CLARK FORKLIFT ET208 Troubleshooting The Curtis Control TECHNICAL TRAINING MANUAL

ET208 Troubleshooting The Curtis 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 AboutThis Class....................................................... ...................................................

CJa Objectives...........................................................................................................

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

Section 1. Overview.....................................................................................................

Control Features ........................... ................... .................................................

Multi-Modem Feature......................................................................................

Logic Control Connections (1242) ...................................................................

Logic Control Connections (1242) ...................................................................

Power Connections (1242) ...............................................................................

Power Connections (1242) ...................................... .................................... .... .

Components.....................................................................................................

Mode Select Switch......................... .................................................... ......... ... .

Section2. Programable Parameters..............................................................................

Acceleration Rate.......................................... ........ ...........................................

Maximum Speed..............................................................................................

Creep Speed......................................................................................................

Neutral Brake% ...............................................................................................

Brake Rate.................................................................................. ......................

DeccelerationRate. .... ...................................... ..... ........................ ...................

Additional Control Features.............................................................................

OutputDriver Parameters................................................................................

CheckoutProcedure.........................................................................................

BenchTesting......................................................................... ..........................

Section3. ProgrammerOperation................................................................................

Operating modes.......... ................................... .................................................

Program Mode.................................................................... .............................

TestMode.............................................................................. ...........................

DiagnosticMode............................................................................... ...............

SpecialProgramMode.....................................................................................

Controller Cloning. .................. ................................ ........... ... .................. ........

SpecialDiagnostics Mode................................................................................

Peace ofMide Programming............................................................................

Self Test...........................................................................................................

Program_merMenu...........................................................................................

TestMenu......................................... ........................................................... .....

Special ProgramMenu.....................................................................................

Diagnostic and SpecialMenu ...........................................................................

Section4. Diagnostics and Troubleshooting................................................................

ProgrammerDiagnostics........... .......... ................... ......... ............................ .....

TroubleshootingChai1 ......................................................................................

LEDDiagnostics........ ......................................................................................

Maintenance.............................................................................. .......................

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Cleaning .............. ... ... . ................................................. . ..................... . ................

Diagnostic Hjstory ...................................... .......................................................

Section 5. Programming Parameters .............................................................................

PWD Parameter ...............................................................................................

HWD Parameters ...............................................................................................

WP 40 Parameter ................ ......... .... ....... ... ... .. .................................. ............ ...

Section 6. Schematics . ... ............................................................... ..... ........... ... ...... ........

PWD Schematic ............... ................................................................... ...............

HWD Schematic ................... ......................... ........................... .........................

©Copyright CLARK Material Handling Company 1999.

Curtis 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 Custis 1242 and 1244 "SEM" Transistor Controls operates and how you can diagnose and troubleshoot problems with the control.

The Custis 1242 and 1244 Transistor Controls are "Separately Excited Motor" Controls (SEM) and consists of a logic control assembly and the electrical components it operates. The controls monitors power demands and responds by controlling the power applied to system components.

This class will cover the control system, the components it operates, how to use the Curtis programmer, and how to diagnose and troubleshoot control problems using a VOM meter as well as the programmer.

Class Objectives

There are two primary objectives for this class. Upon completion of the manual and the class you will be able to: 1. You will understand how the control operates.

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 the groundwork for problem diagnosis and troubleshooting.

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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 injw-y 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 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 and Service Manuals before you operate or repair a truck.

Curtis Control Page 4

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Section 1. Introduction to the Curtis PMC Controls Introduction to the Curtis PMC Controls

The Curtis PMC 1242 and 1244 controllers are separately excited motor speed controllers designed for use in a variety of material handling vehicles.

CLARK uses the 1242 in the PWD model and the 1244 in the HWD model.

Both controllers offer smooth, silent, cost effective control of motor speed and torque.

A four quadrant, full bridge field winding control stage is combined with a single quad­ rant armature power stage to provide solid state motor reversing and either passive regenerative or plug braking power without additional relays or contactors.

These controllers are fully programmable by means of the optional handheld 1307 programmer Clark part number 924648. Use of the programmer provides diagnostic and test capability as well as configuration flexibility.

