Daewoo Doosan MicroController Control System B13T-2 to B18T-2 Testing Adjusting Manual SB2077E03 (1)

SB2077E03 Jan 2002

Specifications Systems Operation Testing & Adjusting MicroController Control System Models : B13T-2, B15T-2, B18T-2 (48V: P/N A154600, P/N A154240) (36V: P/N A154600, P/N A154701)

for Electric Lift Trucks

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skill and tools to perform these functions properly.

Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operater or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING” as shown below.

WARNING The meaning of this safety alert symbol is as follows : Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this pulication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current information available.

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Specifications

Index Specifications Component Measurements....................................... 5 Console ..................................................................... 7 Contactors................................................................. 8 Control Panel (Layout) .............................................. 9 Current Measurements ............................................. 5

Location of Control Panel Components .................. 16 Logic Unit ................................................................ 18 Operational Circuit Elements .................................. 19 Accelerator Control ............................................. 24 Battery Discharge Indicator (BDI)....................... 23 Central Vehicle Monitoring System..................... 19 Contactors .......................................................... 22 Current Sensor ................................................... 22 CVMS International Pictorial Symbols................ 21 On Board “Run Time” Diagnostics (Fault Detection) ................................................. 19 Steer Angle Control ............................................ 24 Wait Mode........................................................... 22

Direction Switch ........................................................ 7 Display Layout .......................................................... 7 Fuses ........................................................................ 8 Head Capacitor ......................................................... 8 Instrument Panel ....................................................... 7 Thermal Switch - Control Panel ................................ 8 Transistor Connections ............................................. 6 Transistor Measurements ......................................... 6

Symbol Library ........................................................ 15

Testing And Adjusting

Systems Operation

Built-In Diagnostic Operation .................................. 47 Accessing Stored Error Codes ........................... 52 Erased Stored Error Codes ................................52 “Run Time” Diagnostics (Lift Truck in Operation) ...................................... 47 Quick Diagnostic Procedure ............................... 53 Saving Service Records ..................................... 52 “Self” Diagnostics (Lift Truck not in Operation) ................................ 49 Stored Error Codes............................................. 53

Accessory Circuits .................................................. 25 DC - DC Converter ............................................. 25 Horn Circuit......................................................... 25 Hour Meter Circuit .............................................. 25 Actuation Circuit ...................................................... 26 Drive Circuit ............................................................ 34 Bypass Circuit..................................................... 39 Control Circuit ..................................................... 34 Current Limit ....................................................... 38 Electrical Braking (Plugging) .............................. 40 Failure Protection Circuit .................................... 42 Flyback Circuit .................................................... 37 Power Circuit ...................................................... 35 Thermal Protection Circuits ................................ 42

Component Tests .................................................. 105 Capacitor (Head) .............................................. 108 Conductor and Switch Continuity ..................... 108 Contactors ........................................................ 109 Contactor Components..................................... 109 Current Sensor .................................................. 111 Diode Replacement .......................................... 112 Diodes ............................................................... 112 Driver Board (Off Vehicle) ................................. 116 Driver Board (On Vehicle)................................. 113 Logic Unit Quick Reference Voltage Check ..... 105 Resistors (DR1, DR2, and PR1) ....................... 119 Thermal Switch ................................................. 120 Transistors DTR1, DTR2 and PTR1 ................. 118 Transistors Replacement DTR1, DTR2 and PTR1.................................... 118

General Information ................................................ 18 Glossary .................................................................. 11 Hydraulic Pump Motor Circuit ................................. 27 Flyback Circuit .................................................... 31 Lift Circuit............................................................ 33 Lift Control Circuit ................................................32 Power Steering Circuit .........................................27 Power Steering Idle .............................................28

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Index

Control and Power System Operational Checks .................................................................... 46 Electrical System Adjustments ...............................121 Accelerator Control Linkage ..............................121 BDI Adjustment ..................................................124 Bypass Dropout Adjustment ..............................128 Current Limit Test and Adjustment.....................127 Electrical Braking (Plugging) Current Test and Adjustment ..........................................128 Lift Sensor..........................................................122 Parking Brake Switch.........................................121 Rapid Tune - Up Procedure...............................124 Tilt and Auxiliary Switches .................................123 Valve Control Card Adjustment..........................122 Preparation Tests and Checks .................................43 Programmable Features ........................................129 Activating Default Settings.................................129 Programmable or Settable Option Features.............................................................130 Quick Procedure for Programmable Features.............................................................132 Setting Procedure Option Features ...................129 System Tests and Adjustments ..............................102 Discharging Head Capacitor (HEAD CAP) ......................................................102 Logics Removal .................................................103 “Run Time” Tests................................................103 Test Equipment ..................................................102 Troubleshooting........................................................43 Troubshooting Problem List ....................................54

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Index

Specifications Component Measurements Component

Meter

Meter Positive

Meter Negative

Scale

(+) Test Lead

(-) Test Lead

Desired Indication

DIODES (voltage indication) All

Diode

Anode

Cathode

0.3 to 0.9 volts

All

Diode

Cathode

Anode

OL

RESISTORS (resistance indication) Panels With D557003(927566) Transistor DRI, DR2, PR1

200Ω

90 ohms

L 5%

R2, R5, R9

200Ω

7.5 ohms

L 5%

HEAD CAPACITOR (resistance indication) Head capacitor

200Ω

Positive side of

Negative side of

0 then change to

capactior (+)

capactior (-)

above 10K ohms

CONTACTOR COILS (resistance indication) Direcitional

200Ω

X

Y

40 to 50 ohms

Line, Pump

200Ω

X

Y

95 to 115 ohms

Bypass

200Ω

X

Y

40 to 50 ohms

Current Measurements CURRENT VALUES (AMPS) Transistor

Current Limit

Plugging Limit

D557003 (927566)

250 L 10A

250 L 10A

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Specifications

Transistor Measurements SPECIFICATIONS Multimeter

(+)

(-)

D557003 (927566)

Setting

Test Lead

Test Lead

Results

Resistance

Emitter

Base

45 to 135 ohms

Diode

Base

Collector

.3 to .9V

Diode

Collector

Base

OL

Diode

Emitter

Collector

.3 to .9V

Diode

Collector

Emitter

OL

Transistor Connections D557065 - for Pump(36V)

D557003 (927566)-for Pump(48V)

2

1

1 2

3 3

(1) Emitter connection (2) Base connection (3) Collector connection

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Specifications

Display Layout

Console

1

Instrument Panel (1) Tighten bolts that fasten the cover to a torque of ............................1.5 to 2.5 N•m (13 to 22 lb•in)

Direction Switch

1

1

2

(1) Tighten screws that fasten the instrument panel to a torque of ....................................0.5 to 0.7 N•m (4 to 6 lb•in) (1) Torque bolts that hold bracket to steering column to ................2.8 to 3.4 N•m (25 to 31 lb•in) (2) Torque bolts that hold bracket to switch to ............................143.4 to 3.9 N•m (31 to 35 lb•in)

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Specifications

Head Capacitor

Thermal Switch - Control Panel Contacts open at ................81 to 89°C (178 to 192˚F) Contacts close at................69 to 77°C (156 to 171˚F)

1

3

2

Contactors

4

Torque for nuts that hold contactor bridge assembly .........................................2.2 N•m (20 lb•in)

5

Fuses Line .....................................................................600A Pump ...................................................................150A Key ....................................................................... 10A Horn...................................................................... 10A Voltage Converter................................................. 10A Light...................................................................... 10A Back up ................................................................ 10A

NOTE : Proper torque and assembly of capacitor hardware is critical. Avoid disassembly unless capacitor has to be replaced.

(1) Tighten capacitor terminal bolt to a torque of.............................4.5 to 5.5 N•m (40 to 50 lb•in) (2) Spring washer D917069.

(3) Ring terminal of wire assembly.

(4) Lockwasher D917071.

(5) Head capacitor terminal.

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Specifications

Control Panel (Layout) Control Panel - Drive 2

3

4

6

7

11

1 12

5

2

2

8

10

9

Control Panel - Pump (48V)

3

2

6

10

9

1

11

2

5

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7

9

12

Specifications

Control Panel - Pump (36V) 12

3

10

9

2 4 7

1

5

11

6

11

NOTE : Apply a small amount of D557047 Thermal Joint Compound on the surface of the transistor, diode or thermal switch that contacts the heatsink.

(7) Tighten diodes DD1, DD2, DD3, DD4 and PD to a torque of ......................9 to 11 N•m (81 to 99 lb•in) (8) Tighten Head Capacitor terminal bolts to a torque of ............................4.5 to 5.5 N•m (40 to 50 lb•in)

(1) Control panel plate. Apply a small amount of D557047 Thermal Joint Compound on control panel plate and mating surface prior to assembly.

(9) Tighten all bolts that fasten bus bars of cables to either heatsink to a torque of ................................5.5 to 9.5 N•m (50 to 85 lb•in)

(2) Apply Sealant (Loctite catalogue No. and nameNo. 242, Adhesive/Sealant) on the threads of all screws that are used to fasten components on the control panel.

(10) Tighten bolts that hold the negative heatsink to the control panel to a torque of .......10 to 14 N•m (90 to 125 lb•in)

(3) Apply Sealant (Loctite catalogue No. and nameNo. 242, Adhesive/Sealant) to the bolts used to tighten the positive heatsink to the control panel to a torque of ..........10 to 14 N•m (90 to 125 lb•in)

(11) Apply Sealant (Loctite catalogue No. and nameNo. 242, Adhesive/Sealant) on portion of setscrew threads that are in the insulator and control panel plate. Tighten bolts to a torque of ................................5.5 to 9.5 N•m (50 to 85 lb•in)

(4) Use a backup wrench to hold nuts and tighten bolts the fasten bus bars to the power transistors to a torque of ...............4 to 6 N•m (35 to 55 lb•in)

(12) Use a backup wrench to hold bolts and tighten the nuts that fasten the cables or bus bars to the contactors to a torque of .....................4 to 6 N•m (35 to 55 lb•in)

(5) Tighten screws that fasten power transistors to positive heatsink to a torque of ......................................4 to 6 N•m (35 to 55 lb•in) (6) Tighten screws that fasten wires to the base of the power transistors to a torque of .............................1.3 to 1.7 N•m (11.5 to 15 lb•in) MicroController Control Systems

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Specifications

Systems Operation Glossary NAME

DESCRIPTION

Accelerator

A device that converts mechanical movement into a analog voltage pattern to the logics for variable drive motor speed.

Activate

Word used with a component or circuit. To change from the normal condition to the “activated” condition because of an application of force or electricity.

Ammeter

An electric meter used to measure current flow in amperes.

Ampere (or Amp)

The unit of measurement of current flow. The amount of current that one volt can push through a resistance of one ohm.

Analog to Digital Converter

A device that converts an analog voltage into a pattern of digital HIGH and LOW voltage signals.

Anode

The positive (+) side of a diode.

Armature

The rotating portion of an electric motor or generator.

Base

The terminal of a transistor through which control current flows (see Transistor).

Battery

Two or more cells connected together for a supply of electric current.

BDI

Battery Discharge Indicator - An electrically controlled display showing the operator the state of battery charge.

Brush

A conductor, normally a block of carbon, that makes sliding contact between the stationary and moving part of the motor or generator.

Bus Bar

A heavy electrical conductor to which other smaller wires are connected.

Capacitor

Device used to store electrical energy for short periods of time.

Cathode

The negative (-) side of a diode.

CVMS

Central Vehicle Monitoring System.

Circuit

A way for current to go from the positive (+) side of an electrical power source to the negative (-) side of an electrical power source. This can be through wires and electrical components.

Coil

A component made from many circles or turns of wire used to concentrate a magnetic field.

Collector

A terminal of a transistor through which main current flows (see Transistor).

Commutator

An armature component used to transfer current from the brushes to the armature windings.

Conduct

To allow the flow of current.

Conductor

A material that provides a path for current flow.

Connector

Part of a wire assembly or harness that connects with another wire assembly or harness. Used for ease of assembly and disassembly.

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Systems Operation

NAME

DESCRIPTION

Contactor Assembly

An electrical component consisting of an electromagnetic coil and a set of heavy contact tips. Control current passes through the coil, building a magnetic field which closes or opens the contact tips.

Contactor Coil

An electromagnet used to close or open contact tips in a contactor assembly.

Contact Tips or Contacts

The portion of a switch, relay or contactor where the circuit can be opened or closed.

Continuity

Having the ability to allow current flow.

Control Circuits

The wires and components carrying low current used to signal the logic unit, turn on main components, or support auxiliary circuits (indicated by narrow lines on a schmatic).

Counter Electromotive Force (CEMF)

An opposing voltage set up by a collapsing or increasing magnetic field within a coil.

Current

The movement or flow of electricity through a conductor. A circuit must be complete for current to flow.

Current Limit

The maximum allowable armature current of a stalled drive motor during pulsing.

Current Sensor

A hall-effect sensor in the drive motor circuit that produces an increasing voltage output as the drive motor current increases.

Deactivate

To change from the activated condition back to the normal (deactivated) condition.

It can be caused by the application of force, the removal of force,or the removal of electricity.

Digital Signal

A signal in which the elements may be either of two distinct values. For example high voltage, low voltage.

Diode

A semiconductor device that allows current to flow in one direction, from the anode to the cathode.

Display

An electrical device that converts voltage inputs to a visual output.

Electrical Braking

Electrically trying to rotate the drive motor opposite to the direction of truck movement.

Electromagnet

A coil of wire, most often wound on an iron core, which produces a strong magnetic field when current is sent through the coil.

Electromotive Force (EMF)

The force that causes an electric current to flow in a circuit. This force is measured in volts.

Emitter

A terminal of a transistor through which low control current and main current flow (see Transistor).

Field Windings

The stationary coils that produce a magnetic field in motors and generators.

Filter

An electrical device or component for restriction or suppression of undesired voltage spikes.

Fuse

A component in an electrical circuit that will open the circuit if too much current goes through it.

Harness

An assembly made of two or more wires that are held together.

Heat Sink

A mounting frame used for semiconductor cooling.

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Systems Operation

NAME

DESCRIPTION

Hour Meter

An electrically activated device used to record the amount of usage a truck receives.

Indicator

LCD that gives an indication of some vehicle condition when it turns on or flashes.

Input

A voltage change at the incoming connection of a component.

Insulator

A material that has a very large resistance so that it will not let current flow through it.

LCD

Liquid Crystal Display.

Logics or Logic Unit

The main printed circuit board containing a microprocessor and circuits to condition the voltage signals that go into or come out of the logics. It electronically monitors and controls the truck's functions.

Magnetic Field

The area around a magnet where magnetic forces can be detected.

Microprocessor

A small computer chip preprogrammed to control the various electrical functions on a lift truck.

Normal Condition

Words used with a switch or relay. Their normal condition is their condition when they are not controlled by the application of force, temperature, pressure, or electricity.

Normally Close (N.C.)

A switch or relay whose contacts are closed in the normal condition.

Normally Open (N.O.)

A switch or relay whose contacts are opened in the normal condition.

OFF-Time

The amount of time current does not flow through a transistor.

Ohm

The unit of measurement of resistance. The amount of resistance that will let one volt push only one ampere of current through it.

ON-Time

The amount of time current flows through a transistor.

Open Circuit

Wiring or components of a circuit that have no continuity.

Output

The current flow from a component which initiated from a voltage change at the component's input.

Overload

The presence of voltage or current which is greater than an electrical circuit or component is designed to handle.

Pin

The male contact of a connector that fits into a female contact (socket) of another connector.

Plugging

A portion of electrical braking where the generated current is directed back through the armature.

Plugging Current Limit

The maximum allowable current at the drive motor armature during the plugging portion of electrical braking.

Potentiometer

An adjustable resistor to preset electronic controls for proper specifications.

Power Circuits

The main current carrying components and conductors (indicated by the heavy lines on a schematic).

Power Transistor

A component in the power circuit which allows main motor current to pass through when turned on.

Pulsing

Current flow in a circuit being turned on and off.

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Systems Operation

NAME

DESCRIPTION

Relay

An electrical component consisting of an electromagnetic coil and a set of small contact tips. Control current passes through the coil, building a magnetic field which closes or opens the contact tips. When the contact tips are closed, low current can flow in a separate isolated circuit.

Resistor

A component made of a material that has a specific resistance to the flow of current.

Schematic

A line drawing of an electrical or electronic assembly which uses symbols to show individual components. It shows how the components, wires and connectors function electrically.

Semiconductor

Components such as, transistors, diodes, thyristors, etc. Having electrical characteristics between a conductor and an insulator.

Series Wound Motor

A motor in which the armature is connected in series with the field windings.

Short Circuit

An electrical connection between two or more components that is not desired.

Socket

The female contact of a connector that slips over a male contact (pin) of another connector.

Solid State

Reference to semiconductor components or circuits that use semiconductor components that have no moving parts, such as diodes and transistors.

Switch

A component used to control an electric circuit . It can close or open a circuit.

Systems

The electrical components, circuits, and connections that deliver power to perform specific tasks.

Terminal

An electrical connection point on an electrical component.

Thermal Switch

A switch that activates at a set temperature.

Transistor

A semiconductor component used in electric lift trucks as an electronic switch. A transistor most often has three terminals, a base (B), a collector (C) and an emitter (E). The main current flow is between the collector and emitter. This main current flow is controlled by a much smaller current flow between the base and emitter.

Turn ON

When an electrical component conducts current.

Varistor

A component terminated across the horn connections to eliminate voltage spikes when the horn is activated.

Volt

The unit of measurement of electromotive force. One volt is the force needed to make one ampere of current flow through one ohm of resistance in a circuit.

Watt

The unit of measurement of power. The amount of power used when one volt pushes one ampere of current through a resistance of one ohm. The result of amperes (current) multiplied by volts (voltage) is watts (power).

Wire

A conductor used to provide a path for current to flow to and from electrical components.

Wiring Diagram

A drawing using visual representation of components the way they actually look. It is used to show the locations of components and the connections between them.

Zener Diode

A special diode used to regulate voltage or as an overvoltage (too high a voltage) protector.

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Systems Operation

Symbol Library

2

3

4

6

5

9 16

7

8

1

10

17 21 11

12

13

18 14 15 20 19

Schematic Symbols (1) Power Transistor. (2) Zener Diode. (3) NPN Transistor. (4) PNP Transistor. (5) Thermal Switch. (6) Battery. (7) Resistor.

(8) Diode. (9) Normally Close Contacts. (10) Normally Open Contacts. (11) Male Terminal of Connector (pin).

(12) Female Terminal of Connector (socket). (13) Wire Connection. (14) No wire Connection. (15) Contactor Coil.

(16) Current Sensor. (17) Armature. (18) Field windings. (19) Capacitor. (20) Fuse. (21) Switch.

