CLARK FORKLIFT TM 10-16 LOT 7000 EM 10-15S LOT 7005 SERVICE MANUAL

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TM 10-16 EM 10-15S

LOT 7000 LOT 7005

TROUBLESHOOTING ELECTRICAL EQUIPMENT

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Page

INDEX

Introduction

1

Basis for successful troubleshooting

2

General troubleshooting

3

Checking the accelerator unit

•

20

•

24

Checking the mtor circuit

•

31

Checking the LED board

•

33

Checking the power unit

•

•

Checking the field weakening

36

Checking the electronically controlled steering

39

Checking the pump control

41

Testing the coRponents

•

• 43

Explosion drawings of components •

.

51

Control unit/ service tips •

.

75

.

77

Supplinent of wiring diagrams

•

•

INTRODUCTION This manual deals with the location and subsequent elimination of troubles in the electrical/electronic syster1 of the CLARK forklift truck models TM 10 - 16, Lot 7000, and EM 10 - 15S, Lot 7005.

The composition and structure of this manual enables even the untrained service technician to thoroughly check the whole system - on one condition: to follow the given scheme when troubleshooting. If the trouble­ shooting flowcharts are only used in parts or extracts, trouble­ shooting can result in wrong results and subsequently wrong con­ clusions.

The design of the troubleshooting system is based on three diffe­ rent geometrical forms, each of which stands for a different repair step. Circles are used for system entry or exit. Rectan­ gular boxes contain instructions to be carried out and rhOllbic boxes contain questions to be answered by "yes• or •no•. To start the respective section always begin with the circle •start•. Then you follow the flowchart downwards until you reach the first instruction. Thoroughly carry out all indicated steps. Continue to follow the flowchart further downwards untfl you reach a rhOllbic box. If you answer the question by "yes•, continue to follow the flowchart downwards. In case the answer is •no• follow the flow­ chart to the right until you reach the nunbered circle. The number indicates further work instructions to eliminate the trouble, which can be found at the end of the chapter. As 110st of the questions are put in away that the flowchart has to be followed in case of •yes• (•no• indicating the trouble), the answers •yes• and •no• are only indicated in the troubleshooting flowchart if the procedure is contrary to the rule.

The first section •General troubleshooting• can be used for direct troubleshooting and is also well suited for checking the electri­ cal system in the frame of a scheduled maintenance program. Always thoroughly carry out all checks and follow the given scheme.

1

BASIS FOR SUCCSESSFUL TROUBLESHOOTING Before beginning to troubleshoot, the proble11s should be discussed with the driver or another informed person. In particular, the driver should be asked whether he or anyone else has atte�pted any repairs.

Drive the truck yourself and check whether the proble�s have been correctly described.

Jack up the truck according to proper procedures and secure the rear wheels with chocks.

Follow the troubleshooting plan step by step. Do not omit any instruction, even if individual steps see11 to be superfluous.

When you have replaced a 110dule or individual component, or elimi­ nated a fault, yoo qust go back through the troobleshooting plan once again fr0111 the beginning to the end. The truck can only be released for operation again when all tests have been perfonned without problems, Reqember that when working on electrically-driven forklifts, you mst remove all rings and watches in order to ■inilli.ze the risk of an accident. The electronic �asurements included in the trouble­ shooting plan are described only as current, voltage or resistance qeasurements, because precise adjustrent specifications cannot be given due to the wide variety of fleasuring instruments used. Note that qultimeters to be used must have an input resistance of at least 20,000 ohm/volt. If th;s is not the case, your measurements possibly deviate frOCI the values to be obtained. Current measure­ ments can be carried out with a snap-on a111neter or by using a shunt.

Use only original coq>onents. The installation of other replace­ ment parts can result in longer out-of-service times, increased frequency of fault and, under some circ1.11stances, damage to the electronics, too.

When you have located the fault, you will find precise test proce­ dure for each individual c01nponent and �odule in the second part of this �anual. Test the c011ponent in accordance with the pre­ scribed procedure before you replace it.

2

GENERAL TROUBLESHOOTING Start

· Jack the drive wheels off the ground. Block the steer Apply the hand brake. Disconnect the battery.

Check for foreign eaterial in the control panel and trap­ ping of control harness.

Are the above points correct?

J

Check that all heavy cables are tightly connected.

Are all cables tight?

J

Select the resistance range on the ohmeter and •easure the resistance from all heavy cables at the connections to the vehicle chassis.

Is the resistance to the vehicle chassis greater than 30 ldl in all cases?

4

3

Connect the ohmeter across the capacitor C 1. Reverse the meter leads and repeat the measureraent. See service tips.

J

Does the meter needle first move against O o and after approx. 10 sec. return against infinite?

Measure the resistance of all fuses. See service tips.

Is the resistance of each fuse O O? J Check that the key switch is in •oFF" position, the hand brake is applied and the direction lever is in neutral.

Connect the battery connector.

Does any contactor try to close?

N

Turn the key switch to "ON" and observe the LEDs on the LED board at the steering column.

Do the green LEDs of the battery charge display light up?

Does the LED of the brake fluid display go out after approx. 5 sec.? Does the houn,eter work?

J

Forklift with weakening of field: Do the LEDs of the brush wear and temperature displays of the drive motors go out after approx. 5 sec.?

4

Press the horn button,

Does the horn sound?

J

Operate the tilt, lift (and if equipped all aux. ) levers.

Does the pump start to run during every operation?

J Push the tilt lever until the hydraulic pump runs in by­ pass. Continue to hold the tilt lever in this position for approx. 40 sec.

J

Does the battery indicator re11ain in the green area of the upper 5 LEDs? (Atleast the lowest LEO has to light up.)

Disconnect the battery and switch the key switch to "OFF".

Select the voltage range of 60 volts, the switch-over to the 15 volts range can be performed if necessary. Connect the positive •eter lead to wire 2, pin 18 of the upper logic card cable connector (connector 1) and the negative lead to fuse l FU (see service tips}. Connect the battery and switch the key switch "OH".

• 5

6

Is the reading 10 +/- 2 volts?

J Remove the testlleter and release the hand brake. With TM trucks check that the rear steer wheel is in c entral po­ sition. Move the direction lever to select the forward direction and close microswitch MS 1 at the drive control.

J

Does the F contacor c lose and remain closed?

Move the direction lever to select the reverse direction and repeat the test.

J

Does the contactor pick up and then drop out irrmediately?

Does the contactor pick up and then drop out innediately?

Does the R contactor close and remain closed?

J

Does the steering booster pump motor continue running and stop after approx. 12 sec. after opening micro-switch Ms1·

7 6