valid for Pump Controller

MEMORY RECALL

Circuits valid for Pump Controller

PB4

TB4

CAUSE OF STATUS INDICATION

Current sensor input voltage polarity check.

This status code will be displayed when the voltage input to PZ4 and PZ3 is of the wrong polarity.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump contactors open and close, then can only be closed by opening and closing the key switch. POSSIBLE CAUSE Reversed yellow and green current sensor wires. • Insure that the green wire connects to PZ4 with no open circuits and that the yellow wire connects to PZ3 with no open circuits or loose connections.

Reversed power cable connection. • Insure that the battery negative cable connects to SCR Negative and the motor A2 cable connects to SCR A2.

➤

-157

DESCRIPTION OF STATUS

A1 A2 A2 Green

SCR CURRENT SENSOR

Yellow

➤

HYDRAULIC STATUS CODE

P COIL

NEG

7-37

PZ4 PZ3

MCFA Document # 000070-10M Issue Date 11/9/2010

TITLE: Down Safety Valve Operating Specifications

MODEL AND SERIAL NUMBER:

All models

SUBJECT: This article provides you with the operating specifications of the Down Safety Valve

CAUSE: Technicians are unable to locate published information pertaining to the activated lowering

speed of the Down Safety Valve.

The information provided on this web site is considered to be confidential information and is intended to assist you in resolving product issues. In addition, the information on this web site is not to be considered as an authorization for any financial claim against MCFA. Always follow all Safety, Warning, Caution and Precaution information that is provided in the appropriate Service Manual and Operation and Maintenance Manual(s).

RESOLUTION: A valve is installed at the base of the lift cylinder that becomes activated ( partially closed ) by high oil velocity if a lift hose or lift pipe were to become damaged and open. This valve reduces oil flow output from the cylinder by 1/3rd of capacity.

All Cat Lift Trucks are designed within accordance of these specifications. ASME B56.2 2009 states 7.25.9 Vertical masts shall be provided with a means to prevent the load from lowering at a rate in excess of 0.6 meter per second in case of a failure in the load supporting hydraulic control circuits.

HYDRAULIC SYSTEM

Down Safety Valve

When in normal condition

Broken area

When piping is broken 204971

The down safety valve is located at the bottom of the right lift cylinder. This valve is a safety valve which regulates the flow of oil to prevent the forks from moving down too quickly if the piping between the lift cylinder and the flow regulator valve is broken. Also if the flow of return oil from the lift cylinder becomes excessive due to a maladjusted regulator valve or a fault of another component.

11-6

MCFA Document # 000071-09M Issue Date 6/22/2009

TITLE: Mitsubishi Fork Lift Trucks June 2009 Technical Communicator Teleconference Webcast Presentation

MODEL AND SERIAL NUMBER:

N/A

SUBJECT: To download a copy of the webcast presentation from June 17, 2009 TC Webcast, copy & paste or click this link: http://download.mcfa.com/. You will need to use your HSS (HEAT Self Service) login and password. The presentation is located in the Diagnostics Software section.

CAUSE: N/A

RESOLUTION: NOTE: This article contains information from the June 2009 TC Webcast Notes. The material in this article may include updated information.

MCFA Document # 000085-09M Issue Date 7/7/2009

TITLE: Finding HPK articles in the Heat Plus Knowledge database

MODEL AND SERIAL NUMBER:

All Models All Serial Number Ranges

SUBJECT: HPK articles hold valuable information regarding product improvements, manual corrections, troubleshooting techniques, and informational tools.

CAUSE: A basic step by step instructional guideline is useful familiarizing anyone with the Heat Plus

Knowledge (HPK) database.

RESOLUTION: On the following pages are 5 steps in accessing the Heat Plus Knowledge (HPK) database and searching for a specific HPK article by article number or by keyword(s).

An index for HPK articles can be found at MCFA's download center at the following web link: http://download.mcfa.com This index is updated quarterly.

1. After logging onto HEAT, select the “Search” icon.

2. Then select “HEAT Plus Knowledge.”

3. To search for a specific HPK article or an article using a specific key word (i.e. Code 60), select “Find More Solutions.”

4. Type in Key word to search or HPK article and click “Find.” Note: When typing in an HPK article, substitute the (‐) for a (+). For example, search “000044+09” when searching for HPK article 000044‐09.