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Systems Operation

Location of Control Panel Components Control Panel - Drive

3

4

1 5 2

6

Control Panel - Pump (48V) 8

9

10

11

7

13

14

12

MicroController Control Panel (1) Logic Unit (Logics). (2) DR1, DR2. (3) Key Fuse. (4) Bypass Contactor. (5) Right Dir. Contactor. (6) Left Dir. Contactor. (7) PR1 (8) Board as – HYD. (9) Thermal Switch – HYD. (10) Fuse – HYD. (11) Line Fuse. (12) Line Contactor.

(13) PTR1 (Pump Transistor one). (14) PD (Pump Diode) Flyback Diode.

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16

Systems Operation

Control Panel - Pump (36V) 8

9

13

25

7 14

12

10

11

Behind Logic Unit

16

17

18

19

20

15

24

23

22

21

Components Behind Logic Unit (1) (15) Head Capacitor. (16) Drive Board. (17) DTR2 (Drive Transistor Two). (18) Thermal Switch.

(19) DD3 (Drive Diode Three) Flyback Diode. (20) DD1 (Drive Diode One) Flyback Diode. (21) Current Sensors.

(22) DD2 (drive Diode Two) Plugging Diode. (23) DD4 (Drive Diode Four) Plugging Diode. (24) DTR1 (Drive Transistor One).

(25) Pump Bypass Contactor(36V only)

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Systems Operation

General Information The speed of the hydraulic pump motor is controlled by switch inputs to and outputs from the logics.

Outputs pulses the hydraulic pump power transistor.

The power transistor pulse to control the speed of the hydraulic pump motor. To provide full speed the logics turns the power transistor ON 100%. The hydraulic pump system includes a failure protection circuit to protect against malfunctions of the power circuit.

The MicroControl Panel is the control center and the Logic Unit (logics) is the decision making part of the MicroController System. The logics provide a self contained Battery Discharge Indicator (BDI) with lift interrupt and built-in diagnostic capabilities. The battery charge state and built-in diagnostic are monitored by the logics and displayed by the Central Vehicle Monitoring System (CVMS) located on the steer console.

Thermal protection circuits are used on the hydraulic pump motor, the drive motor and the control panel to prevent permanent damage caused by over heating.

NOTICE Damage to all motors and control panels will result. The motors and control panels are 48 volt unit and must be operated at their designed voltage. The voltage can not be changed without changing motors and control panel.

Logic Unit

The steering system is activated when the truck is powered up and the line contactor closes. The truck uses a combined power steering/hydraulic system where the hydraulic fluid for steering is provided by a DC series hydraulic motor, pump, and priority valve.

1

12 11 10 9 8

The drive motor and the hydraulic pump motor are controlled by pulsing transistors ON and OFF and controlling contactor operation.

The speed and direction of the drive motor are controlled by voltage inputs to and outputs from the logics. Inputs to the logics are generated by the accelerator control and direction switch. Outputs from the logics control contactor coils and drive transistor pulsing.

4

3

2

5 6 7

Components on Logic Unit (1) Connector P1 (2) Connector P2 (3) Connector P9 (4) Connector P8 (5) DIAG/RUN/SETUP (6) Jumper JP1 - 36 V (7) Jumper JP2 - 48 V (8) VR1 potentiometer - Drive current limit adjustment (9) VR2 potentiometer - Plugging current limit adjustment (10) VR5 potentiometer - BDI adjustment (11) VR6 potentiometer - Bypass dropout adjustment (12) VR8 potentiometer - Electrical Assist Brake adjustment

The drive circuit pulses transistors to provide travel speed control up to 90% of full speed, after which the bypass contactor closes to provide full speed. The drive circuit includes a failure protection circuit which detects malfunctions of the drive power circuit, a plugging circuit to provide electrical braking and a current limit circuit to prevent excessively high currents during transistor pulsing.

NOTE: When you change voltage jumper (JP1 JP2), you should do the default setting on page 129.

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Systems Operation

Operational Circuit Elements

On Board “Run Time” Diagnostics (Fault Detection)

Central Vehicle Monitoring System

“Run Time” diagnostics use letters and numbers on the seven segment LCD portion of the CVMS, International Pictorial Symbols and LCD to signal both improper operating sequences and truck circuit defects.

The Central Vehicle Monitoring System (CVMS) is located on the steering console.

It is a self contained, solidstate instrument panel with two seven segment liquid crystal displays, warning and system condition segments.

The LCD consists of seven segments which are turned on or off to form numbers and letters.

Display = “EE” Static Return to Off (SRO) The logics has a Static Return to Off (SRO) circuit which assures that the direction switch has been returned to neutral and the accelerator returned to the full up position after the key and seat switch are closed. This safeguards against an accidental actuation of direction and speed when an operator resumes operation of an idle truck.

If SRO occurs, the direction lever can be moved to neutral and the accelerator pedal released.

The direction can now be reselected and the accelerator pedal depressed to start normal lift truck drive operation.

Display = “EE” (Flashing) Seat Circuit Problem Anytime the battery is connected, the key is turned to ON and no one is in the seat longer than 6 seconds the letter “EE” will flash on and off.

The truck will not operate until the seat switch is closed.

Seven Segment Display Layout

The Central Vehicle Monitoring System interacts with the logics and failure detection circuits.

It functions as a battery discharge indicator (BDI) and provides on-board diagnostic data on the operational condition of the truck.

During normal operation it provides “Run Time” diagnostics, and during troubleshooting it provides “Self” diagnostics.

Display = “E1” Drive Motor Brush Problem The logics monitor the length of the brushes in the drive motors. As the brushes wear, a wire built into the brushes moves down and makes contact with the commutator. A wire from each motor brush set is connected to the logics. If any brushes wear down to a preset limit, an “E1” will display on the LCD. Display = “E2” Pump Motor Brush Problem The logics monitor the length of the brushes in the pump motor. As the brushes wear, a wire built into the brushes moves down and makes contact with the commutator. A wire from each motor brush set is connected to the logics. If any brushes wear down to a preset limit, an “E2” will display on the LCD.

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19

Systems Operation

Display = “EL” Battery Lock-out

Display = “F5” Drive System Problem (Left)

When the battery is discharged, the CVMS displays “EL” and pump motor will not operate. If key switch turn off and then on, pump will operate for only 3 seconds. Drive motor speed will not exceed 70% of the max. regardless of an accelerator’s output voltage.

The logics at P9-5 uses wire #L64 from the emitter of the left drive transistor to detect battery negative. The logics sends a test pulse out to the left drive transistor when power up. This test pulse is detected at P9-5 also. If battery negative is present or the test pulse is not detected, the line contactor will be deactivated and an “F5” will display on the LCD.

Display = “F2” Drive System Problem (Left) Display = “F5” (Flashing) Drive System Problem (Right)

The logics at P9-5 uses wire #L64 from the emitter of the left drive transistor to detect if the left drive transistor, bypass contactor tips or the driver board are shorted. In normal operation P9-5 has battery voltage only when the logics is pulsing the left drive transistor or the bypass contactor is activated.

When a failure occurs the line contactor will be deactivated and an “F2” will display on the LCD.

The logics at P9-6 uses wire #R64 from the emitter of the right drive transistor to detect battery negative.

The logics sends a test pulse out to the right drive transistor when power up. This test pulse is detected at P9-6 also. If battery negative is present or the test pulse is not detected, the line contactor will be deactivated and an “F5” will flash on the LCD.

Display = “F2” (Flashing) Drive System Problem (Right)

Display = “F6” Pump System Problem

The logics at P9-6 uses wire #R64 from the emitter of the right drive transistor to detect if the right drive transistor, bypass contactor tips or the driver board are shorted. In normal operation P9-6 has battery voltage only when the logics is pulsing the right drive transistor or the bypass contactor is activated. When a failure occurs the line contactor will be deactivated and an “F2” will flash on the LCD.

The logics at P9-7 uses wire #74 from the emitter of the pump transistor to detect battery negative.

The logics sends a test pulse out to the pump transistor when power up. This test pulse is detected at P9-7 also. If battery negative is present or the test pulse is not detected the line contactor will be deactivated and an “F6” will display on the LCD. Display = “F7” Drive and Pump System Problem

Display = “F3” Pump System Problem The logics will release the line contactor and display “F7” on the LCD when BOTH wires #64 and #74 detect battery negative or do not detect the proper pulsing.

See “F5”, “F5” (Flashing) and “F6”.

The logics at P9-7 uses wire #74 from the emitter of the pump transistor to detect if the pump transistor or the driver board are shorted.

In normal operation P9-7 has battery voltage only when the logics is pulsing the pump transistor is activated. When a failure occurs the line contactor will be deactivated and an “F3” will display on the LCD.

Display = “FA” Angle Circuit Problem Steer angle commands are monitored by the logics.

If steer angle switch has defects or each wires #50, 51, 52 and 53 is shorted/opened, the line contactor will be deactivated and an “FA” will display on the LCD.

Display = “F4” Drive and Pump System Problem The logics will release the line contactor and display “F4” on the LCD when BOTH wires #64 and #74 detect battery voltage when it should not be present.

See “F2”, “F2” (Flashing) and “F3”.

MicroController Control Systems

20

Systems Operation

Display = “Fb” Battery Mismatch

Central Vehicle Monitoring System (CVMS) International Pictorial Symbols

The motors and control panels are 48 volt (or 36 volt) units and must be operated at 48 volt(or 36 volt) . If battery condition is abnormal, an “Fb” will display on the LCD. Refer to problem 42 in troubleshooting.

Park Brake Symbol

Display = “Fd” Pressure Switch Problem The logics at P 2-1 uses wire #41 from the pressure switch to detect if the pressure switch is opened for more than 10 seconds after the key switch ON. The “Fd” will be displayed and the truck will be operated normally.

Park Brake Symbol

If the park brake is applied, the park brake symbol will turn on to warn the operator that the brake is applied, and drive operation will be prevented.

Overtemperature Symbol Normally closed thermal switches are constantly monitored by the logics and the CVMS. All these thermal switches are normally closed, so must open for the LCD to turn on. Truck performance will automatically be cut back by the logics, and the CVMS will light the LCD until the component cools.

Control Panel Overtemperature Symbol

Control Panel Overtemperature Symbol

Two thermal switches (HYD and MAIN control panels) are connected in series to the logics. If any of the control panels overheat, the thermal switch in the center of the positive heatsink will open. The logics will slow lifting speeds and reduce drive speed.

Truck acceleration will decrease.

The overtemperature symbol and “Ec” will display on until the controller cools. “Ec” will be saved as stored error code.

MicroController Control Systems

21

Systems Operation

Drive Motor Overtemperature Symbol

Wait Mode If the seat switch is closed, key turned to ON and the direction lever is left in neutral with no other operator requests, the line contactor will deactivate after approximately six seconds. The LCD will display “PP”. The lift truck will remain in this condition until the operator activates the direction switch, accelerator pedal or a control valve lever. The line contactor then reactivates and the truck is ready for normal operatation.

Drive Motor Overtemperature Symbol

Current Sensor The drive motor thermal switch, held against the drive motor field, will open if the motor gets too hot.

The logics will reduce drive pulsing and prevent the bypass contactor from pulling in. The truck speed and acceleration will be reduced.

The overtemperature symbol and “Ed” will display on until the motor cools. “Ed” will be saved as stored error code.

The left current sensor mounts around the cable that carries left drive motor current. The logics supplies a constant voltage to one lead of the current sensor at P1-16 wire #25 (12V). A second lead of the current sensor is connected to battery negative at the negative heatsink. When current passes through the cable, the third current sensor lead wire #L22 causes the voltage to change at logic P1-12. As the current passing through the cable increases, the voltage at logic P1-12 increases. The logics uses the voltage at P1-12 to determine the amount of current flowing through the left drive motor.

Pump Motor Overtemperature Symbol

The right current sensor, similar to the left current sensor, mounts around the cable that carries right drive motor current. A third lead of the right current sensor is connected to logics at P1-13 #R22. The logics uses the voltage at P1-13 to determine the amount of current flowing through the right drive motor.

Pump Motor Overtemperature Symbol

Contactors

The pump motor thermal switch, similar to the drive motor thermal switch, will open if the motor gets too hot. The logics will reduce pump motor speeds.

The overtemperature symbol and “EP” will display on until the pump motor cools. “EP” will be saved as stored error code.

MicroController Control Systems

The control panel is equipped with intermittent duty contactors. The logics controls the voltage supplied to the coils. When a contactor is first activated, full battery voltage is supplied to the coil. After the contactor tips have closed, the logics will pulse the coil to reduce the voltage across the coil to between 18 and 36 volts.

22

Systems Operation

Battery Discharge Indicator (BDI)

BATTERY TERMINAL VOLTAGE BAR SYMBOLS

The logics monitors the battery voltage during truck operation and shows the level of battery charge on the LCD. If the battery voltage is below 40.0V or above 60.0V, this is a battery mismatch or misconnection. If these voltages are monitored, the display will show “Fb” on the LCD and no lift truck operate.

TYPE 1 (OPT) : Closed Voltage

DISPLAY

Full 6 bars on the LCD indicates a fully charged battery. As the battery discharges, the bars decreases to 5, 4 etc, down to 1st bottom bar.

When the battery nears the 80% discharge level, the 1st bar continuously flashes. This is a warning that lift interrupt is near. The operator should complete the current lift operation and travel to the battery replacement or charge area. If the truck is kept in operation, the display go to a “EL”. The lift, tilt and auxiliary functions will be vastly reduced in speed, operating only with steering flows and the vehicle travel speed will be cut in harf. At this point the battery is greater than 80% discharged. The logics will now remember that the battery has been discharged to lift interrupt and require a fully charged battery to reset the remembered interrupt. See Programmable Option Features “3”.

36V

48V

6

above 37.2

above 49.1

5

36.8 to 37.2

48.6 to 49.1

4

36.4 to 36.7

48.0 to 48.5

3

36.0 to 36.3

47.5 to 47.9

2

35.6 to 35.9

47.0 to 47.4

1

35.2 to 35.5

46.5 to 46.9

1*

25.8 to 35.1

33.8 to 46.4

O/EL

below 25.8

below 33.8

1* = Display is flashing

BATTERY TERMINAL VOLTAGE BAR SYMBOLS

TYPE 2 (STD) : Closed Voltage

DISPLAY

Due to different voltage characteristic of battery technologies, it may be necessary to use the battery voltage chart as shown below. You can choose a type in Programmable Option Features “10”.

36V

48V

6

above 37.2

above 49.1

5

36.8 to 37.2

48.4 to 49.1

4

36.3 to 36.7

47.7 to 48.3

3

35.9 to 36.2

47.1 to 47.6

2

35.4 to 35.8

46.4 to 47.0

1

35.0 to 35.3

45.9 to 46.3

1*

34.5 to 34.9

45.0 to 45.8

O/EL

below 34.5

below 45.0

1* = Display is flashing

Descriptions of BDI symbol on the LCD Bar Symbols

BATTERY TERMINAL VOLTAGE BAR SYMBOLS 6 : The highest position

: Max. charged status

TYPE 3 (OPT) : Closed Voltage

DISPLAY

5:

36V

48V

6

above 37.2

above 49.1

4:

5

36.9 to 37.2

48.3 to 49.1

3:

4

36.6 to 36.8

47.4 to 48.2

3

36.3 to 36.5

46.6 to 47.3

2

35.9 to 36.2

45.7 to 46.5

1

35.6 to 35.8

44.9 to 45.6

1*

35.3 to 35.5

44.0 to 44.8

O/EL

below 35.3

below 44.0

2: 1:

: A) Not flashing B) Flashing - 80% discharge warning.

1* = Display is flashing

MicroController Control Systems

23

Systems Operation

Accelerator Control

Steer Angle Control

Accelerator Table

Two drive motors are controlled independently according to steer wheel position. A direction of drive motors is determined with wheel angle as shown in the chart.

OUTPUT VOLTAGE

REMARKS

OVER

ACCELERATOR CIRCUIT

11.00

DEFECT

9.60

BYPASS OPERATION DRIVE SPEED (100%)

9.02 8.44 7.86 7.28 6.70 6.12 5.54 4.96 4.38 3.80 3.22 2.64 2.06 1.48 0.90 0.00

WHEEL ANGLE

DRIVE SPEED STEP 14 DRIVE SPEED STEP 13 **DEAD ZONE I** DRIVE SPEED STEP 12 DRIVE SPEED STEP 11 DRIVE SPEED STEP 10

ON - TIME(%) P2-17 P2-18

P2-19 P2-20

-90°

LOW

HIGH HIGH HIGH

-75°

LOW

HIGH HIGH

-45°

LOW

HIGH

L 25° LOW +45°

HIGH

LEFT RIGHT (-)50

50

LOW

0

75

LOW

LOW

75

100

LOW

LOW

LOW

100

100

LOW

LOW

LOW

100

75

+75°

HIGH HIGH

LOW

LOW

75

0

+90°

HIGH HIGH

LOW

HIGH

50

(-)50

(–) means that the motor will turn opposite direction.

DRIVE SPEED STEP 9 DRIVE SPEED STEP 8 DRIVE SPEED STEP 7 DRIVE SPEED STEP 6 DRIVE SPEED STEP 5 DRIVE SPEED STEP 4 DRIVE SPEED STEP 3 DRIVE SPEED STEP 2 DRIVE SPEED STEP 1 DRIVE SPEED STEP 0 **DEAD ZONE II**

i) DEAD ZONE I In order to eliminate the bypass contactor chattering, the bypass contactor will be engaged if the accelerator output voltage is over than 9.6V. But the bypass contactor should be disengaged if the accelerator output is less than 9.02V. ii) DEAD ZONE II In order to eliminate the direction contactors chattering, the direction contactors will be engaged if the accelerator output voltage is over than 1.48V. But the direction contactors should be disengaged if the accelerator output is less than 0.9V.

MicroController Control Systems

24

Systems Operation

Accessory Circuits Horn Circuit The 12 volt output of the converter is protected against short circuits and overloading by an internal 15 amp current limit circuit. A fuse on the converter protects it from reverse connection of the battery voltage.

The horn will operate when the battery is connected and the horn button is pushed. Current flows from battery positive through horn fuse, horn switch and horn, back to battery negative.

Refer to Problem 31 in Troubleshooting section.

Hour Meter Circuit The hour meter, dependent on marketplace, can be wired a number of different ways. Battery voltage is always supplied from the key switch to the positive terminal of the hourmeter. The negative terminal of the hourmeter can go to seat switch to record seat switch hours, or can be wired into the drive motor armature through a diode assembly to record drive motor hours.

NOTICE Do not connect the 12volt negative output of the DC-DC converter to battery negative. Damage to system components could occur.

DC-DC Converter

DC-DC Converter Circuit System

The DC-DC converter changes the lift truck battery voltage to 12 volts. This 12 volts is used to power accessories such as floodlights, brakes/side lights and backup alarms.

The positive of the 12 volt output is common to the positive of the battery voltage. The negative of the 12 volt output is pulsed to maintain a steady 12 volt supply.

