CLARK FORKLIFT ET207 Troubleshooting the CTS 450 Control TECHNICAL TRAINING MANUAL

ET207 Troubleshooting the CTS 450 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..................................................................................................

Class Objectives..................................................................................................

Class Content.....................................................................................................

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

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

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

Section 1. CTS 450 Control Sequence of Operations .....................................

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

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

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

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

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

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

Sequence 4. Parking Brake and S.R.O Checks.....................................

Sequence 5. Energizing the Power Syteering Contactor....................

Sequence 6. Tw·ning on the Traction controls......................................

Sequence 7. Brake Pedal Regen.............................................................

Sequence Sa. Regenerative Braking (Plugging)....................................

Sequence Sb. Regenerative Braking (Plugging).(Cont.)........................

Sequence 9. Steer Potentiometer Operation..........................................

General Description of the CTS 450 Controllers....................................

Section 2. Using the Handset ......................................................................

Traction Controller Function Settings..................................................

Pump Controller Function Settings.......................................................

Function Descriptions.............................................................................

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

Status code #1..........................................................................................

Status code #2 and 3................................................................................

Status code #5 and 6................................................................................

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

Status code #9 and 10..............................................................................

Status code #11 and 12............................................................................

Status code #15 and 16..........................................................................

Status code #17 and 23...........................................................................

Status code #24 and 27..........................................................................

Status code #28 and 29...........................................................................

Status code #30 and 41...........................................................................

Status code #42 and 43...........................................................................

Status code #44 and 45...........................................................................

Status code #46 and 49...........................................................................

Status code #51 and 52..........................................................................

Status code #57 and 66...........................................................................

Status code #67 and 68...........................................................................

Status code #76 and 77...........................................................................

Status code #80 and 81...................................................... ....................

Status code #84 and 90..........................................................................

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CTS 450 Control page l

Status code #91 and 92..........................................................................

Status code #93 and 94..........................................................................

Status code #95 and 99..........................................................................

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

CLARK Command Dash Schematic.......................................................

Schematic with Pump Control...............................................................

Motor Control Schematic........................................................................

CTS 450 Control Panel Assembly..........................................................

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

@Copyright Clark Material Handling Company 1998.

Revised 2000

CTS 450 Control page 2

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79 80 81 82 83 84 85 86 87

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 CTS 450 Transistor Control operates and how you can diagnose and trouble­ shoot problems with the control.

The CTS 450 Transistor Control consists of two control assemblies and the electrical components it operates. The controls monitors power demands and responds by control­ ling 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 hydraulic and accessory devices. Your knowledge of the control system, the components it operates, and how to diagnose and troubleshoot control problems helps you to keep a truck in top shape and avoid down time.

This class will also cover how to program the CTS 450 diagnostic control.

Class Objectives There are two primary objectives for this class. Upon completion of the manual and the class you will be able to: 1. Trace each sequence of operations on a basic wiring diagram as a way to demon­ strate 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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CTS 450 Control page 3

Class Content There are two major sections in this book, 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 Status Codes to assist you in troubleshooting problems Where necessary, explanations, illustrations, and testing procedures.

At the completion of the 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 effec­ tively.

For additional information, refer to service manual SM 616.

CTS 450 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 correct 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 can result in serious injury or death 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 tne truck, disconnect the battery, and discliarge the capacitor.

These actions prevent injury to yourself and damage to the truck.

Always familiarize yourself with the safety information in the Operator's and Service Manuals before you operate or repair a truck.

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CTS 450 Control page 5

Section 1. CTS 450 Control. 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-100S solid state 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: L

FWD FU p

lMS

PS REV PS PD

Line Contactor Forward Directional Switch Fuse Main Pump Contactor Master Switch Power Steering Contactor Reverse Directional Switch Steering Pump Contactor Main Pump Driver Module

CTS 450 Control page 6

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IDENTIFICATION OF SCHEMATIC SYMBOLS _____.,. ....__ MOMENTARY SWITCH � �

NORMALLY OPEN LIMIT SWITCH NORMALLY CLOSED LIMIT SWITCH

___.d'".,.._ NORMALLY CLOSED LIMIT SWITCH HELD OPEN NORMALLY OPEN LIMIT SWITCH HELD CLOSE0 ------.__....--

---+>-----cJ-----Cr

�

---©---

NORMALLY OPEN CONTACT POINTS PLUG-IN CONNECTION FUSE

RESISTOR COIL (CONT ACTOR COIL, SOLENOID COIL OR RELAY COIL: MOTOR ARMATURE

� INDUCTOR (MOTOR FIELD)

I �A � PERMANENT MAGNET MOTOR � ·i?-:--?·

ACCELERATOR

• �•

DIODE

�

1-«:>RN

-CJ-I f-

-0-

FILTER DRIVER MODULE

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CTS 450 Control page 7

Sequence #1: Normal Off State This standard TMG schematic is shown with all switches and contactors in their normal OFF po ition. No circuits are operating. The four ba ic areas of the circuitry are identified.

POWER

This area includes the contactor tips, motor cables, buss bars, motors and traction control

DIRECTIONAL This includes the forward and reverse switches, lMS switch, foot brake, and parking brake switches.

SPEED

This area includes the accelerator, steer angle potentiometer and its input into the control .

ACCESSORY

Tnis area includes the horn, horn switch, hydraulic switches, dash display, pump driver, and key switch.

CTS 450 Control page 8

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