CLARK FORKLIFT CTT 7 SPM 641 Dash Supplement SERVICE MANUAL - PDF DOWNLOAD

CTT7 Instrumentation Panel Features &Operation Manual SPM 641 Dash Supplement

CTT 7

SERIAL NUMBER ALWAYS GIVE TRUCK SERIAL NUMBER WHEN ORDERING PARTS

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Material Handling Company

Table of Contents

Illustration of the Access Key Pad

2

Features of the Battery Discharge Indicator

3

Features of the Access Key Pad

3

Features of the Access Key Pad

4

Operation of the Access Key Pad

4

Timers and Clocks

5

Operation of the Timers and Clocks

6

Liquid Crystal Display "LCD"

6 - 10

Controller Over Temperature LED

10

Indicators LED's

10

Auto Sleep Mode

11

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LCD DISPLAY

EASY TO READ, ACCESS AND UNDERSTAND

COMMAND SWITCHES

LIGHT SWITCH

PARKING BRAKE SWITCH

PROGRAMMABLE ELECTRONIC KEY SWITCH

ACCESSORY SWITCH

BATTERY DISCHARGE GAUGE OVERSIZED LED S FOR EASY VIEWING

STATUS INDICATORS

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Features of the Battery Discharge Indicator · A ten segment multicolor display that is easy to see and understand. Each bar represents approximately10% of the total battery. · Automatically determines battery voltage. The built in logic detects the battery voltage (24 -48 volt) when the battery is connected to the tractor and makes all needed corrections and calibrations. · Flashes a warning (bar graph will flash up and down continuously) when the battery reaches a 20% state of charge. · The battery discharge indicator comes from the factory pre-adjusted. In the unlikely event you find it necessary to fine-tune the gauge, do so by turning the pot marked "BDI Adjust" on the back of the dashboard. With a known fully charged battery turn the pot until the top LED goes out, then reverse direction to the point that it just comes on again.

IMPORTANT NOTE: As an added reminder to the driver to charge the battery the LCD display will display a "LOW BATTERY CHARGE SOON!" message. Speed limit 1 will also be activated ten minutes after the BDI starts flashing.

Features of the Access Key Pad · Re-programmable four-digit "Driver" access entry code system to prevent unauthorized use. · Re-programmable four-digit "Supervisor/Maintenance" access entry code system. This gives a supervisor or maintenance personal access to all authorized equipment and the ability to program new user codes and clear the service reminder.

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· A "Factory" set four-digit access entry code. In the event the driver and supervisor codes are lost or misplaced. The factory access code allows the instrumentation panel codes to be reset. Consult the factory technical service department for assistance.

Operation of the Access Key Pad · TURN ON TRACTOR: At the "ENTER ACCESS CODE" prompt (this prompt is displayed whenever the tractor is off) enter the driver access code. When the access code is entered correctly the controller automatically runs a complete safety routine and the state of charge bar graph will then light up.

If all start-up requirements are met the LCD screen will display the tractors drive hours and will be ready for use. If all start-up requirements are not met the LCD displays the fault and its correction.

IMPORTANT NOTE: The factory set default driver access code is "1 - 2 - 3 - 4".

· PROGRAM A NEW ACCESS CODE: At the "ENTER ACCESS CODE" prompt (this prompt is displayed whenever the tractor is off) enter the supervisor code. The LCD display will give a list of four options. ">NEW USER CODE" ">CLEAR SERVICE" Select an option by using the up and down arrows in the blue square. Notice the position of the " >" mark in the LCD. When it's next to the option needed push the "ENTER" button. The option you selected will be displayed. At this time enter a new code. Any of the four numbers can be used for any digit of the new code. After the new code has been entered press the "ENTER" button to program the chosen code.

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">SUPERVISOR CODE" ">TURN TRUCK ON"

IMPORTANT NOTE: The factory set default driver access code is "1 - 2 - 3 - 4".

Timers and Clocks · Displays "Drive Hours". This feature tracks the total amount of time that the tractor has been driven in either direction.

· Displays "Key On Hours". This feature tracks the total amount of time that the controller and interment panel has been on.

· Displays "Service Hours". This feature displays the number of drive hours since the last service was preformed and the clock was reset

IMPORTANT NOTE: The supervisor code is required to reset the service clock.