MicroController Control Systems

25

Systems Operation

Actuation Circuit

Actuation Circuit

NOTE: The circuit diagrams have shaded lines for illustration of current flow in each circuit.

Other circuits can be activated at the same time, but each one is shown separately to illustrate current flow in each individual circuit.

When the battery is connected and the key switch is closed, current flows from battery positive through the key fuse, key switch, wire #5 to the logic connector P1-1 and P1-2.

The logic connection to battery negative is at P1-19 and P1-20. The logic circuits are powered up to accept voltage inputs and create voltage outputs whenever the battery is connected and the key is turned to ON.

This circuit supplies power to the MicroController Control System and the Central Vehicle Monitoring System (CVMS). It must be activated before power steering, hydraulics or drive will operate.

MicroController Control Systems

26

Systems Operation

The Central Vehicle Monitoring System (CVMS) is also powered at this time. The CVMS first does a “LCD test” which will light all the warning lights through 6 shield wires, wire #101(5V) and wire #108 (B-) for approximately five seconds.

Hydraulic Pump Motor Circuit Only one hydraulic pump motor (series winding) is used for all power steering, lift, tilt and auxiliary hydraulic functions. To activate the pump circuit, the seat switch, key switch and line contactor must be closed first as explained in the topic, Actuation Circuit.

The logics will start to perform a set of “Run Time” diagnostic checks. The letter “EE” will flash on the CVMS display indicating the key is ON with no operator in the seat.

When the seat switch is closed, current will flow from the logic P2-7 through the seat switch to battery negative. The logics then activates the line contactor by allowing current to flow from P1-3 through the line contactor coil and P1-4 back to battery negative.

Power Steering Circuit

With the line contactor tips closed the logics continues its checks for any “Run Time” faults.

If no faults are detected the display will indicate the battery charge level, the power steering (IDLE) system operates, the pump and drive power circuits receive battery voltage and the logics receives battery voltage on wire #4 at P9-9.

Followings are standard PTR1 pulsing rates of the signal at the logics.

The power steering (PS) circuit has two speeds (PS idle and PS boost-up) independent of the lifting speeds.

Motor Speed

PTR1 Pulsing Rate

Logic Pin#

IDLE

11%

–

POWER STEERING

23%

P2-1

TILT

50%

P2-2

LIFT1

35%

LIFT2

50%

LIFT3

95%

AUX1

50%

P2-2

AUX2

45%

P2-16

P2-3 & P2-4

The above pulsing rate can be adjustable in “Programmable Option Features”.

NOTE: The circuit diagrams have shaded lines for illustration of current flow in each circuit.

Other circuits can be activated at the same time, but each one is shown separately to illustrate current flow in each individual circuit.

MicroController Control Systems

27

Systems Operation

Power Steering Idle Transistor PTR1 Pulsing

TR5 Base Input Signal

After the line contactor is closed the logics generates a positive pulsing signal (approximately 0.7 volts) on P9-3 to the base of transistor TR5. This is a rapidly changing signal that can only be viewed on an oscilloscope. Because TR5 is a NPN type transistor, the positive signal into the base causes current flow through the base/emitter junction. When current flows through the base/emitter junction the transistor turns ON and main current will flow through the collector/emitter junction. If the base signal from the

MicroController Control Systems

logics is ON at TR5, TR5 will be ON. When the base signal is OFF, TR5 will be OFF.

28

Systems Operation

TR6 Base Input Signal, TR5 ON

When TR5 is ON, current flows through the emitter/base junction of transistor TR6, through PR1 and TR5 to battery negative. Because TR6 is a PNP type transistor, the current flow to battery negative through the emitter/base junction causes TR6 to turn ON. When TR5 is OFF, TR6 is OFF.

MicroController Control Systems

29

Systems Operation

PTR1 Base Input Signal, TR5 and TR6 ON

When TR6 is ON, current flows through TR6 into the base of transistor PTR1. This puts a voltage signal at the base of PTR1 causing PTR1 to turn ON. With PTR1 ON, high amperage motor current can flow through PTR1, motor armature and motor field to battery negative.

When TR5 and TR6 are OFF, PTR1 is OFF. The percent “on-time” of the signal at the logics is also the percent “on-time” of PTR1.

PTR1 is pulsed at 11% “on-time” supplying 11% of battery voltage to the pump motor (IDLE).

MicroController Control Systems

30

Systems Operation

Flyback Circuit

Flyback Circuit

PD is a flyback diode for the power steering and hydraulic motor circuit. This circuit uses the current created by the collapsing magnetic field of the field windings in the pump motor to keep current flowing when transistor PTR1 is OFF. When PTR1 is OFF all current from the field goes through P2, PD, P1 and pump motor armature (ARM) back to the field.

When PTR1 is pulsing the flyback circuit causes the average pump motor current to be greater than the average battery current through PTR1.

MicroController Control Systems

31

Systems Operation

Lift Control Circuit

1 Location of Components (1) Valve control card.

This control panel accept a three speed lift control signals and tilt/aux lever signals. The three speed lift control system is controlled by valve control card (1) mounted at the top of the control valve.

When the operator pulls the lift lever, magnet (3) moves closer to the lift sensor (2). The sensor detects the increasing magnetic field and sends an increasing voltage to the valve control card. The valve control card produces voltage changes which input to the logics at P2-3 and P2-4 The logics uses these changing voltages to determine what speed to operate the pump motor. The logics then controls the pump transistor PTR1. The pump motor lift speed as shown in the chart.

The valve control card uses a hall-effect transducer (LIFT SENSOR) and a magnet to sense lift lever movement. The closer the magnet is to the transducer the greater the hydraulic pump motor speed.

2

Motor Speed

P2-3

P2-4

PTR1

Pulse Ratio

0

12V

12V

Steering

Variable

1

0.2V

12V

35% Pulsing

Variable

2

0.2V

0.2V

50% Pulsing

Variable

3

12V

0.2V

95% Pulsing

-

3 Variable : Set by Option Programmbles Feature.

Pump Bypass Contactor (36V only) The Pump Bypass contactor will close at Lift Speed 3 on 36V system. Also this contactor will activate if the Aux2 speed was set at 95% pulsing in option programmable Feature 15.

Location of Components (2) Lift Sensor. (3) Magnet.

MicroController Control Systems

32

Systems Operation

Lift Circuit

Lift Circuit

If the streeing wheel is turned, hydraulic pressure increases and a pressure switch (PRESSURE SW) located in the steering gear load sensing hose, will open. This causes the voltage at logic connector P2-1 to change from a LOW (less than one volt) to a HIGH (12 volts). When a HIGH is present the logics knows that more hydraulic flow is required and will supply a pulse from P9-3 to PTR1 at rate of 23% “on-time” for 48 volt trucks. The pump motor speed will increase.

MicroController Control Systems

When the lift lever is pulled to lift speed 1 the logics will pulse the pump transistors PTR1.

As shown in the chart under Lift Control Circuit, if the lift lever is pulled to lift speeds 2 through 3 the pump transistors are pulsed with a higher percent “on-time”.

The pump motor armature will turn faster.

33

Systems Operation

Drive Circuit Control Circuit

Drive Control Circuit

NOTE: The circuit diagrams have shaded lines for illustration of current flow in each circuit.

Selecting a direction will change the voltage from HIGH to LOW on P2-5 for forward or P2-6 for reverse. Depressing the accelerator pedal will cause the accelerator analog voltage on P1-15.

With the forward direction selected current flows from the logics P1-3 through forward direction contactor coil to logics P1-5 and P1-7 back to battery negative. The forward contactors tips close.

With the actuation circuit complete the logics supplies a HIGH voltage (12volts) to the direction (F/R) switch at P2-5 and P2-6. A HIGH voltage is also supplied to the power of accelerator at P1-16.

Releasing the park brake closes the park brake switch and provides a path to battery negative.

MicroController Control Systems

34

Systems Operation

Power Circuit

TR2 and TR4 Base Input Signal

NOTE: The circuit diagrams have shaded lines for illustration of current flow in each circuit.

Other circuits can be activated at the same time, but each one is shown separately to illustrate current flow in each individual circuit.

The logics generates a positive pulsing voltage (approximately 0.7 volts) on P9-1 and P9-2, to the base of transistors TR2 and TR4. These pulses turn ON TR2 and TR4 which turn ON TR1 and TR3. A more complete description of this transistor turn on circuit can be found in : Hydraulic Pump Motor Circuit under Power Transistor Pulsing.

The high amperage current, which provides the power and torque necessary to drive the lift truck, flows in this circuit. The speed of the drive motor is controlled separately from the pump motor circuit by the MicroController Control System.

MicroController Control Systems

35

Systems Operation

Power Transistors, TR1, TR2, TR3 and TR4 all ON

When TR1 and TR3 are ON, current flows through TR1 and TR3 emitter/collector into the base of drive power transistors (DTR1 and DTR2). This puts a HIGH voltage at the base of the power transistors causing them to turn ON. With the power transistors ON, high amperage motor current can flow through them, the field, forward contact tips, armatures, forward contact tips and current sensors back to battery negative. When TR1 and TR3 are OFF, the power transistors are OFF.

MicroController Control Systems

The percent “on-time” of the voltage at logics P9-1 and P9-2 is also the percent “on-time” of the power transistors. As the “on-time” increases, the average voltage applied to the drive motor increases which increases the speed of the lift truck. The percent “on-time” out of the logics is determined by how far the accelerator is depressed.

36

Systems Operation

Flyback Circuit

Flyback Circuit

When the drive power transistors (DTR1 and DTR2) are ON, battery current flows through the field windings of the drive motor and a magnetic field is created around the windings. When the power transistors are turned OFF battery current through the windings stops and the magnetic field collapses.

This collapsing magnetic field induces current which is used to power the drive motor while the power transistors are OFF (during pulsing). Induced current flows from the field windings through the forward contact tips, armature, forward contact tips, current sensor and diodes DD1, DD3 back to the field windings.

MicroController Control Systems

Because of this, the average drive motor armature current will be greater than the average battery current. Refer to following Average Current Flow chart.

37

Systems Operation

Average Current Flow

Current Limit

The logics monitors the current that flows through DTR1 and DTR2 and limit this current flow to a preset value. As this current flows through DTR1 and DTR2 the drive motor and the current sensors, a voltage is created by the sensor.

This voltage is proportional to the current flowing

MicroController Control Systems

through the sensor and will increase or decrease as current changes. The logics uses this voltage to monitor the current in the circult.

When the current has increased too high, the logics decreases the pulse rate to the transistors to prevent current higher than the preset value.

38

Systems Operation

Bypass Circuit

Bypass Circuit Activated

The bypass circuit bypasses DTR1 and DTR2 and connects the drive motor in series with the battery, applying full battery voltage to the drive motor. If the accelerator pedal is fully depressed, and the logics has pulsed DTR1 and DTR2 through 92% “on-time”, the logics will activate the BYPASS CTR after 1.5 seconds.

MicroController Control Systems

39

Systems Operation

Electrical Braking (Plugging)

Plugging Circuit (Transistor DTR1, DTR2 “ON”)

Plugging is an electrical braking mode which permits the lift truck operator to slow, stop and change the direction of travel electrically without using the service brake.

Plugging begins when the operator selects a direction opposite the lift truck’s motion, while keeping the accelerator depressed. The logics will deactivate the bypass contactor (if activated) and change the direction contactors to the new direction selected. The momentum of the truck causes the drive motor to generate current, and the logics will puise the transistors at a slow rate.

MicroController Control Systems

When DTR1 and DTR2 are ON, battery current flows through DTR1 and DTR2, field windings, direction contactor tips, armature, direction contactor tips and current sensor back to the battery. Current energizes the field and tries to turn the armature opposite the rotation caused by the truck’s motion. The current acts to electrically brake the truck. With the field energized and momentum of the truck turning the armature opposite the pulsed direction, the armature generates current.

40

Systems Operation

Plugging Circuit (Transistor DTR1, DTR2 ”OFF”)

The generated current flows from the armature through the direction contactor, current sensor and diode DD2, DD4, back to the armature. When armature generated current flows through DD2, DD4 wire #1 at P1-20 becomes a more positive voltage than plug sensing wire #32 at P1-10, P1-11, due to the voltage drop across DD2, DD4. The logics detects the voltage change at P1-20 and P1-10, P111, then reduces the tansistor pulsing to stay below the preset plugging current limit.

When DTR1 and DTR2 are OFF, flyback current from the collapsing motor field flows through the direction contactor tips, armature, direction contactor tips, current sensor and diode DD1, DD3,

MicroController Control Systems

back to the field. This current continues the electrical braking action. As long as the truck momentum is turning the armature opposite the pulsed direction, the motor continues to act as a generator with armature generated current flowing through DD2, DD4 back into the armature.

When the truck has come to a stop, the armature no longer is turning opposite the pulsed direction. The armature stops generating current and DD2, DD4 no longer conducts. The logics no longer detects a more negative voltage on plug sensing wire #32 than on wire #1, so normal drive operation begins in the opposite direction.

41

Systems Operation

Thermal Protection Circuits Control Panel

Hydraulic Pump Motor

If the power transistors overheat, a thermal switch mounted in the transistor heatsink will open at a predetermined temperature. When it opens, voltage at logic connection P2-11 will go HIGH (12 volts).

The Central Vehicle Monitoring System will display a “Run Time” diagnostic symbol.

The logics will decrease the pulsing of the drive system and restrict the hydraulic circuit pulsing to 50%. The amount of current allowed to flow through the power transistors is decreased to permit them to cool. When the heatsink cools off and the thermal switch closes, the truck will return to normal operation. Drive system bypass is not affected by an overheated control panel, but due to the reduced pulsing acceleration performance will be decreased.

An “Ec” is stored in memory.

If the hydraulic pump motor overheats a thermal switch mounted in the pump motor housing will open at a predetermined temperature. When it opens, voltage at logic connection P2-13 will go HIGH. The Central Vehicle Monitoring System will display a “Run Time” diagnostic symbol. To decrease the amount of current allowed to flow through the pump motor, the logics will reduce the hydraulic pump motor to 50% pulsing. When the hydraulic pump motor cools off and the thermal switch closes, the truck will return to normal operation.

An “EP” is stored in memory.

Failure Protection Circuit If the logics detects an improper voltage at P9-5 wire #L64 (left drive circuit) and/or P9-6 wire #R64 (right drive motor) or P9-7 wire #74 (pump circuit), the line contactor will be deactivated and a “Run Time” diagnostic code (display = “F2” through “F7”) will display.

Current is also monitored in the drive motor, and should it exceed preset limits in either pulsing or bypass the truck will shut down and display an “F0”.

The logics will monitor the four steering angle switch signals, wires #50, 51, 52 and 53 to determine if there is an out of sequence problem.

An “FA” will be displayed if this should occur.

If the battery voltage is mismatched, the “Fb” will display.

The logics will monitor the two current sensor signals, wires #L22 and #R22 to determine if there is an wrong voltage pattern. An “F5” will be displayed.

Once a failure has been detected the truck must be repaired before normal operation can resume.

Drive Motor If the drive motor overheats a thermal switch mounted in the drive motor housing will open at a predetermined temperature. When it opens, voltage at logic connection P2-12 will go HIGH. The Central Vehicle Monitoring System will display a “Run Time” diagnostic symbol. To decrease the amount of current allowed to flow through the drive motor, the logics will reduce the pulsing and disable the bypass contactor. When the drive motor cools off and the thermal switch closes, the truck will return to normal operation.

Drive system acceleration performance and top travel speed is affected by an overheated drive motor.

An “Ed” is stored in memory.

MicroController Control Systems

42

Systems Operation

Testing And Adjusting Troubleshooting

NOTICE Damage can be caused to the control panel. Do not switch the direction lever from one direction to the other (plug the lift truck) when the drive wheels are off the ground and in rotation at full speed.

The following Troubleshooting Check List is an aid in troubleshooting MicroController lift trucks. The troubleshooting check list, “Run Time” diagnostic indications, “Self” diagnostic tests, problem list and problem flow charts will assist in: 1. Defining the problem and verifying a problem exists.

Troubleshooting Check List

2. Performing the checks in a logical order.

1. Perform Preparation Tests and Checks.

3. Making the necessary repairs.

2. Correct any display problems and “Run Time” diagnostic faults.

4. Verifying the problem has been resolved.

3. Correct the “Self” diagnostic faults.

4. Perform Operational Checks.

WARNING The lift truck can move suddenly.Battery voltage and high amperage are present. Injury to personnel or damage to the lift truck is possible.

Safely lift both drive wheels off the floor. Put blocks of wood under the frame so the drive wheels are free to turn. During any test or operation check, keep away from drive wheels. Before any contact with the control panel is made, disconnect the battery and dis- charge HEAD CAP. Ring's, watches and other metallic objects should be removed from hands and arms when troubleshooting, the MicroController Control System.

5. Correct “Failure Code Problems” in the Troubleshooting Problem List.

NOTICE Damage can be caused to the test equipment.

Make resistance and continuity checks only after the battery is disconnected.

1. Verify proper polarity at the battery connector and the MicroController panel. Positive cable should be at the line contactor and negative at the negative heatsink.

6. Perform Operational Checks to verify repairs.

Preparation Tests and Check Battery Tests A weak battery can cause or contribute to problems in the MicroController and power circuits.

Verify the battery is good before investigating other possibilities.

2. If the lift truck is operational, perform a battery load test.

3. If the truck is not operational and the battery is suspected, perform a cell voltage or specific gravity test.

NOTICE Damage can be caused to the control panel. Do not use steam or solvent to clean the controls. Use pressure from an air hose with a maximum pressure of 205 kPa (30 psi) to clean the control panel when necessary. Make sure the air pressure supply is equipped with a water filter.

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Battery Load Test

Cell Voltage Test

1. Turn the range switch on the multimeter to read battery voltage.

With the truck powered up and the power steering motor running, measure the voltage at each cell.

Normal voltage should be between 1.95V and 2.12V per cell. If the voltage on each cell is below 1.95V the battery must be charged or repaired before continuing to troubleshoot.

2. Connect the battery.

48V

NOTE : The indication between cells should not differ more than 0.05 volts. If it does, the battery must have an equalizing charge or be repaired.

2

Hydrometer Test 1

Test each cell of the battery with a hydrometer. If the specific gravity indication is below 1.140, the battery must be charged. The battery is fully charged if the indication is 1.265 to 1.285.

Battery Voltage Test.

(1) Positive cable connection.

(2) Negative cable connection.

NOTE : The indication between cells should not differ more than .020. If it does, the battery needs an equalizing charge or needs to be repaired.

36V

Battery Maintenance NOTE : It is important that all batteries be charged and maintained according to the battery manufacturers instructions.

1

The care and maintenance of batteries is most important to maximize battery life and efficient truck operation. Periodic inspection and service will increase the life of batteries. Special attention should be given to the rules that follow:

2

1. Keep batteries clean at all times. Cleaning will prevent corrosion, current leakage and shorts to chassis. Tighten all vent plugs, wash the battery with water and a brush, then dry with an air hose.