5. For multiple word search in a single document, place a (+) symbol between each word.

MCFA Document # 000088-09M Issue Date 7/20/2009

TITLE: Download Center now has a New Look

MODEL AND SERIAL NUMBER:

All

SUBJECT: The Download Center now has a new look. This includes the addition of TC Teleconference / Webcast notes from August 1998, TC Conference books from 1999, and separate folders for these notes along with software updates and diagnostic software

CAUSE: High quantity of calls for information

RESOLUTION: Follow the link, http://download.mcfa.com, for access to the Download Center. A description of the folders is attached to the following pages.

Home Page

Diagnostic Software Tab

Software Updates/Mot Files Tab

TC Webcast Information

TC Conference Books

DCAT Software

MCFA Document # 000095-09M Issue Date 7/23/2009

TITLE: Overhead Guard Replacement

MODEL AND SERIAL NUMBER:

ALL Mitsubishi Lift Trucks

SUBJECT: This information is provided to assist you when you must explain to a customer why the overhead guards must be replaced.

CAUSE: Customers may not be fully understanding of the reasoning behind an overhead guard

replacement.

RESOLUTION: All damaged overhead guards (OHGs) need to be replaced. The integrity of a damaged OHG may come into question. In many cases, once the OHG is damaged, there may be metal fatigue or even damaged welds. The replacement is from the outcome of OSHA mandates and is not driven by MCFA or your dealership.

Overhead Guards The following information was gathered from the OSHA website: 1910.178(m)(9) An overhead guard shall be used as protection against falling objects. It should be noted that an overhead guard is intended to offer protection from the impact of small packages, boxes, bagged material, etc., representative of the job application, but not to withstand the impact of a falling capacity load.

1910.178(q)(5) All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent as to safety with those used in the original design.

1917.43(c)(3) Replacement parts whose function might affect operational safety shall be equivalent in strength and performance capability to the original parts which they replace.

1917.43(c)(5) Powered industrial trucks shall be maintained in safe working order. Safety devices shall not be removed or made inoperative except as otherwise provided in this section. Trucks with a fuel system leak or any other safety defect shall not be operated.

1917.43(e)(1)(i) When operators are exposed to overhead falling hazards, fork lift trucks shall be equipped with securely attached overhead guards. Guards shall be constructed to protect the operator from falling boxes, cartons, packages, or similar objects.

1917.43(e)(1)(ii) Overhead guards shall not obstruct the operator’s view, and openings in the top of the guard shall not exceed six inches (15.24cm) in one of the two directions, width or length. Larger openings are permitted if no opening allows the smallest unit of cargo being handled to fall through the guard.

1917.43(e)(1)(iii) Overhead guards shall be built so that failure of the vehicle’s mast tilting mechanism will not displace the guard.

1917.43(e)(1)(v) Overhead guards shall be large enough to extend over the operator during all truck operations, including forward tilt.

Overhead Guards Notes: MCFA overhead guards are testing for impact from above, following ASME B56.1. This allows for a maximum downward deflection of 10 inches. We use 250mm, or slightly less than 10 inches. To test the OHG, a 4000 pound load is dropped from 4 feet over a mounted OHG. Some deflection is allowed as a means of absorbing this impact. In this way, damages can be reduced. There is no test criteria for horizontal impacts and this is not a design issue for material handling equipment. The idea of the OHG is to protect from large falling objects. It’s purpose or design intent is not to be or subject to roll over. In other words, it was never intended to be used as a roll over bar or crash bar.

This replacement of OHG is not established by MCFA or even at the dealer level. This comes from OSHA requirements to maintain a level of operator safety.

MCFA Document # 000170-09M Issue Date 12/17/2009

TITLE: Locating and downloading the MCFA Incident Report for all Mitsubishi Forklift Trucks

MODEL AND SERIAL NUMBER:

All makes, models and serial number ranges

SUBJECT: Step by step guide locate and obtain the incident report and pertinent instructions for filling it out

CAUSE: All dealer that have been notified of any accident / incident involving Mitsubishi Lift Trucks are

required to perform an immediate preliminary investigation which entails filling out an Incident Report Form.

RESOLUTION: Go to Mitlift dealer site. Open page to Dealer Portal. See the " Search Document " box. Type in " Incident Report". Click on " Search" button. Search results will pull up an Incident Report Form. Click on " Incident Report ". The PDF will open and display 2 files. Description: The file contains the Incident Report Form and Instructions for filling out.