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Operation of the Timers and Clocks · The drive hours will be displayed by default whenever the tractor is turned on. · The "KEY ON HOURS" and "SERVICE HOUR" clocks can be accessed by the operator by pushing the "MENU" button and scrolling the options using the up and down arrows. Select the clock by pressing the "ENTER" button when the ">" is next to the desired clock.

· CLEAR THE SERVICE HOUR CLOCK: At the "ENTER ACCESS CODE" prompt (this prompt is displayed whenever the tractor is off) enter the "SUPERVISOR CODE". The LCD display will give a list of four options. ">NEW USER CODE" ">CLEAR SERVICE"

">SUPERVISOR CODE" ">TURN TRUCK ON"

Select the clear service option by using the up and down arrows in the blue square, position of the " >" mark next to "CLEAR SERVICE" then push the "ENTER" button. The service hours will be reset to "0".

Liquid Crystal Display "LCD" The LCD screen will display "ENTER ACCESS CODE" normally when the tractor is off and in a dormant state; this is prompting the operator to enter an access code. · The LCD read out displays operational "Faults" as they occur and corrections needed to resume operation.

1. "SAFETY ERROR 1 SIT/RELEASE BRK" When this message is displayed the tractor will not drive. The operator must sit in the seat and release the parking brake before the tractor will drive. If the driver has sat in the seat and the parking brake has been released the possible cause is probably faulty wiring or a faulty seat or brake switch, and will require repairing before normal operations can be resumed.

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2. "DIRECTIONAL ERROR 2 CHECK SW & WIRING" This message is telling the operator that both forward and reverse inputs are being applied to the controller at the same time.

The most probable cause is either a sticking switch (when in neutral observe if either the FWD or REV "INPUT LED's" are lit on the controllers, if so check the switch that showing an input) or its associated wiring.

This fault will be stored in the FAULT HISTORY of the controller 3. "START UP ERROR 3 RELEASE THROTTLE" The most common source for this error is the operator has tried to start the tractor while applying throttle. The operator must remove the throttle input, place the directional lever in neutral, and close the seat switch. After satisfying all the start up requirements the tractor will start without re-entering the access code.

Other causes of this fault are faulty throttle set up and or faulty wiring.

4. "START UP ERROR 3 LIFT MUST BE OFF" The controller has received a lift input upon start-up. This input must be removed to resume normal operations. This error will not be applicable on a tractor because the lack of a hydraulic system. If the error occurs check the tractors wiring.

5. "START UP ERROR 3 PLACE IN NEUTRAL" The directional lever was left in a direction upon start-up, to remove error place it into neutral.

6. "THROTTLE ERROR 4 CHK FOR BKN WIRE" This error is alerting the operator that either the throttle has a broken wire or faulty accelerator components. In either case it will be necessary to make repairs before resuming normal operations.

This fault will be stored in the FAULT HISTORY of the controller 7. "CONTACT ERROR 5 CHECK COILS" If a coil in one of the drive system contactors shorts (draws over four amps), the controller will immediately shut down and display the # 5 fault code.

After replacing or repairing the contractor coil and meeting all the normal startup conditions the controller will return to normal operation.

This fault will be stored in the FAULT HISTORY of the controller

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8. "STALL ERROR 6 RESET KEY SWITCH" The controller will shut down the tractor when the motor is stalled. To reset the operator must turn off tractor and then restart it. This feature has been designed to help prevent motor damage caused by misuse or abuse of the tractor.

IMPORTANT NOTE: A stall is when the controller is in current limit for longer then the pre-set time period. A stall will normally occur when the drive motor has a locked rotor (not turning under a high load) this can be caused when the tractor is trying to move a load that is too great or up too steep of a grade.

The stall time period can be adjusted or turned off completely although it's not recommended.

IMPORTANT NOTE: Continuous stalling the motor can cause permanent damage.

This fault will be stored in the FAULT HISTORY of the controller 9. "BATTERY ERROR 7 CHECK VOLTAGE" The controller will not activate upon start-up if the battery voltage is below or above accepted levels. If this error occurs check the battery voltage. Its possible that it's faulty or maybe just the wrong size.

Meeting normal start-up conditions after charging the battery or correcting the battery condition will cause the controller to return to normal operation.

IMPORTANT NOTE: The battery must be disconnected from the controller when charging the vehicle.

10."ERROR 8 MOSFET/1A FAULT" If the controller's power MOSFET devices receive damage due to extreme conditions, the controller will open all contactors, shut down, and display a MOSFET error.