It may be necessary to use a baking soda solution if water alone will not clean the top of the battery.

3. Connect the multimeter leads between positive (+) cable connection (1), and negative (-) cable connection (2).

4. In a safe area, operate the hydraulic system, (hold tilt lever to maximum position momentarily) while reading the voltage indicated on the multimeter.

2. Add enough water to cover the plates before charging. This will ensure the proper chemical reaction over the entire plate surface. After charging is complete, add water until it is about 12.7 mm (.50 in) above the plates. Use distilled water or water that has tested free from minerals.

5. If the indication is less than 44.2 volts, the battery needs to be charged or repaired before continuing to troubleshoot.

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3. Charge the battery correctly. A battery should be discharged to 80% of its capacity then fully recharged. It should cool four to eight hours to allow the voltage to stabilize before being put back in use. The battery should have an equalizing charge (an extra three or four hour charge at a low finish rate) once a month to make sure all cells are in a fully charged condition. Properly charged batteries should be identified to prevent low batteries from being installed in trucks.

switch and accelerator linkage for adjustment or interference problems.

Resistance to Chassis Checks Resistance between any point in the truck wiring and the chassis should be a minimum of 10,000 ohms or more.

Many malfunctions are caused by shorts to chassis.

Usually, two shorts must exist before a malfunction will occur. But, since batteries can have chassis leakage, only one short to chassis in the truck wiring can cause problems. To prevent problems because of shorts, do the following:

4. Operation with a low battery must be prevented.

Low battery operation may damage the battery and will cause higher than normal current in the electrical system. High current draw due to a low battery will damage contactor tips and shorten motor brush life.

1. Disconnect the battery and discharge the HEAD CAP.

5. The battery's maximum temperature is critical. The electrolyte temperature should never exceed 43°C (110˚F) either while operating or charging.

Overcharging a battery will cause over heating and warp the battery plates. Maximum battery life will result from maintaining 25˚C (77˚F) electrolyte temperature. Most of the charging equipment is fully automatic but should be checked periodically to assure proper working order.

2. Randomly measure any component connection or wiring connection in respect to the lift truck chassis for a minimum resistance of 10,000 ohms. Any test point with low resistance must have the short to chassis removed.

3. Always keep batteries clean to minimize current leakage to the chassis.

6. Keep accurate battery records. Regular battery readings should be taken with a battery tester or voltmeter and a written record kept. Specific gravity and voltage of each cell should be checked and recorded at least once each month. This inspection should be made after an equalizing charge. Readings should never be taken directly after water has been added. Records of all battery maintenance should be made and filed so it will be known which batteries are being abused or wearing out.

4. Routinely clean the brush dust from the motors.

5. Be sure that all attachments, such as horns and lights are designed for no chassis connection (a two wire system).

Removal of Shorts to Chassis When a short is found, it must be cleared even if the machine has normal operation. It is necessary to narrow the field of possible problem areas before inspection of individual wires and components.

Repairs should be made immediately otherwise the battery may become damaged. Batteries stored in a discharged condition may be difficult to recharge due to sulfate formation.

When a low resistance circuit is located, it should be opened at various points. This will permit the shorted wire or component to be pin-pointed for repair or replacement.

Visual Checks 1. Verify all components and wires are in their proper place. Check fuses, components, contactor tips, wires and connections. Verify that they are not burned, broken or loose.

2. Verify there is no mechanical binding or interference in the contactors.

3. Visually check the parking brake switch, the lift MicroController Control Systems

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Testing And Adjusting

Control and Power System Operational Checks All operational checks are to begin with the battery connected, directional switch in neutral, drive wheels off the ground and the accelerator and parking brake released.

4. Depress the accelerator fully. The forward contactors should remain activated. The bypass contactors should activate. The drive wheels will turn forward at full speed.

NOTE: Perform all operational checks before returning to the Troubleshooting Check List.

Check 5: Reverse Drive Performance

Check 1: Key Switch, Seat Switch and Power Steering

1. Select reverse direction and depress the accelerator slightly. The reverse contactors should activate and the drive wheels should turn in reverse slowly.

1. Activate the key and seat switch. The line contactor activate and the hydraulic pump motor should turn on at slow speed (idle).

2. Slowly increase the amount of accelerator depression. The reverse contactors should remain activated. The drive wheels should turn in reverse and slowly increase in speed.

2. Turning the steering wheel will increase the hydraulic pump motor speed (boost-up).

3. Depress the accelerator fully. The reverse contactors should activated. The bypass contactors should activate. The drive wheels will turn in reverse at full speed.

3. After five to ten seconds the line contactor deactivates and the motor turns off.

Check 2: Lift Performance

Check 6: Electrical Braking (Plugging) Performance

1. Pull the lift lever half way. The hydraulic pump motor activates slowly to a preset speed.

2. Pull the lift lever to maximum. The hydraulic pump motor activates full speed.

NOTICE Do not perform this check with the lift truck in bypass mode. Damage to the Drive Train can result.

Check 3: Tilt and Auxiliary Performance 1. Slowly pull and push the tilt and auxiliary levers.

The hydraulic pump motor activates to one of the preset speeds with each lever movement.

1. Select forward direction and depress the accelerator to the point before bypass occurs.

While continuing to depress the accelerator, change the direction switch to reverse. The forward contactors should deactivate and the reverse contactors should activate. There should be a smooth deceleration of forward tire rotation.

After the forward tire rotation stops, there is a smooth acceleration of reverse tire rotation.

Check 4: Forward Drive Performance 1. Engage the parking brake. Select forward direction and depress the accelerator slightly. The forward contactor should NOT activate and the drive wheels should NOT turn.

2. Release the parking brake, select forward direction and depress the accelerator slightly. The forward contactors should activate and the drive wheels should turn forward slowly.

2. Continue to depress the accelerator while in reverse direction. Change the direction switch to forward. The reverse contactors should deactivate and the forward contactors should activate. There should be a smooth deceleration of reverse tire rotation. After the reverse tire rotation stops, there is a smooth acceleration forward tire rotation.

3. Slowly increase the amount of accelerator depression. The forward contactors should remain activated. The drive wheels should turn forward and slowly increase in speed.

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Built-In Diagnostic Operation The logics and the display provide built-in diagnostic analyzer functions. Several diagnostic functions occur while the lift truck is in operation. These are called “Run Time” diagnostics. The other diagnostics are called “Self” diagnostics. They are performed when the lift truck is not in operation by using a switch located in the logics.

Display =“Ec” Lift truck will not operate, see Troubleshooting Problem 20. Possible cause, control panel thermal problem.

The overtemperature indication will display on LCD. Display =“Ed” Lift truck will not operate, see Troubleshooting Problem 21. Possible cause, drive motor thermal problem. The overtemperature indication will display on LCD.

Central Vehicle Monitoring System (CVMS) Problems

Display =“EP” Lift truck will not operate, see Troubleshooting Problem 22. Possible cause, pump motor thermal problem.

The overtemperature indication will display on LCD.

If the display does not work, or it’s operation seems incorrect see Troubleshooting Problems 1, 2, 3 and 4.

“Run Time” Diagnostics (Lift Truck in Operation)

Display =“EL” Lift truck will not operate, see Troubleshooting Problem 23. Possible cause, low battery voltage.

The diagnostic functions that follow would occur during normal lift truck operation and are shown on the seven segment display.

Display =“F0” Lift truck operates, then shuts down during travel. See Troubleshooting Problem 32.

Possible cause, excessive currents in drive motor.

NOTE: Improper lift truck operation with normal battery indication, should be checked with “Self” diagnostics.

Display =“F2” Lift truck will not operate, see Troubleshooting Problem 33. Possible cause, a failed left drive power transistor (DTR1).

Display =“F2” (Flashing) Lift truck will not operate, see Troubleshooting Problem 34.

Possible cause, a failed right drive power transistor (DTR2).

Display =“F3” Lift truck will not operate, see Troubleshooting Problem 35. Possible cause, a failed pump power transistor (PTR1).

Display =“F4” Lift truck will not operate, see Troubleshooting Problem 36. Possible cause, failed pump and drive power transistors.

Display =“F5” Lift truck will not operate, see Troubleshooting Problem 37. Possible cause, left drive flyback diode DD1 failed.

Display Layout

Display =“EE” No Lift truck operation, see Troubleshooting Problem 17. Possible cause, static return to off.

Display =“F5” (Flashing) Lift truck will not operate, see Troubleshooting Problem 38. Possible cause, right drive flyback diode DD3 failed.

Display =“EE” (Flashing) Lift truck will not operate, see Troubleshooting Problem 18. Possible cause, seat switch open.

Display =“F6” Lift truck will not operate, see Troubleshooting Problem 39. Possible cause, pump flyback diode PD failed.

Display =“E1” or “E2” Lift truck will operate, see Troubleshooting Problem 19. Possible cause, pump or drive brush problem.

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Display =“F7” Lift truck will not operate, see Troubleshooting Problem 40. Possible cause,pump and drive flyback diodes (DD1,DD3 and PD) failed.

Display =“FA” Lift truck will not operate, see Troubleshooting Problem 41. Possible cause, steer angle switch failure or harness problem.

Display =“Fb” Lift truck will not operate, see Troubleshooting Problem 42. Possible cause, abnormal battery condition.

Display =“Fd” Lift truck will operate, see Troubleshooting Problem 43. Possible cause, pressure switch failure or harness problem.

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Testing And Adjusting

“Self” Diagnostics (Lift Truck not in Operation)

WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible.

Disconnect the battery and disconnect the line fuse to prevent lift truck movement.

The diagnostic procedure should be used to aid in troubleshooting after a problem occurs. It will help to find the faulty circuit or component.

Complete all the tests before returning to the MicroController Troubleshooting Check List.

Before testing, do the steps that follow :

4. Release the parking brake to close the park brake switch.

1. Turn the key to off.

2. Disconnect the battery and discharge the head capacitor below 5 volts by holding the discharge resistor in place for 10 seconds.

3

48V

2

1 Removing Cover from Logic Unit (Logics) (2) Screws. (3) Cover.

5. Loosen four screws (2) to remove logic cover (3).

Location of Fuse (1) Line fuse.

36V

4

DIAG/RUN/SETUP Switch Location (4) Switch.

1

6. Move switch (4) to “DIAG” position. This places the controller in diagnostics when the battery is connected and key is turned to ON.

3. Disconnect line fuse (1) to prevent lift truck movement.

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Testing And Adjusting

7. Connect the battery and turn key to ON.

Test 4 : Lift Switch Circuit

Display = “blank” See Troubleshooting Problems 1 or 2.

Pull lift lever slowly.

Display now shows the speed that the lift lever is set to. As lever is pulled back, 0 through 3 will be shown.

Display = “F” Logics has a failure. Replace logics.

This indicates at what position the lift lever changes the pump motor speed.

Display = “d” Line fuse is not disconnected or discharge the head capacitor. Return to step 2.

If still “A0” lift switch circuit defect, see Troubleshooting Problem 10.

Display = “8b” Direction lever is in the reverse position. Move direction lever to neutral.

Test 5 : Tilt Switch Circuit Pull tilt lever to maximum.

Display = “A6” Tilt switch circuit OK.

NOTE: This test does not check all the logics circuit, so the logics may pass this test and still have a failure.

Release tilt lever.

Display = “A0” Tilt switch circuit OK.

The LCD will display all symbols about 2 seconds.

Display = “A0” Ready for test 1.

If still “A0” or “A6”, tilt switch circuit defect, see Troubleshooting Problem 11.

Test 1 : Seat Switch

Test 6 : Auxiliary Switch Circuit

Press seat to close seat switch.

Display = “A1” Seat switch circuit OK.

Pull auxiliary lever to maximum.

Display = “A7” Auxiliary switch circuit OK.

Release seat to open seat switch.

Display = “A0” Seat switch circuit OK.

Release auxiliary lever.

Display = “A0” Auxiliary switch circuit OK.

If still “A0” or “A1”, see Troubleshooting Problem 8.

If still “A0” or “A7”, auxiliary switch circuit defect, see Troubleshooting Problem 12.

Test 2 : Reverse Direction Switch Test 7 : Parking Brake Switch Move direction switch from neutral to reverse.

Display = “A2” Direction switch circuit OK.

Pull park brake lever to maximum.

Display = “A9” Park brake circuit OK.

Move direction switch from reverse to neutral.

Display = “A0” Direction switch circuit OK.

Release Park brake lever.

Display = “A0” Park brake circuit OK.

If still “A0” or “A1”, see Troubleshooting Problem 9.

If still “A0” or “A9”, Park brake circuit defect, see Troubleshooting Problem 13.

Test 3 : Forward Direction Switch Move direction switch from neutral to forward.

Display = “A3” Direction switch circuit OK. Move direction switch from forward to neutral.

Display = “A0” Direction switch circuit OK. If still “A0” or “A3”, see Troubleshooting Problem 9.

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Testing And Adjusting

Test 8 : Accelerator Control Press accelerator pedal to maximum.

Display = The speed symbols will increase from 0 to 10 on the LCD, Accelector circuit OK.

6 7

Release accelerator pedal.

Display = The speed symbols will decrease from 10 to 0 on the LCD, Accelector circuit OK. If the speed symbols is not full on the LCD, see Troubleshooting Problem 14.

Test 1 through 8 may be checked without sequence and there are repeatable checkings to adjust switches and levers.

8 Contactor Locations (6) Bypass contactor. (7) Right direction contactor.

(8) Left direction contactor.

48V

Contactor Test Test 9 through 14 may be activated in regular sequence by movement of the DIAG/RUN/SETUP (4) to “Run” then back to “Diagnostic” position, and “AC” will display on the LCD. Test 9 : Line Contactor Test 10 : Bypass contactor

5

Test 11 : Left Forward Direction Contactor

Contactor Locations (5) Line contactor.

Test 12 : Right Forward Direction Contactor Test 13 : Left Reverse Direction Contactor

36V

Test 14 : Right Reverse Direction Contactor Test 15 : Pump Bypass Contactor (36V only) If the above actions do not occur, see Troubleshooting Problem 15.

This completes the built-in diagnostic test.

Contactor test may be repeated contiune by movement of the DIAG/RUN/SETUP to “Run” then back to “Diagnostic” position.

After running through the contactor testing, pull tilt lever and then release to netural position will access the stored error codes. See Accessing Stored Error Codes.

5

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Testing And Adjusting

Accessing Stored Error Codes

Saving Service Records

The B18T series of trucks remembers the last 24 error codes. This is useful in case the truck has had an intermittent problem, but the operator cannot remember which code appeared on the display. Also by analyzing the contents of the last 24 error codes, it may be possible to determine what sort of application the truck has been working in.

To save service records, the following procedures are used at the end of self diagnostics and service records are numbered from 1 to 9.

1. Access all of the error codes until display shows static “E” on the LCD. 2. Move the direction lever to the forward then display will show static “8d”.

The stored error codes are accessed at the end of diagnostics by using the following procedure:

3. Move the DIAG/RUN/SETUP switch to “SETUP” and back to “DIAG” two times.

1. Access the self diagnostics procedure as usual.

2. Either step through the self diagnostics procedure, or override each test by moving the DIAG/RUN/SETUP switch from DIAG to RUN and back to DIAG until the contactor testing is completed.

4. Pull the tilt lever to maximum position and then release.

3. Cycle the DIAG/RUN/SETUP switch once more, and cycle through the contactor testing again. After the right reverse contactor drops out, now the display will indicate a “AC”.

6. Wait until the display will show a flashing “8d”, the display indicates that a service record have been saved.

5. A saved service records will show for a few second.

7. Turn OFF the key switch.

The error codes can now be accessed one at a time by pulling tilt lever and then release. This will display the most recent error code. By cycling the tilt lever more times, more error codes will appear on the display, up to a total of 24.

When the display shows a solid “E”, it will indicate that all of the stored error codes have been displayed. It is possible that the “E” will appear immediately, indicating no error codes have been encountered.

Erased Stored Error Codes To erase all of the error codes, the following procedures are used at the start of self diagnostics.

1. Move the direction lever to the reverse and the DIAG/RUN/SETUP switch to the DIAG position.

2. Turn on the key switch and wait until display shows a solid “8b”, then move the DIAG/RUN/SETUP switch to the SETUP position and back to DIAG two times.

3. Move the direction lever to neutral.

4. Wait until the display will show a “A0”, the display indicates that all error codes have been erased.

5. Turn off the key switch.

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Stored Error Codes

Quick Diagnostic Procedure

The following are possible error codes stored in memory. Most error codes are identical to the ones displayed during RUN.

An alternative method of entering diagnostics has been programmed into the logics. This will enable quick diagnostics of some of the components without removing the controller room, line fuse, or placing the DIAG/RUN/SET switch to the “Diagnostic” position.

Contactors and seat circuit will NOT be energized.

E1 : Drive motor brush problem.

E2 : Hydraulic motor brush problem.

Ec : Control panel thermal problem.

Ed : Drive motor thermal problem.

EL : Battery lock out.

EP : Pump motor thermal problem.

F0 : Excessive drive motor current in pulsing or bypass operation.

F2 : Left drive problem, voltage on left drive transistor emitter (wire #L64).

F2 (Flashing) : Right drive problem, voltage on right drive transistor emitter (wire #R64).

F3 : Pump problem, voltage on pump transistor emitter (wire #74).

F4 : Both F2 and F3 problems together.

F5 : Left drive problem, no voltage on left drive transistor emitter (wire #L64).

F5 (Flashing) : Right drive problem, no voltage on right drive transistor emitter (wire #R64).

F6 : Pump problem, no voltage on pump transistor emitter (wire #74).

F7 : Both F5 and F6 problems together.

FA : Steer angle problem.

Fb : Battery mis-match.

Fd : Pressure switch problem.

MicroController Control Systems

To enter quick diagnostics, open the seat switch and place the direction lever to forward and ensure that the park brake is released. While depressing the accelerator to maximum position other than OFF, and key switch to ON. Display will go to a solid “A3” and the speed symbols will increase from 0 to 10 on the LCD, indicating that you have entered diagnostics and you are ready for Test: You can test the direction control lever, all hydraulic levers, the park brake switch and the accelerator.

See Built-In Diagnostic Operation on page 50-52.

NOTE : This test enables a salesman to demonstrate some of the diagnostic procedure without ever having to open up the controller room.

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Testing And Adjusting

Troubleshooting Problem List TROUBLESHOOTING PROBLEM LIST Problem #

CENTRAL VEHICLE MONITORING SYSTEM (CVMS) PROBLEMS

1

CVMS does not work, with no lift truck operation.

2

CVMS does not work at all, lift truck operation normal.

Display portion of CVMS seems random or wrong.

3 4

Lift truck operation normal.

Display portion of CVMS works until seat switch is closed then blank, no lift truck drive or pump motor operation.

