CLARK FORKLIFT ET205 Troubleshooting the EV Tl5 Control TECHNICAL TRAINING MANUAL

ET205 Troubleshooting the EV Tl5 Control

TECHNICAL TRAINING Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Contents About this Class.................................................................................................. 3 Class Objectives.................................................................................................. 3 Class Content.....................................................................................................

Sequence of Operations....................................................................................

Troubleshooting.................................................................................................

4 4 4

About Safety......................................................................................................

Section 1. EV T15 Control Sequence of Operations .....................................

Identification of Abbreviations..............................................................

Identification of Schematic Symbols........................................................

5 6 6

Sequence 1. Drive Control......................................................................

Sequence 2a. Connect the Battery..........................................................

Sequence 2b. Connect the Battery..........................................................

Sequence 3a. Closing the Key Switch....................................................

Sequence 3b. Closing the Key Switch (Cont.)........................................

Sequence 4a. Steering Function.............................................................

Sequence 4b. Steering Function.............................................................

7 8 10 12 14 16 18 20

Sequence 5. Brake Switch and S.R.O Checks.....................................

Sequence 6. Energizing the Directional Contactors.............................

Sequence 7. Turning on the Transistors...............................................

Sequence 8. Turning off the Transistors, Flyback................... ............

Sequence 9. Accelerator, TP, and PMT................................................

Sequence 10. 1A Contactor operation..................................................

Sequence lla. Plugging Operation......................................................

22 24 26

Sequence llb. Plugging Operation......................................................

36 38

Sequence llc. Plugging Operation......................................................

Sequence 12. Travel Speed Limit........................................................

Sequence 13a. Solenoid Functions......................................................

Sequence 13b. Solenoid Functions......................................................

Sequence 14. Lift..................................................................................

Sequence 15. Lower..............................................................................

Sequence 16a. Reach and Retract........................................................

Sequence 16b. Reach and Retract.........................................................

Sequence 17a. Tilt..................................................................................

Sequence 17b. Tilt..................................................................................

Sequence 18a. Sideshifter (optional).....................................................

Sequence 18b. Sideshifter (optional).....................................................

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28 30 32 34

40 42 44 46 48 50 52 54 56 58 60

EV T 15 Control page l

Section 2. Using the Handset IR Compensation Function 14................................................................

IR Compensation Worksheet..................................................................

Stored Status Code Retrieval.................................................................

Stored Status Code Worksheet...............................................................

24 Volt Function Settings...................................................................... .

36 Volt Function Settings .......................................................................

Section 3. Diagnostic Status Codes...................................................................

Status code #1 and 2................................................................................

Status code #3 and 6................................................................................

Status code #7 and 8................................................................................

Status code #9 and 15..............................................................................

Status code #16 and 17............................................................................

Status code #23 and 24 ........................................................................... .

Status code #26 and 27..........................................................................

Status code #41 and 42 ...........................................................................

Status code #43 and 44..........................................................................

Status code #45 and 46...........................................................................

Status code #48 and 50..........................................................................

Status code #51 and 53...........................................................................

Status code #54 and 57...........................................................................

Status code #99 and Blank .....................................................................

Section 4. Misc Information...............................................................................

Solenoid Card...........................................................................................

Hydraulic Schematic.................................................................................

62 63 65 66 67 68 69 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 86 87

EV T5 Steering Control Adjustments...................................................... 88

@Copyright Clark Material Handling Company 1994.

Revised 1998.

EV Tl5 Control page 2

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About this Class The most important part of an electric truck is the control that operates the electrical components. Knowledge of this control - how it works, and how it operates the other components - is vital to maintenance and service. This class is designed to teach you how the EV T15 Transistor Control operates and how you can diagnose and troubleshoot problems with the control.

The EV T15 Control consists of a control card and the electrical components it operates.

The card monitors power demands and responds by controlling the power applied to system components.

The control operates a series of switching devices that enable it to direct the power load across different electrical circuits. These circuits control everything on the truck from the traction motors to forward and reverse drives and accessory devices So your knowledge of the control system, the components it operates, and how to diagnose and troubleshoot conti·ol problems helps you to keep a truck in top shape and avoid down time.

Class Objectives There are two primary objectives for this class. Upon completion of the manual and the class you will be able to: I.Trace each sequence of operations on a basic wiring diagram as a way to demonstrate your understanding of the control and its operation 2.Make preliminary diagnosis of and troubleshoot problems related to the control and its components.