NOTE: To print the form, you MUST download the PDF package. To print the completed form, select "print all documents". Attach any documentation and or photographs relevant to the incident report.

-A5-

SAMPLE OF PARTS CATALOGUE Not applicable to the model of this column

GROUP NAME

Applicable to Serial NO. SHOWN on cover and up if blank

GROUP NUMBER Part not to be supplied. See (3)

01-01-02 COOLING SYSTEM Model Type

MODEL & APPLICABLE SERIAL NO. REF. PART NO. NO.

R SC / EN P QG

* 97E04-20000 1 91301-00500 2 91301-40100 3 F3200-01700 4 91301-11030 4 01 F3202-04700 4 02 91301-0090 5 F1805-06020 C F1805-10020 N 1 6 91207-07500 7 91301-10600 8 * 9 91201-01700 Q 91202-01700 1 10 F3200-01500 Part not to be supplied See (3)

PART NAME & DESCRIPTION CONSOLE BOX FAN COOLING SUPPORT RING, SNAP PULLEY ASSY, DRIVEN RING,SNAP PULLEY BOLT,W/WASHER BOLT, W/WASHER NUT PULLEY BOSS SHIM SHIM RING, SNAP

DRY,WET DRY,WET DRY,WET DRY,WET DRY,WET DRY,WET B/W DRY,WET,TRQ B/W DRY,WET,TRQ DRY,WET,TRQ DRY,WET,TRQ DRY,WET,TRQ T=1.0 DRY T=1.0 DRY DRY,WET,TRQ

See(8)-(a) Description codes

See(4) Interchangeability codes

See(5) Sequence-of-change numbers

See (6) Change codes

See(2) Reference number

See(8)-(b) Description codes

Q T Y

XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX M V FRM-UPT

FRM-UPT

* 1 1 n/a n/a 1 Applicable up to serial NO. indicated 1 1 1 4 -10180 n/a -60160 n/a 4 10181601614 1 1 1 @10151 @40150@60140 @80130 2 10152@ 10151@60141@ 80131@ 1 High-demand part. See (11)

Part newly changed or added. See (12)

See(8)-(c) Specification codes

Quantity per unit

Applicable from serial No. indicated

Applicable from 40151 (Scheduled) if suffixed with @ and sometimes differs from real serial No.

Applicable up to 40151 (Scheduled) if prefixed with @ and sometimes differs from real serial No.

NOTE: Some of the model designations, number of variations and serial numbers, indicated above, are quoted from other parts lists. Read these items of information as those for this parts list.

Note: For the description of each item, refer to the pages which follow.

/R RD A

FRM-UPT

A A A AV A

-A6HOW TO USE THIS PARTS CATALOGUE (to be referred together with the former SAMPLE OF PARTS CATALOGUE) (1) 01-01-01 COOLING SYSTEM (PART-1) - 6 MODEL & APPLICABLE SERIAL NO. REF. PART NO. NO. 1 2 3 4 5 6 7

90420-00860 90420-00840 90420-00980 90420-00830 90420-00870 90420-00970 90420-00820

(2)

(3)

R SC / EN P QG

Q T Y

PART NAME & DESCRIPTION BEARING KIT BALANCER BEARING RETAINER BOLT GEAR KIT BOLT

(4)(5)(6)

XXXX

XXXX M V

FRM-UPT

/R RD

1 1 1 1 2 1 6 (7)

(8)

(9)

(10)

(11)(12)

The items (1) through (12) are as described below: (1) Compiling System The systems of unit are grouped according to their location in the unit. The groups, each identified by group number, are listed in the order by CONTENTS. Each group is preceded by an “exploded view” which clearly illustrates each part in its correct relation to the other parts in the illustration. EXAMPLE: “01”-01-01 Chassis

01-“01”-01 Cooling system

01-01-“01” number of section within cooling system

(2) Reference Number Abbreviated to “REF. No.,” this number is used to locate a part in the illustration. In cases where the reference number is of three to four figures, the first and second figures show the reference number on an assembly, and the last two figures show the numbers of its component parts. (3) Part Numbers The part numbers shown on the parts list are those assigned to genuine Mitsubishi parts. NOTE: Parts with asterisk (*) are not supplied individually. Part numbers with an asterisk (*) in the reference number and the quantity column are engineering drawing numbers.