“SELF” DIAGNOSTIC PROBLEMS

5

Display = “d”, no lift truck operation or “Self-diagnostics” operation.

6

Display = “F”, no lift truck operation.

7

Display = “8b”, no lift truck operation.

8

Seat switch circuit defect.

9

Direction switch circuit defect.

10

Lift switches circuit defect.

11

Tilt switch circuit defect.

12

Auxiliary switch circuit defect.

13

Park brake switch circuit defect.

14

Accelerator circuit defect.

15

Incorrect contactor operation.

16

Any contactor closes when key switch is activated.

“RUN TIME” DIAGNOSTIC PROBLEMS

17

Display = “EE”, no lift truck drive operation.

18

Display = “EE” (Flashing), no lift truck drive operation.

19

Display = “E1”, or “E2” lift truck operation normal.

20

Overtemperature is ON and display =

Lift truck accelerates slower than normal. Lifting speed is

slower than normal.

Overtemperature is ON and display =

21

Bypass contactor will not close.

Pump and steering operation normal. Acceleration slow.

Overtemperature is ON and display =

22

Lifting speed slow.

Drive and power steering operation normal.

23

Display = “EL”. No hydraulic (lift and tilt). Steering normal.

24

Hourmeter does not work.

25

Normal hydraulic operations, display is normal and no drive operations.

26

Current limit adjustment cannot be made.

27

Slow steering, but pump motor does turn. Drive system operation normal.

Pump motor runs continously when neutral is selected. Pump motor turns at high power steering

28

speed continuously.

Drive motor does not operate or operates with low power or is erratic.

29 30

Pump and power steering systems operation normal.

Horn does not function correctly. Lift and drive operation normal.

Auxiliary lighting and/or alarm does not function correctly.

31

Lift and drive operation normal.

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Testing And Adjusting

TROUBLESHOOTING PROBLEM LIST Problem #

FAILURE CODE PROBLEMS

32

Display = “F0”, no lift truck operation.

33

Display = “F2”, no lift truck operation.

34

Display = “F2” (Flashing), no lift truck operation.

35

Display = “F3”, no lift truck operation.

36

Display = “F4”, no lift truck operation.

37

Display = “F5”, no lift truck operation.

38

Display = “F5” (Flashing), no lift truck operation.

39

Display = “F6”, no lift truck operation.

40

Display = “F7”, no lift truck operation.

41

Display = “FA”, no lift truck operation.

42

Display = “Fb”, no lift truck operation.

43

Display = “Fd”, lift truck operation normal.

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Testing And Adjusting

PROBLEM 1 Central Vehicle Monitoring System (CVMS) does not work, with no lift truck operation.

POSSIBLE CAUSE Battery polarity not correct on control panel; Key fuse open circuit; Key switch defect; Logics defect.

CHECKS With battery connected, check control panel battery connections for correct polarity.

Positive battery connected to line contactor and negative battery connected to negative heatsink.

If correct

If not correct

Push horn buttton to close horn switch.

Make correction to cables.

Horn work

Horn does not work

Does CVMS pass self test at actuation of key and seat switches.

Yes

Disconnnect battery and check the horn fuse for continuity.

NO

Continuity

See Problem 2, CVMS does not work, lift truck operation normal.

Check for shorts and replace fuse.

Check continuity from horn fuse holder to control panel battery positive connection at the line contactor. Also check continuity from key fuse holder to wire #3 on key switch

Close key switch. Measure voltage on P1-1 and P1-2.

Battery voltage

No continuity

Less than Battery voltage

Continuity

Replace key switch or repair broken wire #5 between key switch and P1-1 and P1-2.

Repair horn circuit.

No continuity

Repair or replace open wire.

Check continuity from negative heatsink to logics P1-19 and P1-20.

Continuity

Replace logics.

No continuity

Repair or replace open wire.

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Troubleshooting

PROBLEM 2 CVMS does not work at all, lift truck operation normal.

If only part of CVMS works, replace the CVMS.

POSSIBLE CAUSE Disconnected logic connector P8; Open circuit from P8-1 to CVMS connector PIN 1; Open circuit from P88 to CVMS connector PIN 8; CVMS defect.

CHECKS Make sure CVMS connector is connected to CVMS. If connected

If not connected

Connect multimeter positive lead to P8-1 wire #101 and negative lead to P8-8 wire #108. Measure the voltage.

5 volts

Replace the CVMS module.

MicroController Control System

Connect CVMS connector.

0 volt

Repair or replace open circuit between 8 wires from logics to CVMS.

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Troubleshooting

PROBLEM 3 Display portion of the CVMS module seems random or wrong.

Lift truck operation normal.

POSSIBLE CAUSE Connection defect; Wiring defect; Logics defect; Display defect.

CHECKS Check continuity from logics to CVMS connector (wire #101/WH/YL/GN/BU/BK/RD/108).

Continuity

No Continuity

Check for shorts to battery negative from PIN 2 to PIN 7 on CVMS connector.

No shorts found

Repair or replace open wire.

Shorted

Replace logics.

MicroController Control System

Repair or replace shorted wire.

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Troubleshooting

PROBLEM 4 Display portion of CVMS works until seat switch is closed then blank, no lift truck drive or pump motor operation.

POSSIBLE CAUSE Line contactor defect; Line fuse open circuit; Wire #4 at P9-9 open circuit; Logics defect.

CHECKS Does the line contactor close and remain closed ?

Yes

No

Check voltage at bottom of line fuse with line contactor activated.

Battery voltage

See Problem 15. Incorrect contactor operation.

Less than Battery voltage

Check voltage at top of line fuse with line contactor activated.

Battery voltage

Repair or replace line contactor tips or power connections.

Less than Battery voltage

Check voltage at logic connector P9-9, wire #4 with line contactor activated.

Less than Battery voltage Battery voltage

Replace logics.

MicroController Control System

Check for possible shorts in the power circuit (Head Capacitor, diode, shorted cables) and replace line fuse. If repeat failures occur, check drive motor current limit and/or lift truck application.

Repair open circuit between line fuse and P9-9, wire #4.

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Troubleshooting

PROBLEM 5 Display = “d”, no lift truck or “Self-diagnostics” operation.

POSSIBLE CAUSE Logic DIAG/RUN/SETUP switch in DIAG position with line fuse installed; Head capacitor not discharged below 5 volts; Logics defect.

CHECKS Trying to run “Self-Diagnostics” ?

Trying to operate lift truck ?

Disconnect battery, discharge head capacitor below 5 volts, remove line fuse, set DIAG/RUN/SETUP switch to DIAG position, reconnect the battery and recycle key switch.

Display remains at “d”

Measure voltage on P9-9.

Disconnect battery, remove logic cover, set DIAG/RUN/SETUP switch to RUN position, reconnect the battery and recycle key switch.

“Self-diagnostic” Operation OK

Display remains at “d”

Continue with “SelfDiagnostics” operation.

Replace logics.

Lift Truck Operation OK

Place lift truck into operation.

Below 5V.

Replace logics.

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Troubleshooting

PROBLEM 6 Display = “F”, no lift truck operation.

POSSIBLE CAUSE Wiring defect; Logics defect.

CHECKS With the key on, check the voltage at logic P1-1 and P1-2, wire #5.

Battery voltage

No voltage

Check continuity from control panel battery negative to logic P1-19 and P1-20.

Continuity

Replace logics.

Repair or replace open wire.

No continuity

Repair or replace open wire.

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Troubleshooting

PROBLEM 7 Display = “8b”, no lift truck operation.

POSSIBLE CAUSE Wiring defect; Direction switch defect; Logics defect.

CHECKS Does the DlAG/RUN/SETUP switch in “Diagnostic” position ?

NO

YES

Does the direction switch in neutral ?

YES

NO

Check continuity from logic P2-6 to battery negative.

No continuity

Replace logics.

Move switch to “Run” position.

Move switch to neutral.

Continuity

Repair or replace short wire or direction switch.

MicroController Control System

62

Troubleshooting

PROBLEM 8 Seat switch circuit defect.

POSSIBLE CAUSE Seat switch defect; Wiring to seat defect; Logics defect.

CHECKS Disconnect the battery and remove logic cover.

Disconnect P2 connector. Check continuity from P2-7 harness connector to negative heatsink with multimeter in diode test position. Should be closed circuit when seat is pressed on and open circuit when seat is released.

No continuity

Constant continuity

Disconnect seat switch connector. Push on the seat and check the continuity across the seat switch.

Continuity

No continuity

Replace seat switch.

Check OK

Replace logics.

Disconnect seat switch connector. Check continuity from logic harness connector P2-7 to control panel battery negative with multimeter in diode test position.

Continuity

No continuity

Check continuity from terminal #1 of seat switch to control panel battery negative.

Replace seat switch.

Continuity

No continuity

Repair or replace open wire

Check wiring for short circuits between harness connector P2-7 and control panel battery negative.

Repair any short circuit found.

Check continuity from terminal #2 of seat switch to logic harness connector P2-7 with multimeter in diode test position.

Repair or replace open wire.

MicroController Control System

63

Troubleshooting

PROBLEM 9 Direction switch circuit defect.

POSSIBLE CAUSE Direction switch defect; Wiring to direction switch defect; Logics defect.

CHECKS Release park brake. Disconnect the battery and remove logic cover. Disconnect P2 connector.

Disconnect service brake switch connector.

Check continuity from control panel battery negative to P2-5 logic connector; With direction lever in forward should have a closed circuit, in neutral should be open.

Check OK

Check failed

Check continuity from control panel battery negative to logic connector P2-6. With direction lever in reverse should have a closed circuit, in neutral should be open.

Check OK

Disconnect direction switch connector.

Check continuity of wire #27.

Continuity

Check failed

Repair or replace wire.

Replace logics.

Check continuity from terminal #2 of direction switch harness connector to control panel battery negative.

Disconnect direction switch connector.

Check continuity of wire #28.

Continuity

No continuity

Continuity

No continuity

No continuity Replace direction switch.

Repair or replace wire.

Repair or replace open wire.

Check continuity from terminal #2 of direction switch harness connector to control panel battery negative.

Continuity

No continuity

Replace direction switch.

MicroController Control System

Repair or replace open wire.

64

Troubleshooting

PROBLEM 10 Lift sensor circuit defect.

POSSIBLE CAUSE Lift sensor not adjusted properly or defective; Lift sensor wiring defect; Valve control card (board) defect; Logics defect.

CHECKS Disconnect the tilt and auxiliary switch connectors.

Retest lift sensor circuit in self diagnostics.

Circuit passes “Self-Diagnostics”

Perform Problem 11,12 Tilt or auxiliary circuit defect.

Circuit fails “Self-Diagnostics”

Disconnect PV connector at the valve control board.

Connect multimeter negative lead to PV-5 and the positive lead to PV-2. Measure the voltage.

Battery Voltage

Measure each voltage from : PV-1, PV-3 to battery negative PV-5.

All = 11.5 to 12.5

Any/All = 0V

0 Volt

Repair or replace broken wire between key switch and PV-2 (wire #5) or between PV-5 and battery negative(-).

Reconnect PV and adjust the lift sensor and valve control card to specifications.

Measure each voltage from P2-3, P2-4 to battery negaive.

Display does not change 0 to 3

All = 11.5 to 12.5

Display changes 0 to 3

Repair or replace broken wire between P2 logic connector and PV connector.

Perform “Self-Diagnostics”.

Lift circuit should work.

Measure each voltage from P2-3, P2-4 to battery negative as the lever is pulled.

11.5 to 12.5 and .2v Measured on each

Replace logics.

Any one or all 0V

Remove P2 logic connector. Check P2-3, P2-4 for shorts to negative.

11.5 to 12.5 and .2V NOT measured on each

If shorted

Replace valve Control Card.

Replace or replace wire.

No shorts

Replace logics.

NOTE : Before lift truck is placed into service, connect tilt and auxliary switches and verify proper adjustment.

MicroController Control System

65

Troubleshooting

PROBLEM 11 Tilt switch circuit defect.

POSSIBLE CAUSE Tilt switch defect; Wiring defect; Logics defect.

CHECKS Disconnect the battery and remove logic cover.

Disconnect P2 connector. Pull tilt lever to maximum.

Check continuity from P2-2 logic connector to control panel negative.

Continuity

No continuity

Replace logics.

Check continuity of wire #49.

Continuity

Check continuity from tilt switch terminal of wire #1 to control panel negative.

Continuity

Replace tilt switch.

MicroController Control System

No continuity

Repair or replace wire.

No continuity

Repair or replace wire.

66

Troubleshooting

PROBLEM 12 Auxiliary switch circuit defect.

POSSIBLE CAUSE Wiring defect; Auxiliary switch defect; Logics defect.

CHECKS Disconnect the battery and remove logic cover.

Disconnect P2 connector. Pull auxiliary lever to maximum. Check continuity from P2-16 logic connector to control panel negative.

Continuity

No continuity

Replace logics.

Check continuity of wire #46.

Continuity

Check continuity from Aux. switch terminal of wire #1 to control panel negative.

Continuity

Replace Aux. switch.

MicroController Control System

No continuity

Repair or replace wire.

No continuity

Repair or replace wire.

67

Troubleshooting

PROBLEM 13 Park brake switch circuit defect.

POSSIBLE CAUSE Park brake switch defect; Wiring defect; Logics defect.

CHECKS Disconnect the battery. Check continuity from wire #71 to #1 on the park brake switch; With park brake released should have a closed circuit; With park brake applied should have an open circuit. Check park brake switch to make sure it is activated by the park lever.

Check OK

Check failed

Check continuity from wire #1 on the park brake to control panel battery negative.

Continuity

Replace park brake switch.

No continuity

Check continuity from wire #71 on the park brake switch to logic P2-8 Continuity

Repair or replace wire.

No continuity

Replace logics.

MicroController Control System

Repair or replace wire.

68

Troubleshooting

PROBLEM 14 Accelerator circuit defect.

POSSIBLE CAUSE Wiring defect; Accelerator defect; Logics defect.

CHECKS With the key switch on, the seat switch closed, park brake released and connect multimeter positive lead to P1-16, negative lead to P1-20.

Measure the voltage.

12 volts

Other voltage

Connect multimeter positive lead to P1-15, negative lead to P1-20. Measure the voltage accelerator pedal released : 0 volt.

Press accelerator pedal to max. : 9.6 to 11 volts.

Check OK

Replace logics.

Check failed

Disconnect P1 logic connector.

Check continuity of wire #18.

Continuity

Replace accelerator.

No continuity

Check continuity from terminal #1 of accelerator harness connector to logic harness connector P1-16.

Continuity

No continuity

Check continuity from terminal #3 of accelerator harness connector to logic harness connector P1-20.

Continuity

Replace logics.

Repair or replace wire.

Repair or replace wire.

No continuity

Repair or replace wire.

MicroController Control System

69

Troubleshooting

PROBLEM 15 Incorrect contactor operation.

POSSIBLE CAUSE Wiring defect; Contactor defect; Logics defect.

CHECKS During the “Self-Diagnostic” test, which of the following occurs?

Contactor does not activate or does not remain activated.

A contactor activates whenever the key switch is closed through all tests.

Disconnect the battery. Check for free mechanical movement of contactor tips Movement OK

See Problem 16. “Any contactor closes when key switch is closed”.

Movement not free

Remove logic cover. Disconnect P1. Check continuity from P1-3 (wire #15) to terminal of the contactor with incorrect operation.

Continuity

No continuity

Measure continuity from the appropriate P1 socket to the coil terminal of the contactor that has incorrect operation. Determine the P1 socket with respect to the contactor that has incorrect operation as follows: Line ....................................................P1-4, wire #33 Forward direction left .........................P1-5, wire #L34 Reverse direction left .........................P1-6, wire #L35 Forward direction right .......................P1-7, wire #R34 Reverse direction right .......................P1-8, wire #R35 Bypass ..............................................P1-9, wire #36 Pump Bypass Contactor ....................P1-14,wire #37 Continuity

Repair or replace wire.

No continuity

Check the contactor coil resistance.

See Component Measurements in Specifications section.

Check OK

Replace contactor.

Repair or replace wire.

Check not OK

Connect P1 and run “Self-Diagnostics” again. If contactor does not close, replace logics.

MicroController Control System

Replace contactor.

70

Troubleshooting

PROBLEM 16 Any contactor closes when key switch is activated.

POSSIBLE CAUSE Wiring defect; Logics defect.

CHECKS Connect the battery. Does the line contactor close when the key switch is closed ?

Yes

No

Did the seat switch pass “Self-Diagnostics”?

No

Yes

See Problem 8 Seat Switch Circuit Defect.

With contactor closed ? Disconnect the battery. Remove logic cover and disconnect logic P1 connector.

Check for a short circuit from control panel battery negative to P1 harness connector socket.

Determine the P1 socket with respect to the contactor that closed as follows: Line................................................................P1-4 Forward direction left.....................................P1-5 Reverse direction left ....................................P1-6 Forward direction right ..................................P1-7 Reverse direction right ..................................P1-8 Bypass...........................................................P1-9 Pump Bypass Contactor ...............................P1-14 Short circuit

Repair or replace shorted wire.

MicroController Control System

71

Open circuit

Replace logics.

Troubleshooting

PROBLEM 17 Display = “EE”, no lift truck drive operation.

POSSIBLE CAUSE Static Return to Off (SRO) circuit activated by improper operation sequence; Direction switch defect; Accelerator linkage not fully released; Accelerator control defect; Logics defect.

CHECKS Check for SRO by release of accelerator, release park brake move, the direction lever to neutral, reselect direction and press the accelerator.

No change

Run “Self-Diagnostics” to find faulty circuit or component.

Lift Truck Operation OK

Inform operator of correct start–up procedure.

Also, that the direction lever must be left in neutral when leaving the truck.

If no faulty component is found, replace logics.

MicroController Control System

72

Troubleshooting

PROBLEM 18 Display = “EE” (Flashing), no lift truck drive operation.

POSSIBLE CAUSE No opterator in seat; Seat switch defect; Open wiring; Logics defect.

CHECKS See Problem 8, seat switch circuit defect.

MicroController Control System

73

Troubleshooting

PROBLEM 19 Display = “E1”, or “E2” lift truck operation normal.

POSSIBLE CAUSE Worn brushes; Short wiring; Display defect.

CHECKS If “E1” displays, drive motor brush wear.

If “E2” displays, hydraulic motor brush wear.

Disconnect the respective wire from the motor.

Wire #31 for drive motor or wire #72 for pump motor.

Connect the battery and close the key switch and seat switch.

Does the LCD go out ?

No

Yes

Disconnect the battery. Check continuity of the respective wires to the logics.

Continuity

Check the brushes and replace as necessary.

No continuity

Replace or repair wires.

Disconnect logic P2 and check for shorts from logic P2-14 and P2-15 to battery negative.

Shorted

Repair wires.

MicroController Control System

Opened

Replace logics.