These objectives are intended to give you a sound understanding of how the Control works and lay a groundwork for problem diagnosis and troubleshooting.

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EV T 15 Control page 3

Class Content There are two major sections in this book that will be covered in the class; the Sequence of Operations and Troubleshooting.

Sequence of Operations

This section includes:

•a list of abbreviations used in the text and on the wiring diagram •a legend defining the symbols used on the diagrams •a list of the control sequence of operations •a wiring diagram for each sequence.

To meet one of the objectives of the course, you will be required to trace the operation sequence on the diagram as a way to completely understand how the control works.

Troubleshooting

This sections includes: •a list of basic, required steps necessary to initiate troubleshooting.

•diagnositic codes.

•where necessary, explanations, illustrations, and testing procedures related to ti·oubleshooting a particular component.

At the completion of this class, you will be required to take a quiz. This is a way to help determine if you are meeting the objectives of the course.

If you follow both the Sequence of Operations and the Troubleshooting materials closely, system operation will be clearer. This will help you to understand the electrical system more completely and diagnose and troubleshoot Control problems more effectively.

EV Tl5 Control page 4

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About Safety The following messages may be used to emphasize important information: Note This message is used when special information, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities and other special data.

Important This message is used when special precautions should be taken to ensure a co1Tect action or to avoid damage to or malfunction of the truck or a component.

CAUTION This message is used as a reminder of safety practices which can result in personal injury if proper precautions are not taken.

WARNING This message is used when a hazard exists which can result in injury or death if proper precautions are not taken.

DANGER

This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken.

When checking electrical components on an electric truck, always raise the drive wheels off the floor and put blocks under the truck, disconnect the battery, and discharge the capacitor. These actions prevent injury to yourself and damage to the truck.

Always familiarize yourself with the safety information in the Operator's Manual before you operate a truck.

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EV T15 Control page 5

Section 1. Sequence of Operations

This sequence of operation is designed to provide a complete step-by-step description of the operation of Clark lift trucks equipped with GE model EV TIS solid state transistor control.

Please read each operation sequence and then trace the sequence onto the diagram as described.

If you will follow the steps carefully, and not skip around you should be familiar with the entire operation of the lift truck electrical system. Then, if you wish to review any particular part or sequence, consult the Table of Contents and refer to the particular sequences involved.

Identification of Abbreviations The following abbreviations are used in the text and in the wiring diagrams:

1A

Bypass Contactor & Coil

IC.

Capacitor

F.W.

Field Weakening

F.

Forward

FWD

Forward Directional Switch

FU

Fuse

p

Main Pump Contactor & Coil

PS

Power Steering Contactor & Coil

L

Line Contactor & Coil

MS

Master Switch

PD

Pump Driver Module

REC

Rectifier (Diode )

RES

Resistor

R

Reverse

REV

Reverse Directional Switch

TP

Thermal Protector

TRI

Transistor

EV Tl5 Control page 6

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IDENTIFICATION OF SCHEMATIC SYMBOLS --e .,_

MOMENTARY SWITCH

�

NORMALLY OPEN LIMIT SWITCH NORMALLY CLOSED LIMIT SWITCH

........,d".,_

r--0

NORMALLY CLOSED LIMIT SWITCH HELD OPEN NORMALLY OPEN LIMIT SWITCH HELD CLOSED NORMALLY CLOSED CONTACT POINTS

___.,...._

NORMALLY OPEN CONTACT POINTS

--cn-

PL�IN CONNECTION

RJSE

-"v--

COIL (CONTACTOR COIL, SOLENOID COIL OR RELAY COIL.

---.>---

---c=J- RESISTOR

---0•l�I• 0 � •

�f--

--H-, � �

MOTOR ARMATURE INDUCTOR (MOTOR FIELD, REACTOR,CHOKE, ETC.) PERMANENT MAGNET MOTOR ACCELERATOR DIODE CAPACITOR

SENSOR TRANSISTOR HORN TWISTED PAIR WIRES ALTER THERMAL PROTECTOR

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EV T15 Control page 7

OPERATIONAL SEQUENCE #1 This standard schematic is shown with all switches and contactors in their normal 'OFF' position. No circuits are operating. The four basic areas of circuitry are identified.

TRACTION CONTROL STEER and AUXILIARY CONTROL HYDRAULIC CONTROL ACCESSORY

EV Tl5 Control page 8

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