- A7 (4)

Interchangeability Codes The interchangeability codes used in this parts list are as follows:

PART NO.

CODE (R/P)

DESCRIPTION

A(Old) B(New) A(Old)

B(New) A(Old

A (Old Part) is not supplied. B (new part) can be substituted for A (Old Part).

B(New) A(Old)

B (new part) and A (old part) are mutually interchangeable

B (new part) can be substituted for A (old part). A (old part) cannot be substituted for B (new part)

B (new part) and A (old part) are not interchangeable

B(New) A(Old)

B (new part) can be substituted for A (old part) in

B(New)

combination with other part(s). (For the parts to be combined, refer to the page beginning with E1 at the end of this parts list.)

(5)

Sequence-of-change number The parts are changed for improved quality or performance. Their changes are indicated in sequence by numbers (1.2.3...) Blank: Original 1 : 1st change 2 : 2nd change 3 : 3rd change

(6)

Change codes These codes indicate the reason or purpose of changes of the parts. A: Added part (a part entered into service) C: Change of part number D: Deleted part (a part applicable up to serial no. expressed in Serial No. column) E: Added part except above reasons Q: Change of quantity

- A8 (7)

Part name Abbreviations are sometimes used. For the abbreviations, refer to TABLE OF SYMBOLS & ABBREVIATIONS following this general information chapter. NOTE: The words “left” (L.H.) and “right” (R.H.), when used in this list, are as these directions would appear from the seat facing forward. Sitting in the seat.

(8)

Description & Specification codes (a) Description codes (expressed in the first part of Description column). B/W : Assembled bolt (with washer) KIT : Part supplied as a kit STD : Standard part OPT : Optional part AR : Part used, as required or by selection or in adjusted quantity necessity SFN : Semi-finished part (b) The description codes in above paragraph (a) are followed by supplementary Explanation such as dimensions (thickness, length, etc.), manufacturer name, etc. as occasion demands. NOTE: Unless otherwise indicated, the dimensions are shown in millimeter and the name of unit is abbreviated. (Examples) Thickness : T = 1.00

Length : L = 1000;

Width : W = 1500

Height : H = 500

(c) Specification codes Each specification or type of model and/or selective specifications of a unit are indicated by codes of three figures. For these codes, refer to LIST OF SPECIFICATION CODES following this general information chapter. NOTE: Unless indicated by the specification codes, the parts may be used for the products of all specifications. (Examples) DRY : with synchromesh transmission (with dry clutch) (d) The parts indicated as “NOT SHOWN”. such as component parts for repair kit, are not shown in the illustration.

- A9 (9)

Quantity Quantity of part or assembly and its component parts required for one unit of product is indicated. NOTE: In cases “AR” appears in QTY column, it is required to adjust quantity for use.

(10) Model & Applicable serial numbers (a) Model

: Model, type, specification, destination, etc. of product to which a parts list applies are indicated in the title column of each variation.

(b) Applicable serial numbers

: Applicable serial numbers of product are indicated in the “UP TO” or “FROM” column. Serial numbers with “@” are scheduled ones and sometimes differ from the real serial numbers. If the “FROM” column is blank, the parts is applicable to serial number shown on this cover and up.

NOTE: In this parts catalogue, the appropriate production date is indicated in the Serial NO. column instead of the applicable serial number. When placing an order for any of the chassis or mast parts which are classified “N” (not interchangeable) or “G” (interchangeable as an assembly), ask and confirm to our authorized dealer in advance by giving the chassis or mast model name and serial number to choose an applicable part between the new and old parts. [Example of approximate date of production] 2301- : Manufactured not later than January, 2003 -2301 : Manufactured in and after January, 2001 -2306 : Manufactured not later than January, 2002 2307- : Manufactured in and after July, 2003

(11) Management rank Parts ranked as “A” are high-demand parts. This ranking is to be referred to by dealers, and is devised to facilitate and rationalize their distribution, stocking and inventory of the parts. (12) Parts changed or added after the last parts list that has been published are identified by “V.”

e-PSB whenBulletin you need answers A Product...Support from Service Engineering in a hurry M06-001 Issue No. _______________