74

Troubleshooting

PROBLEM 20 Overtemperature is ON and Display = . Lift truck accelerates slower than normal. Lifting speed is slower than normal. Power steering operation normal.

POSSIBLE CAUSE Control panel overheated; Control thermostat (thermal switch) defect; Open wiring; Display defect; Logics defect.

CHECKS Let the truck cool for 15 minutes.

Overtemperature indicator ON

Disconnect the battery. With the controller at close to room temperature, disconnect the control thermal switch connectors P10 and PP. Check continuity of thermal switches.

Should have continuity below 69°C (156°F) Continuity

Control panel was overheated, resume normal operation. If repeats occur, check drive and pump motors current draw or operating cycle for excessive ramp climbing, towing or excessive lifting.

No continuity

Replace thermal switch.

Check continuity of wire #69 between themostat connector P10 and PP. Continuity

No continuity

Check continuity of wire #1 at HYD. thermostat to negative heatsink (control panel negative).

Continuity

Repair or replace wire.

No continuity

Remove logic cover. Check continuity of wire #69 at P10-7 to logic P2-11.

Continuity

Replace logics.

Normal display

Repair or replace wire.

No continuity

Repair or replace wire.

MicroController Control System

75

Troubleshooting

PROBLEM 21 Overtemperature is ON and Display = . Bypass contactor will not close. Pump and power steering operation normal. Acceleration slow.

POSSIBLE CAUSE Drive motor overheated; Drive motor thermostat (thermal switch) defect; Open wiring; Display defect; Logics defect.

CHECKS Let the truck cool for 15 minutes.

Overtemperature indicator ON

Disconnect the battery. With the drive motor at close to room temperature, disconnect the drive motor thermal switch connector.

Check continuity of thermal switch.

Should have continuity below 123°C (253°F) Continuity

Drive motor was overheated, resume normal operation. If repeats occur, check drive motors current draw or operating cycle for excessive ramp climbing or towing.

No continuity

Replace thermal switch.

Check continuity of wire #43 between left and right drive motor thermal switch.

Continuity

No continuity

Check continuity of wire #1 at left drive motor thermal switch to negative heatsink.

Continuity

Repair or replace wire.

No continuity

Remove logic cover. Check continuity of wire #43 at right drive motor thermal switch to logic P2-12.

Continuity

Replace logics.

Normal display

Repair or replace wire.

No continuity

Repair or replace wire.

MicroController Control System

76

Troubleshooting

PROBLEM 22 Overtemperature is ON and Display = . Lifting performance slow. Drive and power steering operation normal.

POSSIBLE CAUSE Pump motor overheated; Pump motor thermostat (thermal switch) defect; Open wiring; Display defect; Logics defect.

CHECKS Let the truck cool for 15 minutes.

Overtemperature indicator ON

Disconnect the battery. With the pump motor at close to room temperature, disconnect the pump motor thermal switch connector. Check continuity of thermal switch.

Should have continuity below 123°C (253°F).

Continuity

Pump motor was overheated, resume normal operation. If repeats occur, check pump motor current draw or operating cycle for excessive lifting and tilting.

No continuity

Repair or replace switch.

Check continuity of wire #1 at pump motor thermal switch to negative heatsink.

Continuity

No continuity

Remove logic cover. Check continuity of wire #42 at pump motor thermal switch connector to logic P2-13.

Continuity

Replace logics.

Normal display

Repair or replace wire.

No continuity

Repair or replace wire.

MicroController Control System

77

Troubleshooting

PROBLEM 23 Display = “EL”. No hydraulic (lift and tilt).

Steering normal.

Battery discharge indicator (BDI) circuit defect.

POSSIBLE CAUSE Battery discharged or has a defect; Logics defect.

CHECKS Connect battery, turn on key switch, close seat switch and measure voltage from line contactor to negative heatsink. Voltage must be greater than 45 volts.

Voltage OK

Voltage low

With key ON, seat switch and line contactor closed, measure voltage at P9-9.

Battery voltage

Check battery connections; Charge or replace battery.

Less than battery

Replace logics.

MicroController Control System

Repair shorted wire or high resistance connection causing the improper voltage.

78

Troubleshooting

PROBLEM 24 Hourmeter does not work.

POSSIBLE CAUSE The hourmeter requires battery voltage to run.

Measure voltage at hourmeter to ensure that it is battery voltage.

No voltage

Battery voltage

Check continuity from key switch to hourmeter positive (+) terminal.

Continuity

Replace hourmeter.

No continuity

Check continuity from hourmeter negative (-) to seat switch wire #45.

Continuity

Repair or replace wire.

No continuity

Repair or replace wire.

Check continuity from seat switch to battery negative wire #1.

No continuity

Repair or replace wire.

MicroController Control System

79

Troubleshooting

PROBLEM 25 Normal hydraulic operations, display is normal and no drive operations.

POSSIBLE CAUSE Service brake switch shorted.

Short wires (#27, #28).

Charged head capacitor.

CHECKS Disconnect the battery connector and discharge the head capacitor fully.

Check continuity from wire #27 (logic P2-5) to wire #28 (logic P2-6).

Continuity

No continuity

Check service brake switch and wires #27, #28 from logics to service brake switch.

Check direction switch.

All checks OK

Replace logics.

Any checks failed

Replace logics.

Repair or replace wire or switches.

MicroController Control System

80

Troubleshooting

PROBLEM 26 Current limit adjustment cannot be made.

POSSIBLE CAUSE Current sensor defect; Wiring defect; Logics defect.

CHECKS Perform current sensor component check.

Check OK

Check failed

Replace logics.

MicroController Control System

Repair wiring or replace current sensor.

81

Troubleshooting

PROBLEM 27 Slow steering, but pump motor does turn. Drive system operation normal.

POSSIBLE CAUSE Steering pressure switch defect; Wiring defect; Logics defect.

CHECKS Check the battery, close the seat and key switches.

Put the direction lever in forward.

Disconnect pressure switch connector.

Pump motor speed remains the same

Pump motor speed increases

Replace the pressure switch.

Disconnect pressure switch connector.

Check for a continuity between P2-1 and battery negative.

No continuity

Continuity

Replace logics.

Repair the wiring.

MicroController Control System

82

Troubleshooting

PROBLEM 28 Pump motor runs continuously when neutral is selected (no wait mode). Pump motor turns at high power steering speed continuously.

POSSIBLE CAUSE Steering pressure switch defect; Pressure switch connector disconnected; Wiring defect; Logics defect.

CHECKS Check steering pressure switch connector for proper connection.

Connected

Disconnected

Disconnect the pressure switch connector. Place jumper wire between both pressure switch connector terminals.

With the key ON, seat switch closed and a direction selected, the pump motor should run at slow speed.

Remains at high speed

Runs at slow speed

Disconnect the battery and discharge the head capacitor. Check continuity from terminal #1 of pressure switch connector to the control panel negative. Also check continuity from terminal #2 of pressure switch connector to logic connector P2-1.

Continuity

Replace logics.

Connect connector.

Replace the pressure switch.

No continuity

Repair or replace open wire.

MicroController Control System

83

Troubleshooting

PROBLEM 29 Drive motor does not operate or operates with low power or is erratic. Pump and power steering systems operation normal.

POSSIBLE CAUSE Accelerator defect; Direction control circuit defect ; Current limit set too low; Wiring defect ; Logics defect.

CHECKS Perform self-diagnostics.

Passed

Does not pass

See respective problem for defective circuit.

Readjust current limit to specifications.

Check DR1 and DR2 for correct resistance.

Resistance is 90Ω I 5%.

In specification

Not in specification

Check wire #L67, #L68, #R67 and #R68 for a good connection on DR1 and DR2.

Check wires #L63 and #R63 to base of transistors DTR1 and DTR2.

Check continuity of wire #L64 and #R64 from emitter of power transistors to logics P9-5 and P9-6.

All OK

Defective wiring

Repair or replace defective wiring or connection.

Check diode DD1, DD2, DD3 and DD4 for shorts or open circuit.

Diode OK

Defective diode

Check drive motor, cables and contactor for open circuits.

Check OK

Replace logics.

Replace resistor.

Replace defective diode.

Open circuit

Repair open circuit or replace drive motor.

MicroController Control System

84

Troubleshooting

PROBLEM 30 Horn does not function correctly. Lift and drive operation normal.

POSSIBLE CAUSE Open fuse; Faulty wiring; Defective switch; Horn defect.

CHECKS With the faulty horn circuit activated, check for voltage on the load side of the horn fuse.

Battery voltage

No voltage

Check for voltage on the load side of the horn switch.

Battery voltage

Check for short circuits; Replace horn fuse.

0 volt

Repair or replace open wire from fuse or replace defective switch.

Check for voltage at the negative connection of the load.

0 volt

Battery voltage

Repair or replace open wire from the horn switch or replace horn.

MicroController Control System

Repair or replace open wire going to battery negative.

85

Troubleshooting

PROBLEM 31 Auxiliary lighting and/or alarm does not function correctly. Lift and drive operation normal.

POSSIBLE CAUSE Open fuse; Faulty wiring; Defective switch; Shorted load; Open load; Loss of input voltage to DC-DC converter; Defective DC-DC converter.

CHECKS Connect the battery and close the key switch.

Measure from the DC-DC converter 12V positive terminal to the 12V negative terminal.

No voltage output

Voltage above 13V

Con’d Next Page

Con’d Next Page

Voltage below 11V

Con’d Next Page

Voltage 11 to 13V

With the faulty auxiliary circuit activated, check for voltage on load side of the auxiliary fuse.

11 to 13 volts

Check for voltage on the load side of the auxiliary switch.

11 to 13 volts

Check for short circuits; Replace auxiliary fuse.

0 volt

Check for voltage at the negative connection of the load.

0 volt

No voltage

Repair or replace open wire from fuse or replace detective switch.

11 to 13 volts

Repair or replace open wire from the auxiliary switch or replace the defective auxiliary component.

Repair or replace open wire going to battery negative.

MicroController Control System

86

Troubleshooting

Problem 31 (continued)

No voltage output.

Measure the voltage from (POS INPUT) to (NEG INPUT).

Battery voltage

0 volt

Measure the voltage from (12V POS) terminal of the DC-DC converter to battery negative.

Battery voltage

0 volt

Measure the voltage from (ENABLE) terminal of the DC-DC converter to battery negative.

Battery voltage

Measure the voltage from the battery positive cable at the line contactor to the (NEG INPUT) terminal of the DC-DC converter.

Replace the DC-DC converter.

0 volt

Battery voltage

0 volt

Check for open fuse or wiring between the line contactor and the (POS INPUT) terminal of the DC-DC converter.

Repair open negative connection from converter (NEG INPUT) to battery negative.

Open fuse Open wiring Repair or replace open wiring from the key sw to the (ENABLE) terminal of the DC-DC converter.

Replace fuse and check wiring for shorts. If no shorts are found and the fuse continues to fail, replace the DC-DC converter.

Repair or replace faulty wiring.

Test the fuse at the DC-DC converter for continuity.

Fuse good

Fuse open

Remove the load connections at the (12V POS) and (12V NEG) terminals of the DC-DC converter. Measure the voltage from the (12V POS) to the (12V NEG) terminals of the DC-DC converter.

11 to 13 volts

<11 or >13 volts

Replace the DC-DC converter.

Check for a short circuit in each auxiary circuit.

No shorts found

Replace fuse. If fuse continues to fail, replace the DC-DC converter.

Shorts found

Replace the DC-DC converter.

Repair or replace faulty wiring or components.

MicroController Control System

87

Troubleshooting

Problem 31 (continued)

Voltage bellow 11 volts.

Measure the voltage from (POS INPUT) or (+IN) terminal to the (NEG INPUT) or (-IN) terminal of the DC-DC converter.

36 volts or above

Below 35 volts

Remove all connections at the (12V POS) and(12V NEG) or the (+OUT) and (-OUT) terminals of the DC-DC converter. Measure the voltage from (12V POS) to (12V NEG) or (+OUT) to (-OUT).

11 to 13 volts

Check the battery and DC-DC converter input connections from the battery.

Battery low

Poor connection

Below 11 volts Charge or replace battery.

Repair or replace faulty wiring or connections.

Check for a short or low resistance in the auxiliary circuits and loads.

NOTE : Excessive loading places the converter into current limit (12A maximum).

DC-DC converter faulty.

Replace converter.

Voltage above 13 volts.

Remove all connections at the (12V POS) and (12V NEG) or the (+OUT) and (-OUT) terminals of the DC-DC converter. Measure the voltage from (12V POS) to (12V NEG) or (+OUT) to (-OUT).

11 to 13 volts

Above 13 volts

Check the output load circuits for incorrect wiring or shorts to battery negative.

DC-DC converter faulty.

Replace converter.

MicroController Control System

88

Troubleshooting

PROBLEM 32 Display = “F0”, no lift truck operation.

POSSIBLE CAUSE Logic potentiometers VR1 and VR6 out of adjustment.

Excessive drive motor currents due to pushing or ramp application. Failed drive motor. Failed logics.

Weak or discharged battery.

CHECKS Adjust current limit to specification : 48 V - 250 amps OK

Still “F0”

Place lift truck into operation.

Determine when the “F0” occurs.

Before bypass

During bypass

Is there a steep ramp that the truck must stop on ?

If so the Excessive Drive Motor Current option may not be applicable in this application.

Set option Programmable Feature 9 to Data Codes 3.

Determine if there is a steep ramp in the application. Adjust VR6 so that current is greater than maximum drive motor current going up the ramp.

No ramp, or continues “F0”

No ramp, or continues “F0”

Does the “F0” occur due to excessive pushing or abuse. Ensure that the battery is not being deep discharged, causing high currents. Inspect the battery for poor maintenance or bad cells.

Explain situation to the customer. If abuse continues, any drive failure will not be warranted.

Discussion : The logic card monitors the current in the drive motors, and prevents high currents that may damage the drive motor, or possibly blow the line fuse. It uses two current limits settings for this purpose.

Potentiomenter VR1 sets current limit for transistor pulsing, and if drive motor current exceeds the VR1 current setting for longer than 3 seconds, it will failsafe and display an “F0”. Similary, if the bypass contactor is closed, and the current exceeds the potentiometer VR6 setting for longer than 3 seconds, the truck will failsafe in a similar manner. In addition, the bypass operation will be prevented if the drive motor currents exceed the VR1 current limit.

MicroController Control System

89

Troubleshooting

PROBLEM 33 Display = “F2”, no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Shorted DTR1; Welded bypass contactor tips ; Open wiring; Driver board defect; Logics defect; Frame voltage on LS1 drive motor cable.

CHECKS Disconnect the battery, check bypass contactor for welded tips. Check contactor for free tip movement.

Not welded

Welded

Disconnect battery, remove logic cover, check continuity and connections of wire #L64 at DTR1 emitter to P9-5 on logics.

Continuity

No continuity

Disconnect LS1 cable at panel and retry.

Still “F2”

Repair or replace contactor tips.

Check BDI adjustment and battery Check current limit adjustment.

Repair or replace wiring or connection.

OK

Investigate voltage present on LS1 cable.

Check DTR1 for failure Test OK

Test driver board (drive side only).

Test OK

Failed

Replace transistor.

Failed

Replace logics.

MicroController Control System

Replace driver board.

90

Troubleshooting

PROBLEM 34 Display = “F2” (Flashing), no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Shorted DTR2; Welded bypass contactor tips ; Open wiring; Driver board defect; Logics defect; Frame voltage on RS1 drive motor cable.

CHECKS Disconnect the battery, check bypass contactor for welded tips. Check contactor for free tip movement.

Not welded

Welded

Disconnect battery, remove logic cover, check continuity and connections of wire #R64 at DTR2 emitter to P9-6 on logics.

Continuity

Repair or replace contactor tips.

Check BDI adjustment and battery.

Check current limit adjustment.

No continuity

Disconnect RS1 cable at panel and retry.

Still “F2” (Flashing)

Repair or replace wiring or connection.

OK

Investigate voltage present on RS1 cable.

Check DTR2 for failure Test OK

Test driver board (drive side only).

Test OK

failed

Replace transistor.

Failed

Replace logics.

MicroController Control System

Replace driver board.

91

Troubleshooting

PROBLEM 35 Display = “F3”, no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Shorted PTR1; Open wiring; Driver board (HYD.) defect; Open circuit pump motor or P1, P2 cables ; Logics defect.

CHECKS Connect the battery, close the seat and key switches.

Line contactor closes then opens, pump motor does not turn. Display = “F3”

Line contactor closes then opens, pump motor turns a small amount. Display = “F3”

Disconnect battery, remove logic cover, check continuity of wire #74 at emitter connector of PTR1 to P9-7 on logics.

No continuity

Check PTR1 for a short circuit.

Not failed

Failed

Continuity Replace transistor.

Repair or replace wiring

Check continuity from P1 to P2 at panel.

Check driver board (HYD.).

Continuity

No continuity

Not failed

Failed

Check motor and cables and repair.

Replace logics.

Replace driver board (HYD.)

Replace logics.

*

*

* See Notice NOTICE Damage to the control panel could result. To prevent further damage, before PTR1 or driver board are replaced, complete the following checks: 1. Check the diode PD for a failure.

2. Check Head capacitor for a failure.

3. Check PTR1 for a failure.

4. Check Driver board for a failure.

5. Check for continuity from PTR1 emitter (wire #74) to logics P9-7.

MicroController Control System

92

Troubleshooting

PROBLEM 36 Display = “F4”, no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Bypass contactor tips shorted; Shorted DTR1, DTR2 and PTR1. Poor connection at logic P9 connector ; Driver board defect.

CHECKS See Problems 33, 34 and 35, Display = “F2” or “F2” (Flashing) and “F3”. Do both procedures.

MicroController Control System

93

Troubleshooting

PROBLEM 37 Display = “F5”, no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Faulty wire connections; DTR1 failed; Current limit set to low; Failed DD1 or DD2; Failed driver board; Failed current sensor; Failed logics.

CHECKS Disconnect the following wires, visually inspect them for burnt or discolored terminals; Loose connections; Smashed or compressed connectors; Corrosion or foreign material. Wire #L65 at P9-1.

Wire #L64 at P9-5 and emitter bus bar of left drive power transistors. Wire #L67 and #L68 at resistor DR1. Wires #L63 at DTR1. Wire #4 from driver board to positive heatsink. Wire #1 from driver board to negative heatsink. Wire #L22 from logics P1-12 to current sensor. Wire #25 from logics P1-16 to current sensor. Current sensor PIN3 to negative heatsink. Repair any defects then reconnect the wires.

Display = “F5”

Display normal

Test DTR1 for a failure.

Return truck to operation.

Not failed

Failed

Replace transistor.

Make sure that the connecter of current sensor is connected. Measure the voltage at P1-12 with the key switch closed. If the voltage is over than 10V, replace the current sensor.

*

Test diodes DD1 and DD2 for a failure.