Both controllers offer superior operator control of the vehicle's motor drive speed.

Features include:

Full-bridge field and quarter-bridge armature power MOSFET design, Providing; Infinitely variable forward, reverse, drive, and brake control Silent high frequency operation High efficiency

Programmability through the 1307 handheld programmer Complete diagnostics through the 1307 programmer and the internal Status LED Continuous armature current control, reducing arcing and brush wear Automatic braking when throttle is returned to neutral from either direction; this "neutral braking'' provides a compression braking feel and enhances safety by auto­ matically initiating braking in an operator hands off condition Allows up to four user-selectable vehicle operating personalities Meets or exceeds EEC fault detect requirements Vehicle top speed is controlled and limited in each mode Linear temperature and under voltage cutback on motor drive currents; no sudden loss of power under any thermal conditions High pedal disable (HPD) and static return to off (SRO) interlocks prevent vehicle runaway at startup Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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Emergency reverse with a single input Creep speed adjustable from 0% to 50% in each mode Continuous diagnostics during operation, with power-on self-test Internal and external watchdog circuits ensure proper software operation Fully protected inputs and short-circuit protected output drivers.

In addition the 1244 controller has: Regenerative braking, providing longer operation on a single battery charge and reducing motor brush wear and motor heating.

Deceleration Rate, Load Compensation, and Restraint features prevent downhill runaway conditions; speed is controlled to with in approximately 20% of level surface value.

Multi-Modem Feature The Multi-Modem feature of both controllers allows the operator to select up to four distinct modes, two in the PWD and Four in the HWD. These modes can be pro­ grammed to provide four different sets of operating characteristics, which can be useful for operating in different conditions-such as slow precise indoor maneuvering in one mode; faster, long distance, outdoor travel in another mode; and application-specific special conditions in the remaining two modes.

Logic Control Connections The 1242 has a 16 pin logic control connector. The 1244 has a 24 pin logic connector.

PWD 1242 A 16-pin wire connector in the controller provides the logic control connections: Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14 Pin 15 Pin 16

(Not Used) (Not Used) (Not Used) Main contactor driver output (Not Used) Accelerator input: 0-5 volts (Not Used) (Not Used) Mode Select 2 input (Turtle/Rabbit) Emergency reverse check output Reverse input Forward input Emergency reverse input (Not Used) Interlock input (Brake Switch) Key switch input (KSI)

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Tuttle/Rabbit Switch ------------Reverse Switch --------------Forward Switch --------------, Emergency Reverse Input ---------.

Brake Interlock Switch -----.

Key Switch ----------.

1

Accelerator0-5Volt ________.I Main Line Contactor Driver ______.....

PWD (1242) 16 Pin Connector HWD 1244

A24-pin wire connector in the controller provides the logic control connections: Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8 Pin9 Pin10 Pin11 Pin12 Pin13 Pin14 Pin15 Pin16 Pin17 Pin18 Pin19 Pin20 Pin21 Pin22

Key switch input (KSI) Interlock input (Brake Switch) Mode Select1 input (Walk/Ride Switch) Mode Select2 input (Turtle/Rabbit Switch) (Not Used) (Not Used) Emergency reverse input (Not Used) Coil return input Forward input Reverse input (Not Used) (Not Used) (Not Used) Accelerator input: 0-5volts (Not Used) Main contactor driver output (Not Used) (Not Used) (Not Used) (Not Used) Emergency reverse check output Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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Pin 23 Pin 24

(Not Used) (Not Used)

Accelerator O-5V0lt Main Line Contactor Driver Emergency Reverse Check Output

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Reverse Switch Forward Swi·tch Coil Return Input Emergency Reverse Input Tuttle/Rabbit Switch Walk/Ride Switch Brake Interlock Switch Key Switch

HWD (1244) 24 Pin Connector A 4-pin connector is provided on both controllers for the handheld 1307 programmer.

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If a programmer is already available but has an incompatible cable, the 1242/1244 mating cable can be ordered as a separate part:

Hand Set with Cord 924628 Cord only 924647 Curtis Control Page 8

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