CLARK Material Handling CTMCEM 10-20 70967101 with HPB1 - Control Training Manual

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Material Handling CTM/CEM 10-20 Lot No. 7096 / 7101

with HPB1 - Control

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Training Manual Electr. System incl. Trouble Shooting with LC-Di�play I

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SM 5167 GEF GB 02/97 Copyrighted Material lntendcd for CLARK dealer:, only Do not �ell or di!>tnbutc

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_J_J Illustrations, descriptions, diagrams and other particular only serve for elucidation and presentation of the text. They are not binding as regards details of construction, in­ stallation or delivery We do not undertake liability for conformity of the text with natio­ nal or local regulations. Subject to revision.

Copyrlght(C) 1997

by CLARK Material Handling GmbH

Copyrighted Material Intended for CLARK denier, only Do not �ell or d1�tributc

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TABLE OF CONTENTS PAGE

SECTION NAME

1

Introduction

1.1

2

Location of the components - subassemblles

2.1

Layout of HPB1 control system Layout of B1 con1rol Cable Connections - Traction Control 81 Connectors Traction Control B1 Cable Connections - Pump Control HP Connectors Pump Control HP

2.2

2.3 2.4

2.5 2.6 2.7

3

Exerpts from the spare parts catalogue

3.1

4

General repair information

4.1

5

6

Fault finding in 1he HPB1 control LC-Display unit (Dash Panel) Maintenance- and interference input Display operation Diagnostic and adjustments 1.Diagnostic truck periphery 2.Diagnos1ic pulse control S1eer wheel angle adjustment Parametertist Traction Control 81 Parameterlist Hydraulic-Pump Control Trouble-shooting Table fault r:ode

4.2 4.3 4.5 4.6

How to check lhe components

5.1 5.1 5.2

General information Annual safety check Removal control card Motors Insulation testing Current measurements Thermal protector F/A contactor Fuses Accelerator unit Sensor Wiring diagrams

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4.7

4.9 4.10 4.11 4.12 4.15 4.15

5.3

5.4 5.5 5.6 5.6

5.7 5.7 5.7 5.9 6.1

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Introduction

Starting with 1995 the lift trucks of the CTM/CEM 10-20 family will be equipped and delivered with new electronic controls (HPB1 & LT200D). These lift trucks have the Lot No. 7096 / 7101 new The respective control are located at the rear-pan of the lift truck, protected between battery and counterweight. They are directly accessible with opening the cover.

This manual describes an HPB1 microprocessor-control.

That means, that the internal operations will be controlled with an microprocessor.

The control of drive speed, hydraulic and torque ensues with transistor-technic.

The fault finding and also part of the maintenance and setting work may be done with in to the Dash Panel integrated LCD (liquid-crystal display).

The electronic components which are not part of the actual control unit itself should be also checked with the LC-Display.

The purpose of this manual is to enable service mechanics and other technically interested staff - to become familiar with the control's components, - to learn about the internal functional sequences, - to perform fault finding by using of the LC-Display and exchange the defective components.

Therefore, you wlll also find In this manual the part numbers of the control's components, which are not listed in the parts catalogue.

1.1 Copyrighted Material Intended for CLARK dealers only Do not �ell or dbtribute

Notlees

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Location of the components - subassemblies Emergency switch

Potentiometer Lift

Horn switch HS

Mikro switch Tilt,

AUX 1 and AUX 2 Key switch KS LC-Display

Micro switch forward F Micro switch reverse R 2 Handbrake switches HBS Brake fluid level switch US

Accelerator incl. Micro switch MS1 Hom incl. surpressor diode Brake pressure switch

Traction motor Pump motor incl. sensor Battery Panel with HPB1 control system Seal switch SSW

2.1

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Layout of HPB1 control system Pumpmot<>r

Tracton motor left

Trdon motor right

Emergency switch

J Pump control HP·

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Layout of B 1 control Battery connector

To Emergency switch

Fuse 2 Fu

Fuse 1 Fu

Traction control B1

2.3

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Contactor, right & left traction motor

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Cable Connections - Traction Control B1

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