SUBJECT AREA New Parts ❏ Look-up Tip ❏

Manual Corrections ❏ Part Chart ❏ Service Info. ❏

MODEL CATEGORY IC & EL IC ❏

Electric ❏

Narrow Aisle ❏

Level 1 of ______ K2 Page ______

GROUP NUMBERS:

Apr. 27, 2006 Page 1 of 1

Warranty ----Parts Manual -----

Model(s): All METTLER TOLEDO Wireless Scales

Serial Numbers: All METTLER TOLEDO Wireless Scales Parts Manual Parts Manual: ❏ WENB2713-01 Service Manual: ❏ WENB2713-01 Manual Section: Chapter 8 Manual Page:

8-1 through 8-9

SUBJECT:

METTLER TOLEDO Wireless Scales

PURPOSE:

Provide several component tests and inform the dealers of the correct warranty procedures for METTLER TOLEDO Scale parts.

BACKGROUND:

Dealers have returned METTLER TOLEDO Scale components in such a way that the parts were damaged during removal from the lift truck or damaged in shipping (loose packaging) resulting in the vendor not being able to conduct component testing.

PROCEDURE:

Please follow the procedures described below:

Monitors/Scale Controller (90401-08501): If the technician finds the monitor will not display information or boot up, they must replace the flash card (90401-10228) and retest prior to determining the monitor is not working. To remove the monitor, remove the harness intact from the overhead guard leg or on newer Monitors, simply disconnect the monitor at the harness connection. Ship the monitor in bubble wrap, Styrofoam, or equivalent. DO NOT pack monitors with other hard parts that could damage the monitor during shipment. Monitors returned with the power harness connector cut will be returned to the dealer along with the denied claim. Chain Load Cell (90401-08844): Remove the Chain Load Cell with the harness intact. Use the chain tool to remove the master link pins. Ship the Chain Load Cell wrapped in bubble wrap, Styrofoam, or equivalent. DO NOT pack the Chain Load Cell with other hard parts that could damage the load cell during shipment. Chain Load Cells returned loose and unprotected will be returned to the dealer along with the denied claim. Drag Load Cell (90401-08843): Remove the Drag Load Cells. Remove the Drag Load Cell with the complete wiring harness. Ship the Drag Load Cell wrapped in bubble wrap, Styrofoam, or equivalent. DO NOT pack the Drag Load Cell with other hard parts that could damage the load cell during shipment. Drag Load Cells returned and unprotected will be returned to the dealer along with the denied claim. Batteries (90401-09294): Charge all batteries for 12 hours and retest, prior to determining the battery will not operate correctly. A fully charged battery should last 36 hours. Ship batteries wrapped in bubble wrap, Styrofoam, or equivalent. Do not pack the battery with other hard parts that could damage the battery during shipment. Be sure to tag the box with the appropriate hazardous shipping label for nickel metal hydride batteries.

Subject Area:

Issue #

M10006

New Parts Part Chart Look-Up Tip

Level:

Manual Correction Service Information

Issue Date:

02/11/2010

Model Category: IC

Electric

Narrow Aisle

Model (s)

All

Serial Numbers

All

Parts Manual:

All

Service Manual

N/A

Manual Section

Steering Wheel

Manual Page:

N/A

Subject: Horn Contact Ring for new style steering wheel (SE000249) Cat Lift Trucks is now offering the horn contact ring for the new style steering wheel. Previously it was required to purchase the complete steering wheel and the contact ring was not available.

Purpose: The Horn Contact Ring recently became available as a serviced part for the new style steering wheel. See attached parts list.

01-54-03

STEERING WHEEL

– 112–

715062-00

91A5428

01-54-03

STEERING WHEEL – 113– MODEL & APPLICABLE SERIAL NO.

REF. –NO.

PART NO.

1 1 01 1 02 1 03 2 3 4

91A54-03032 91A54-05800 91A54-06300 SE000249 91A54-05600 F2515-14000 91255-04700

2009-12-15

R SC / EN P QG

PART NAME & DESCRIPTION WHEEL ASSY, STEERING PLUG SCREW, TAPPING RING, CONTACT PAD ASSY, HORN WASHER, SPRING NUT

Q FG15N FG18N FG20CN M V T / R Y FROM@- -@UPTO FROM@- -@UPTO FROM@- -@UPTO R D 1 1 1 1 1 1 1

A A

716062-00