Not failed

Failed

Measure voltage at P1-16 with the key switch closed.

Voltage = 11 to 12V

Any other voltage

Perform Rapid Turn-Up procedure for current limit (VR1).

Display “F5”

Replace logics.

Replace logics.

*

*

Display normal

Test driver board (drive) for a failure.

Not failed

Replace failed components.

Recalibrate current limit to specifications.

Recalibrate current limit adjustments to specifications.

Failed

Replace failed components. Recalibrate current limit to specifications.

*

* See Notice #1 MicroController Control System

94

Troubleshooting

PROBLEM 38 Display = “F5” (Flashing), no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Faulty wire connections; DTR2 failed; Current limit set to low; Failed DD3 or DD4; Failed driver board; Failed current sensor; Failed logics.

CHECKS Disconnect the following wires, visually inspect them for burnt or discolored terminals; Loose connections; Smashed or compressed connectors; Corrosion or foreign material. Wire #R65 at P9-2.

Wire #R64 at P9-6 and emitter bus bar of right drive power transistors. Wire #R67 and #R68 at resistor DR2. Wires #R63 at DTR2. Wire #4 from driver board to positive heatsink. Wire #1 from driver board to negative heatsink. Wire #R22 from logics P1-13 to current sensor. Wire #25 from logics P1-16 to current sensor. Current sensor PIN3 to negative heatsink. Repair any defects then reconnect the wires.

Display = “F5” (Flashing)

Display normal

Test DTR2 for a failure.

Return truck to operation.

Not failed

Failed Replace transistor.

Make sure that the connecter of current sensor is connected. Measure the voltage at P1-13 with the key switch closed. If the voltage is over than 10V, replace the current sensor.

*

Test diodes DD3 and DD4 for a failure.

Not failed

Failed

Measure voltage at P1-16 with the key switch closed.

Voltage = 11 to 12V

Any other voltage

Perform Rapid Turn-Up Procedure for current limit (VR1).

Display “F5” (Flashing)

Replace logics.

Replace logics.

*

*

Display normal

Test driver board (drive) for a failure.

Not failed

Replace failed components.

Recalibrate current limit to specifications.

Recalibrate current limit adjustments to specifications.

Failed

Replace failed components. Recalibrate current limit to specifications.

*

* See Notice #2 MicroController Control System

95

Troubleshooting

NOTICE #1 Damage to the control panel could result. To prevent further damage, before DTR1 or driver board are replaced, complete the following checks: 1. Check the diode DD1 and DD2 for a failure.

2. Check DTR1 for a failure.

3. Check Driver board for a failure.

4. Check Head capacitor for a failure.

5. Check for continuity from DTR1 emitter (wire #L64) to logics P9-5.

6. Check Current sensor for a failure.

NOTICE #2 Damage to the control panel could result. To prevent further damage, before DTR2 or driver board are replaced, complete the following checks: 1. Check the diode DD3 and DD4 for a failure.

2. Check DTR2 for a failure.

3. Check Driver board for a failure.

4. Check Head capacitor for a failure.

5. Check for continuity from DTR2 emitter (wire #R64) to logics P9-6.

6. Check Current sensor for a failure.

MicroController Control System

96

Troubleshooting

PROBLEM 39 Display = “F6”, no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Failed Fuse - Hydraulic; Faulty wire connections; PD, PTR1 failed; Failed driver board (HYD.); Failed logics.

CHECKS Check the continuity of Fuse - Hydraulic.

Disconnect the following wires, visually inspect them for burnt or discolored terminals, loose connections, smashed or compressed connectors, corrosion or foreign material.

Wire #75 at P9-3. Wire #77 and #78 at resistor PR1.

Wire from driver board (HYD.) to positive heatsink.

Wire #1 from driver board (HYD.) to negative heatsink.

Wire #73 at base of transistor PTR1.

Repair any defects then reconnect the wires.

Display = “F6”

Display normal

Check diode PD for a failure.

Return truck to operation.

Not failed

Failed

Check transistor PTR1 for a failure.

OK

Replace failed diode.

Failed

Check driver board (HYD.).

Not failed

*

Replace transistor.

*

Failed

Replace logics.

Replace driver board (HYD.).

*

* See Notice NOTICE Damage to the control panel could result. To prevent further damage, before PTR1 or driver board are replaced, complete the following checks: 1. Check the diode PD for a failure.

3. Check PTR1 for a failure.

2. Check Head capacitor for a failure.

4. Check Driver board for a failure.

5. Check for continuity from PTR1 emitter (wire #74) to logics P9-7.

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97

Troubleshooting

PROBLEM 40 Display = “F7”, no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Failure in both the drive and pump circuits.

Incorrect wiring of wires #L67, #L68, #R67, #R68, #77 and #78.

CHECKS See Problem 37, 38 and 39, Display = “F5” or “F5” (Flashing) and Display = “F6”. Do both procedures.

MicroController Control System

98

Troubleshooting

PROBLEM 41 Display = “FA”, no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Faulty wire connections; Failed steer angle switch; Failed logics.

CHECKS Disconnect steer angle switch connector.

Check continuity of wires #50, #51, #52 and #53 from logic P2-17 ~ 20 to steer angle switch connector.

Continuity

Not continuity

Repair or replace wires.

Check continuity wire #1 at steer angle switch connector to negative heatsink.

Continuity

No continuity

Put steer wheel in straight position.

Remove steer angle switch assembly cover. Check continuity of steer angle switches.

Continuity

Repair or replace wires.

Not continuity

Check steer angle switch operation by steer wheel position. (See steer angle control - page 24) Check OK

Replace logics.

MicroController Control System

Replace failed switches.

Failed

Adjust steer angle switches.

99

Troubleshooting

PROBLEM 42 Display = “Fb”, no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Battery defect; Logics defect.

CHECKS Disconnect battery, measure voltage at battery connector terminal. Voltage must be higher than 30 volts on 48V system and 20 volts on 36V system.

Voltage OK

Wrong voltage

Check battery connections; Replace battery.

With key on, seat switch and line contactor closed, measure voltage at logic P9–9.

Battery voltage

No battery voltage

Replace logics.

MicroController Control System

Repair or replace wire.

100

Troubleshooting

PROBLEM 43 Display = “Fd”, lift truck operation normal.

POSSIBLE CAUSE Pressure switch defect; Wiring defect; Logics defect.

CHECKS Disconnect the battery. Check continuity from wire #41 to #1 on the pressure switch.

Continuity

No continuity

Check continuity from wire #1 on the pressure switch to control panel battery negative. continuity

No Continuity

Check continuity from wire #41 on the pressure switch to logic P 2-1 continuity

Repair or replace wires.

No Continuity

Replace logics.

MicroController Control System

Repair or replace wires.

Repair or replace wires.

101

Troubleshooting

System Tests and Adjustments

Potentiometer Adjustment Tool -Trimmer

Test Equipment

Available from most electronic suppliers, this insulated tool allows for fast and easy adjustments of potentiometers.

Hydrometer Hydrometers are usually available from any battery supplier. Battery maintenance is a crucial part of maintaining the electric vehicle. The ability to measure specific gravity and adjust the battery discharge indicator to match battery manufacturers specifications is an important part in the total maintenance of the electric vehicle.

Discharging Head Capacitor (HEAD CAP)

There are various pieces of electric truck test equipment that Daewoo recommends for all service personnel. This equipment is available from a number of world wide manufacturers and local electronic suppliers. Contact your Daewoo dealer or the factory for further recommendations.

WARNING Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

Handheld Multimeter A digital multimeter that measures DC voltage, resistance, and has a diode tester, is required. It is recommended that a high quality meter that is drop protected, or comes with a drop proof case, be purchased. Autoranging features, fast becoming an industry standard, are convenient for the service personnel, but are not required for servicing the lift truck. A variety of miniature test leads, alligator clips, and needle probes are also useful, and some of these usually come with the multimeter.

Clamp-on Current Probe The electric lift truck testing and adjusting procedures require the measurement of average DC currents.

Currents in excess of 600 amps may be present, so a clamp-on meter that will exceed this level is required. It is also highly recommeded that a device that has a voltage output, as well as a visible display, be used. This makes viewing and adjusting currents from the operator's seat possible. The jaws of the current probe should be able to accept at least a 19mm (.75 inch) cable diameter.

MicroController Control Systems

2

1

3

Discharging Head Capacitor (HEAD CAP) (1) Resistor. (2) Positive heatsinks.

(3) Negative heatsinks.

1. Disconnect the battery and discharge the head capacitor.

2. Put a 82 ohm, 80 watt resistor (1) Part No. 929315, in position between the positive (2) and negative (3) heatsinks. Hold the resistor in position for 10 seconds. This will discharge the capacitor below 5 volts.

102

Testing And Adjusting

Logics Removal 8 WARNING Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

7

Logics Removal (7) Nuts. (8) Logics.

1. Disconnect the battery and discharge the head capacitor.

5. Remove screws (7) which hold logics (8) to control panel.

6. Remove logics and replace logic cover to prevent damage.

2

“Run Time” Tests

1

WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

Component Location (1) Screws. (2) Logic Cover.

2. Loosen screws (1) that hold logic cover (2).

3. Remove the logic cover.

WARNING

3

5

6

The lift truck can move suddenly. Battery voltage and high amperage are present. Injury to personnel or damage to the lift truck is possible.

Safely lift both drive wheels off the floor. Put blocks of wood under the frame so the drive wheels are free to turn. During any test or operation check, keep away from drive wheels.

4

Key ON, No Operator Warning, Display =“EE” (Flashing) 1. Connect the battery.

2. Turn key to ON with no one on the seat.

Connector Re4moval (3) Connector P1. (4) Connector P2. (5) Connector P8.

(6) Connector P9.

3. The display should show the letter “EE” flashing on and off.

4. Disconnect connectors P1(3), P2 (4), P8 (5) and P9 (6). When disconnecting connectors pull on plastic connector housing, not on the wires.

MicroController Control Systems

4. With an operator on the seat or by pressing on the seat the letter “EE” should stop flashing.

103

Testing And Adjusting

Static Return to Off (SRO), Display = “EE”

Overtemperature Protection

1. Connect the battery and sit on the seat.

2. Select a direction before turning key to ON. 3. Turn key to ON. An “EE” should appear on the display and the drive system should not operate.

4. Return the direction lever to neutral, then back to forward or reverse. The “EE” should disappear from the display and the drive system should operate.

5. Turn key to OFF. Depress and hold the accelerator pedal.

To turn on overtemperature indicator.

6. Turn the key to ON. An “EE” should appear on the display and the drive system should not operate.

1. Disconnect the battery and discharge the head capacitor.

7. Release the accelerator padal. The “EE” should disappear from the display and the drive system should operate.

2. Disconnect the control panel thermal switch connector.

3. Connect the battery, close the seat switch and turn the key ON. The overtemperature indicator and “Ec” should be truned on. The drive and hydraulic speed will be reduced. “Ec” stored.

Steps 1 through 3 can be repeated for the drive and pump motor thermal switches, the results should be: Drive – Drive pulse ratio reduced, bypass operation prevented, and “Ed” stored.

Pump – Lifting performance reduced, and “EP” stored.

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104

Testing And Adjusting

Logic Unit Quick Reference Voltage Check

Component Tests

The chart that follows is a quick reference of the expected voltages at the logic pin connectors. All voltage measurements are made with respect to battery negative.

WARNING Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible.

Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels.

NOTICE Do not use steam or solvent to clean the controls.

Damage can be caused to the control panel. Use pressure from an air hose with a maximum pressure of 205 kPa (30 psi) to clean the control panel when necessary. The air supply must be equipped with a water filter.

1. Put blocks of wood under the frame so both drive wheels are free to turn.

2. Disconnect the battery and discharge the head capacitor.

NOTE: When control wires and power cables or bus bars are to be connected to the same bolt or stud, place all control wires together on the top of the bus bar or power cable.

3. Remove the logic cover.

4. Set the multimeter to the 200 volt DC range.

Use the electrical schematic (located in left side panel) to locate components referred to by name and number in the procedures that follow. All wires must be located as shown on the schematic.

Refer to SB2082E02 schematic(A154764) as attached.

5. Connect the multimeter negative lead to control panel battery negative.

6. Use the multimeter positive lead with an Needle Tip to measure the voltages under normal and activated conditions as shown in the Logic Voltage Reference chart.

Make sure the chart matches the control system being tested.

1

3

4

2

Connector Layout (1) Connector P1.(2) Connector P2. (3)Connector P8.

(4) Connector P9.

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105

Testing And Adjusting

Logic Terminal P1-1 P1-2 P1-3

Wire No.

P1-4 P1-5 P1-6 P1-7 P1-8 P1-9 P1-10 P1-11 P1-12 P1-13 P1-14 P1-15

33 L34 L35 R34 R35 36 L32 R32 L22 R22 18

Battery (+) from key switch Battery (+) to all CTR coils Line CTR coil Left-FWD coil Left-REV coil Right-FWD coil Right-REV coil Bypass CTR coil Left Plug sensor Right Plug sensor Left drive CT Right drive CT Not used Accelerator

P1-16

25

12 Voltage (+)

P1-17 P1-18 P1-19 P1-20

– –

Not used Not used

1

Battery Negative

P2-1

41

P2-2

49

P2-3 P2-4 P2-5 P2-6 P2-7

47 48 27 28 45

Pressure switch Tilt switch AUX1. switch Lift 1 switch Lift 2 switch FWD switch REV switch Seat switch

P2-8

71

P2-9 P2-10

20 24

P2-11

69

P2-12

43

P2-13

42

P2-14

31

P2-15

72

5 15

Function

LOGIC VOLTAGE CHECKS Normal Activated Voltage Voltage B (+)

B (+)

B (+)

B (+)

B (+) B (+) B (+) B (+) B (+) B (+) 0 0 0 to 0.03 0 to 0.03

Low Low Low Low Low Low -0.8 to -0.2 -0.8 to -0.2 0.03 to 12 0.03 to 12

0 to 0.89

0.9 to 12

11 to 13

11 to 13

Activate pedal from full up to full down 0V = key switch OFF, 12V = key switch ON

0

Logic board negative

Low

High

Activate steering wheel

High

Low

Activate lever from OFF to ON

High High High High High

Low Low Low Low Low

Park brake switch

Low

High

Height 1 switch Height 2 switch Control thermal switch Drive motor thermal switch Pump motor thermal switch Drive brush wear indicator sensor Pump brush wear indicator sensor

High High

Low Low

Low

High

Low

High

Low

High

High

Low

High

Low

Activate lever from OFF to ON Activate lever from OFF to ON Activate lever from OFF to ON Activate lever from OFF to ON High: switch open, Low: closed Low: Park brake activated High: Park brake released Activate lever from OFF to ON Activate lever from OFF to ON Activated by overtemperature of control panel Activated by overtemperature of drive motor Activated by overtemperature of pump motor Activated by brush wear of drive motor Activated by brush wear of pump motor

MicroController Control Systems

0

Test Function Procedure 0V: key switch OFF, B (+): key switch ON. B (+) to all coils with key ON, 0V key OFF. B (+): Line CTR open, 0V: closed B (+): Left FWD open, 0V: closed B (+): Left REV open, 0V: closed B (+): Right FWD open, 0V: closed B (+): Right REV open, 0V: closed B (+): Byp. CTR open, 0V: closed Voltage exchanges 0 to negative Voltage exchanges 0 to negative Voltage increases with current Voltage increases with current

106

Testing And Adjusting

LOGIC VOLTAGE CHECKS Logic

Wire

Normal

Activated

Test Function

Terminal

No.

Voltage

Voltage

Procedure

P2-16

46

AUX2 switch

High

Low

Activate lever from OFF to ON

P2-17

50

ANGLE SWITCH 1

High/Low

High/Low

Turn steer wheel lock to lock

P2-18

51

ANGLE SWITCH 2

High/Low

High/Low

Turn steer wheel lock to lock

P2-19

52

ANGLE SWITCH 3

High/Low

High/Low

Turn steer wheel lock to lock

P2-20

53

ANGLE SWITCH 4

High/Low

High/Low

Turn steer wheel lock to lock

P8-1

101

LCD: DC 5 Volt (+)

4.5 to 5.5

4.5 to 5.5

Key switch OFF: 0V, ON: 5V

P8-2

WH

LCD: DATA

0

High / Low

0V: segment OFF, High: On

P8-3

YL

LCD: DATA-bar

0

High / Low

0V: segment ON, High: OFF

P8-4

GN

LCD: CLOCK

0

High / Low

0V: segment OFF, High: On

P8-5

BU

LCD: CLOCK-bar

0

High / Low

0V: segment ON, High: OFF

P8-6

BK

LCD: LOAD

0

High / Low

0V: segment OFF, High: On

P8-7

RD

LCD: LOAD-bar

0

High / Low

0V: segment ON, High: OFF

P8-8

108

Battery negative

0

0V

P9-1

L65

0

0.1 to 1.3

Activated as drive TR pulses (Left TR)

0

0.1 to 1.3

Activated as drive TR pulses

P9-2

R65

P9-3

75

P9-4

–

P9-5

L64

P9-6

R64

P9-7

74

P9-8

–

P9-9

4

Function

Logic board negative

Pulse drive TR base (Left motor) Pulse drive TR base (Right motor)

(Right TR)

Pulse pump main TR base

0

0.1 to 1.3

0

1.5 to B (+)

0

1.5 to B (+)

0

1.5 to B (+)

Activated as pump TR pulses

Not used Drive TR emitter sensor (Left)

Voltage increases as drive TR pulses

Drive TR emitter sensor (Right)

Voltage increases as drive TR

Pump main TR emitter Not used

faster (Left TR)

pulses faster (Right TR) Voltage increases as pump TR pulses faster

0

B(+) from positive heatsink

0

B (+)

B (+) with line CTR closed

NOTE : “Normal” ; battery connected, key switch and park switch closed.

High voltage signal should be 9 to 12 volts. Low voltage signal should be 0 to 0.9 volt.

MicroController Control Systems

107

Testing And Adjusting

Conductor and Switch Continuity 1. Set the multimeter to the 200 Ω range.

2. Use the multimeter to perform the continuity test. lf continuity exists, the measurement will be less than 1 ohm. lf the measurement is more than this, continuity does not exist and the problem will have to be repaired.

Capacitor (Head) 5

2

1

4

3

WARNING Location of Components (1) Positive connection point. (2) Positive cable.

(3) Negative connection point. (4) Negative cable.

(5) Capacitor.

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

4. Disconnect positive cable (2) from the positive connection point (1).

5. Disconnect negative cable (4) from the negative connection point (3).

NOTICE Damage can be caused to the head capacitor. Do not remove bolts from capacitor to perform tests.

Remove capacitor connecting cables at heatsink connections.

6. Set the multimeter to the 20 KΩ range. Connect the multimeter positive lead to positive cable (2) of head capacitor (5). Connect the multimeter negative lead to negative cable (4) of head capacitor (5).