A MOSFET error will also be given if the bypass, or 1A contactor (if used) is welded shut or faulty wiring.

This fault will be stored in the FAULT HISTORY of the controller

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11."ERROR 2-1 CHECK FWD CONTACTOR" This error has been generated because the forward contactor was too slow to engage (pull in) or possibly did not pull in at all.

Probable causes are contact tips, weak contactor coil or worn contactor.

This fault will be stored in the FAULT HISTORY of the controller 12."ERROR 2-2 CHECK REV CONTACTOR" This error has been generated because the reverse contactor was too slow to engage (pull in) or possibly did not pull in at all.

Probable causes are contact tips, weak contactor coil or worn contactor.

This fault will be stored in the FAULT HISTORY of the controller 13."ERROR 2-3 CHECK FWD CONTACTOR" This error has been generated because the forward contactor was too slow to disengage (drop out) or is welded closed.

Probable causes are welded contact tips or worn contactor.

This fault will be stored in the FAULT HISTORY of the controller 14."ERROR 2-4 CHECK REV CONTACTOR" This error has been generated because the reverse contactor was too slow to disengage (drop out) or is welded closed.

Probable causes are welded contact tips or worn contactor.

This fault will be stored in the FAULT HISTORY of the controller 15."ERROR 2-5 CHECK DIR CONTACTORS" The controller has detected that a directional contactor is welded or stuck closed upon start up. The contactor must be repaired prior to resuming normal operations.

This fault will be stored in the FAULT HISTORY of the controller 16."ERROR 3-1 TURN OFF & ON" The controller did not load the proper EEPROM values upon start-up. To reload the proper EEPROM values turn the tractor off and then restart it.

This fault will be stored in the FAULT HISTORY of the controller

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17."ERROR 3-2 TURN OFF & ON" The controller detected a FATAL EEPROM error upon start-up. Try to reload the proper EEPROM values by turning the tractor off and then restarting it. If after restarting the tractor the controller stills shows this error it must be sent in for repair.

This fault will be stored in the FAULT HISTORY of the controller 18."LOW BATTERY CHARGE SOON!" The LCD displays this message along with flashing the battery bar graph to alert the operator that the battery is 80% discharged. Speed limit #1 will become active ten minutes after this message has been displayed.

Controller Over Temperature LED · The yellow Temperature LED will turn on to alert the operator that the controller is overheating. This will cause the controller to reduce current output to the motor. This will also allow it time to cool (the controller will automatically return to a normal operation when its within its thermal limits).

IMPORTANT NOTE: The controller does not overheat during a normal operation. If the controller is overheating it would be an indication that its being misused, abused or the controller has been damaged and will require replacement or repair.

Indicators LED's · The Service Interval Indicator is factory set to 200 hours of driving time. When the 200 hours occurs the Service Indicator LED will flash on and off. Four hours after the service indicator has been activated speed limit 1 will be automatically be turned on.

· The Parking Brake Indicator will be activated (flash on and off) when the parking brake is applied.

The tractor will automatically turn off after the parking brake has been applied for a period of thirty minutes.

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· The Motor Temperature Indicator will flash on and off, an audible alarm will sound and speed limit 1 will be activated if the drive motor is overheated. All temperature warnings will automatically reset when the motor returns to a normal operating range.

IMPORTANT NOTE: The drive motor does not overheat during a normal operation. If the motor is overheating it would be an indication that its being abused, misused or it has been damaged and will require replacement or repair.

· The Brush Wear Indicator will flash on and off when the drive motor brushes are worn out. Four hours after the indicator started flashing an audible alarm will sound and speed limit 1 will be activated. Replacing the motor brushes will reset all warnings.

· The Speed Limit Indicators 1 and 2 (where applicable) are lit whenever a speed limit is activated. This alerts the operator that the tractor is operating with a speed limit activated. The indicator will turn off automatically as soon as intended speed limit is deactivated or a possible fault condition is cured. Speed limits are adjustable or turned off via the handset. To make adjustments to the speed limits refer to the handset manual.

Auto Sleep Mode · The Sleep Mode automatically turns off the tractor after the parking brake has been set or the seat switch has not been closed (operator not in seat) for a period of thirty minutes. This important safety, as well as energy saving feature, will help prevent unauthorized use of the tractor in the event the operator fails to turn off the electronic key switch when it's not in use.

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