7. The meter must increment to above 10 KΩ.

lf the capacitor fails the Head Capacitor Test, then replace capacitor.

8. If the head capacitor fails this test, then capacitor should be replaced.

1. Disconnect the battery and discharge the head capacitor.

See Head Capacitor in Specifications section for proper assembly order of the head capacitor connections and bolt torque specifications.

2. Visually inspect the capacitor for bulges at the terminals.

3. Verify the plastic top is not melted around the terminals and that the blow plug is not leaking.

WARNING Head Capacitor “blow plug” will rupture with reverse polarity. Vapors and contents of Head Capacitors are toxic, flammable and corrosive.

Personal injury can be caused from breathing the fumes or if its contents make contact with the skin. Be sure to always connect the positive wire, from the positive heatsink, to the positive terminal of the Head Capacitor.

MicroController Control Systems

108

Testing And Adjusting

Contactors

Contactor Components WARNING

WARNING

The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible.

Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels that turn.

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

1. Disconnect the battery and discharge the head capacitor.

NOTICE Damage can be caused to the control panel. Do not switch the direction lever from one direction to the other (plug the lift truck) when the drive wheels are off the ground and in rotation at full speed.

Coil Suppression Diodes

1. Connect the battery and close the seat switch.

1 35

2. Turn the key to ON and release the parking brake.

The line contactor will close.

3. Select a direction and rapidly depress the accelerator pedal all the way to the floor.

246

4. Measure and record the time it takes the bypass contactor to close. This should be 1.5 to 2.5 seconds after the accelerator is fully depressed.

5. If the recorded value from Step 5 is less than 1.0 seconds, the logics may need to be replaced.

(During normal operation this time will vary with the load on the truck).

Suppression Diodes (1) D3-Line. (2) D4-Left Forward. (3) D5-Left Reverse.

(4) D6-Right Forward. (5) D7-Right Reverse.

(6) D8-Bypass.

6. If the recorded value from Step 5 is more than 2.5 seconds, check the bypass contactor tips for free movement. Check wiring for bad connections, and check current limit.

2. Disconnect the logic connector P1.

3. Set the multimeter to the diode test position.

NOTE : The bypass contactor will not close if the accelerator linkage is not adjusted correctly.

4. Connect positive multimeter lead to anode, and the negative multimeter lead to cathode of diode in the logics.

5. The multimeter must indicate .3 to .9 volts.

6. Reverse the leads (positive multimeter lead to cathode and negative multimeter lead to anode).

The meter must indicate OL.

MicroController Control Systems

109

Testing And Adjusting

Coil Resistance

Contactor Tips

2. Disconnect all leads to both terminals of the coil.

3. Set the multimeter to the 200Ω range.

4. Measure the resistance of the coil at both teminals. If must be within specifications. See Component Measurements in Specifications section.

5. If the coil is not within specifications, the contactor assembly will be replaced.

Coil Pulsing

Checking Contactor Tip Gap

2. With the contactor coil leads and suppression assembly leads connected, set the multimeter to the 200 volts DC range.

2. Visually inspect the tips to verify they are not welded, melted, burned, or pitted.

3. Pull and release the tips quickly to verify there is no binding.

3. Connect the multimeter negative lead to the negative coil terminal wire #33 and the meter positive lead to the coil positive terminal wire #15.

4. Visually inspect the contactor assembly.

Verify foreign objects don't interfere with normal contactor operation.

4. Connect the battery and activate the controls necessary for the contactor to be activated.

5. Check contactor tip gap with a feeler gauge as shown. Refer to Specifications section for correct settings.

5. After the contactor activates the multimeter must indicate 24 to 36 volts. If the voltage is not correct and the contactor passed the Coil Suppression Diodes test and the Coil Resistance test, the logics must be replaced.

MicroController Control Systems

110

Testing And Adjusting

Current Sensor 4. Check continuity from harness connector PIN2 wire #L22 to logic P1-12 (3) and connector PIN2 wire #R22 to logic P1-13 (4). Repair or replace any defective wires.

WARNING Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery. The head capacitor (HEAD CAP) must be discharged before any contact with the control panel is made. Disconnect the battery and discharge HEAD CAP.

5. Set the multimeter to the 200V DC range. With connector P1 disconnected, connect the multimeter positive lead to logic P1-16 (5).

Connect the multimeter negative lead to control panel battery negative.

1. Disconnect the battery, discharge the head capacitor, and remove the logic cover.

6. Connect the battery and turn the key to ON. The measurement must be 11 to 13 volts. If the measurement is not correct replace the logics.

7. Disconnect the battery and discharge the head capacitor. Connect P1.

WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible.

Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels that turn.

2

1 8. Set the multimeter to the 200V DC range and connect the positive lead to logic P1-12 (3) or P113(4)

Location Of Components (1) Current Sensor - Right. (2) Current Sensor - Left.

2. Disconnect current sensor connector.

9. Connect the battery and turn the key to ON. The measurement must be 0 volts.

3. Make sure wire #1 from current sensors is connected to the negative heatsink.

3

10. Move the direction lever to forward and depress the accelerator. The voltage being measured should increase. If there is no voltage measured or the voltage being measured does not change, the current sensor must be replaced.

4 5

NOTE: If the current sensor is replaced current limit must be adjusted.

P1 Connector Locations (3) P1-12. (4) P1-13. (5) P1-16.

MicroController Control Systems

111

Testing And Adjusting

Diodes

Diode Replacement WARNING

WARNING

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

1

5

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

1. Disconnect the battery and discharge the head capacitor.

6

2. Remove the logics.

3. Disconnect the lead wire and remove the diode.

1

2

7 9 3

4 8

Location of Comporrents (1) DD1. (2) DD1cathode lead wire. (3) DD2.

(4) DD2 cathode lead wire. (5) DD3.

(6) DD3 cathode lead wire.(7) DD4.

(8) DD4 cathode lead wire. (9) Battery negative heatsink.

Diode installation (1) Contact surfaces.

DD1 (1) is shown in the procedure that follows.

Use a similar procedure for the other diodes. DD1 (1), DD2 (3), DD3 (5) and DD4 (7) have a cathode lead wire.

4. Wipe clean contact surfaces (1). Put a small amount of D557047 Thermal Joint Compound on contact surfaces (1), but not on the threads.

5. lnstall the diode and tighten to the specification listed in the chart that follows.

1. Disconnect the battery and discharge the head capacitor.

2. Disconnect DD1 cathode lead wire (2).

Diode

Torque

DD1, DD2, DD3, DD4

9 to 11 N•m (81 to 99 lb•in)

3. Set the multimeter to the diode test position.

6. Connect all wires that were removed.

4. Connect the negative multimeter lead on DD1 cathode lead wire (2). Connect the positive multimeter lead to battery negative (9). The multimeter should indicate .3 to.9 volts.

5. Reverse the multimeter leads. The multimeter should indicate OL. If any of the measurements are not correct, replace the diode.

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Testing And Adjusting

Driver Board (On Vehicle) NOTE: Driver board components are soldered parallel to each other. The tests that follow may not be typical of individual components tests. The driver board must be replaced if any incorrect test results are obtained.

WARNING Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

Drive Side Tests Refer to Driver Board Components and Connections.

If any of the measurements that follow are incorrect the driver board must be replaced.

NOTICE Damage to the control panel could result. To prevent further damage before the Driver Board is replaced, complete the check list that follow;

1. Disconnect the battery, discharge the head capacitor.

2. Disconnect CONN A from driver board - main.

3. Resistor R2 test.

Set the multimeter to the 200Ω range. Connect the positive lead to CONN A-8. Connect the negative lead to CONN A-9. The measurement must be 7.1 to 7.9 ohms.

1. Check head capacitor for a failure.

If the drive circuit failed: 2. Check diodes DD1, DD2.

3. Check diodes DD3, DD4.

4. Check transistors DTR1, DTR2.

5. Check continuity of current sensor wires.

6. Check continuity from DTR1 emitter (wire #L64) to logic connector P9-5 and DTR2 emitter (wire #R64) to logic connector P9-6.

4. Resistor R5 test.

Set the multimeter to the 200Ω range. Connect the positive lead to CONN A-2. Connect the negative lead to CONN A-3. The measurement must be 7.1 to 7.9 ohms.

5. Transistor TR1 (collector/emitter) and ZD1 test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-9. Connect the negative lead to CONN A-1.

The measurement must be .3 to .9 volts.

If the hydraulic pump circuit failed: 2. Check diode PD. 3. Check transistor PTR1.

4. Check continuity from PTR1 emitter (wire #74) to logic connector P9-7.

Reverse the test leads.

The measurement must be OL.

NOTE: Visually inspect the following connections to ensure proper connection and lack of corrosion.

6. Transistor TR3 (collector/emitter) and ZD2 test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-2. Connect the negative lead to CONN A-1.

The measurement must be .3 to .9 volts.

1. Wire #L63 to the base of DTR1.

2. Wire #R63 to the base of DTR2.

3. Wire #73 to the base of PTR1.

4. Wire #74 to the emitter of PTR1.

5. Wire #4 to the positive heatsink.

6. Wire #1 to the negative heatsink.

7. Wires #L67 and #L68 to DR1.

8. Wires #R67 and #R68 to DR2.

9. Wires #77 and #78 to PR1.

10. Wires #L65, #R65 and #75 to connector P9–1, P9-2 and P9-3.

Reverse the test leads.

The measurement must be OL. 7. Transistor TR1 (collector/base) test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-9. Connect the negative lead to CONN A-10.

The measurement must be .3 to .9 volts.

Reverse the test leads.

The measurement must be OL.

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Testing And Adjusting

8. Transistor TR3 (collector/base) test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-2. Connect the negative lead to CONN A-4.

The measurement must be .3 to .9 volts.

15. Transistor TR2 (emitter/base) and R3 test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-12.

Connect the negative lead to CONN A-7.

The measurement must be .3 to .9 volts as above

Reverse the test leads.

The measurement must be OL.

Reverse the test leads.

The measurement must be almost same as above.

9. Transistor TR1 (emitter/base) and R1 test.

Set the multimeter to the 200Ω range.

Connect the positive lead to CONN A-1. Connect the negative lead to CONN A-10.

The measurement must be 3.5 to 4.3 ohms.

16. Resistor R3 test.

Set the multimeter to the 2 KΩ range. Connect the positive lead to CONN A-7. Connect the negative lead to CONN A-12. The measurement must be 1000 to 1400 ohms.

10. Transistor TR3 (emitter/base) and R4 test.

Set the multimeter to the 200Ω range.

Connect the positive lead to CONN A-1.

Connect the negative lead to CONN A-4.

The measurement must be 3.5 to 4.3 ohms.

17. Transistor TR4 (emitter/base) and R6 test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-6. Connect the negative lead to CONN A-7.

The measurement must be .3 to .9 volts.

11. Transistor TR2 (collector/emitter) test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-7. Connect the negative lead to CONN A-11.

The measurement must be .3 to .9 volts.

Reverse the test leads.

The measurement must be almost same as above.

Reverse the test leads.

The measurement must be OL.

18. Resistor R6 test.

Set the multimeter to the 2 KΩ range. Connect the positive lead to CONN A-7. Connect the negative lead to CONN A-6. The measurement must be 1000 to 1400 ohms.

12. Transistor TR4 (collector/emitter) test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-7. Connect the negative lead to CONN A-5.

The measurement must be .3 to .9 volts.

19. Connect all disconnected connectors.

Reverse the test leads.

The measurement must be OL.

13. Transistor TR2 (collector/base) test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-12.

Connect the negative lead to CONN A-11.

The measurement must be .3 to .9 volts.

Reverse the test leads.

The measurement must be OL. 14. Transistor TR4 (collector/base) test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-6. Connect the negative lead to CONN A-5.

The measurement must be .3 to .9 volts.

Reverse the test leads.

The measurement must be OL.

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Testing And Adjusting

Hydraulic Pump Side Tests

8. Transistor TR6 (collector/base) test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN P-3. Connect the negative lead to CONN P-5.

The measurement must be .3 to .9 volts.

Refer to Driver Board Components and Connections.

If any of the measurements that follow are incorrect the driver board must be replaced.

1. Disconnect the battery, discharge the head capacitor.

Reverse the test leads.

The measurement must be OL.

2. Disconnect CONN A, CONN B from driver board main and CONN P from driver board - hydraulic.

9. Transistor TR6 (emitter/base) and R11 test.

Set the multimeter to the 200 Ω range.

Connect the positive lead to positive heatsink.

Connect the negative lead to CONN P-5.

The measurement must be 3.5 to 4.3 ohms.

3. Transistor TR5 (collector/emitter) test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN A-7. Connect the negative lead to CONN B-4.

The measurement must be .3 to .9 volts.

10. Resistor R9 test.

Set the multimeter to the 200 Ω range.

Connect the positive lead to CONN P-3. Connect the negative lead to CONN P-4.

The measurement must be 7.1 to 7.9 ohms.

Reverse the test leads.

The measurement must be OL. 4. Transistor TR5 (collector/base) test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN B-6. Connect the negative lead to CONN B-4.

The measurement must be .3 to .9 volts.

11. Connect all disconnected connectors.

Reverse the test leads.

The measurement must be OL. 5. Transistor TR5 (emitter/base) and R7 test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN B-6. Connect the negative lead to CONN A-7.

The measurement must be .3 to .9 volts.

Reverse the test leads.

The measurement must be almost same as above.

6. Resistor R7 test.

Set the multimeter to the 200Ω range.

Connect the positive lead to CONN B-6. Connect the negative lead to CONN A-7.

The measurement must be 1000 to 1400 ohms.

7. Transistor TR6 (collector/emitter) and ZD3 test.

Set the multimeter to the diode test position.

Connect the positive lead to CONN P-3. Connect the negative lead to positive heatsink. The measurement must be .3 to .9 volts.

Reverse the test leads.

The measurement must be OL.

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Driver Board (Off Vehicle) Driver Board – Main

2 1

1 1

6

7

5

6

12

3

4

10

Driver Board – Hydraulic

8

8

1 9 10

Driver Board Components and Connections (1) CONN A. (2) CONN B. (3) TR1. (4) TR2. (5) TR3. (6) TR4. (7) TR5. (8) CONN P. (9) TR6.

(10) Positive heatsink.

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Testing And Adjusting

DRIVER BOARD TEST (OFF VEHICLE) Component

Multimeter Range

+ Lead

- Lead

Result

DRIVE SIDE TR1 (C to E)

Diode

#R63-A9

#4-A1

0.3 to 0.9 volts

TR1 (C to E)

Diode

#4-A1

#R63-A9

OL

TR1 (C to B)

Diode

#R63-A9

#R67-A10

0.3 to 0.9 volts

TR1 (C to B)

Diode

#R67-A10

#R63-A9

OL

TR1 (E to B) AND R1

200Ω

#4-A1

#R67-A10

3.5 to 4.5 ohms

R2

200Ω

#R64-A8

#R63-A9

7.1 to 7.9 ohms

TR2 (C to E)

Diode

#1-A7

#R68-A11

0.3 to 0.9 volts

TR2 (C to E)

Diode

#R68-A11

#1-A7

OL

TR2 (C to E)

Diode

#R65-A12

#R68-A11

0.3 to 0.9 volts

TR2 (C to B)

Diode

#R68-A11

#R65-A12

OL

TR2 (E to B) AND R3

Diode

#R65-A12

#1-A7

0.3 to 0.9 ohms

R3

200Ω

TR3 (C to E)

Diode

#L63-A2

#4-A1

0.3 to 0.9 volts

TR3 (C to E)

Diode

#4-A1

#L63-A2

OL

TR3 (C to B)

Diode

#L63-A2

#L67-A4

0.3 to 0.9 volts

TR3 (C to B)

Diode

#L67-A4

#L63-A2

OL

TR3 (E to B) AND R4

200Ω

#4-A1

#L67-A4

3.5 to 4.3 ohms

R5

200Ω

#L63-A2

#L64-A3

7.1 to 7.9 ohms

TR4 (C to E)

Diode

#1-A7

#L68-A5

0.3 to 0.9 volts

TR4 (C to E)

Diode

#L68-A5

#1-A7

OL

TR4 (C to B)

Diode

#L65-A6

#L68-A5

0.3 to 0.9 volts

TR4 (C to B)

Diode

#L68-A5

#L65-A6

OL

TR4 (E to B) AND R6

Diode

#L65-A6

#1-A7

0.3 to 0.9 ohms

R6

200kΩ

#1-A7

#R65-A12

#1-A7

#1-A7

1000 to 1400 ohms

1000 to 1400 ohms

PUMP SIDE TR5 (C to E)

Diode

#1-A7

#78-B4

0.3 to 0.9 volts

TR5 (C to E)

Diode

#78-B4

#1-A7

OL

TR5 (C to B)

Diode

#75-B6

#78-B4

0.3 to 0.9 volts

TR5 (C to B)

Diode

#78-B4

#75-B6

OL

TR5 (E to B) AND R7

Diode

#1-A7

#75-B6

0.3 to 0.9 ohms

R7

200kΩ

#1-A7

#75-B6

TR6 (C to E)

Diode

#73-P3

+ HEATSINK

0.3 to 0.9 volts

TR6 (C to C)

Diode

+ HEATSINK

#73-P3

OL

TR6 (C to B)

Diode

#73-P3

#77-P5

0.3 to 0.9 volts

TR6 (C to B)

Diode

#77-P5

#73-P3

OL

TR6 (E to B) AND R11

200Ω

#77-P5

+ HEATSINK

3.5 to 4.3 ohms

R9

200Ω

#73-P3

#74-P4

7.1 to 7.9 ohms

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1000 to 1400 ohms

Testing And Adjusting

1. Check head capacitor for a failure.

Transistors DTR1,DTR2 and PTR1

If drive circuit failed:

WARNING

2. Check DD1,DD2 for a failure.

3. Check DD3,DD4 for a failure.

4. Check DTR1,DTR2 for a failure.

5. Check driver board (drive side) for a failure.

6. Check continuity from DTR1,DTR2 emitter bus bar (wire #L64, #R64) to logic P9-5, P9-6.

7. Perform Current Sensor test.

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

If the pump circuit failed: 1. Disconnect the battery, discharge the head capacitor and remove the logics.

2. Check PD for a failure.

3. Check PTR1 for a failure.

4. Check driver board (pump side) for a failure.

5. Check continuity from PTR1 emitter (wire #74) to logic P9-7.

2. Remove wires and bus bars from base and emitter terminals of the transistors to be tested.

2

1

Transistor Replacement DTR1, DTR2 and PTR1 WARNING Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

3 D557003 (927566) Transistor (1) Emitter. (2) Base. (3) Collectror.

TRANSISTOR SPECIFICATIONS Multimeter

(+)

(-)

D557003

Setting

Test Lead

Test

Results

Resistance

Emitter

Base

45 to 135Ω

Diode

Base

Collector

3 to .9 V

Diode

Collector

Base

OL

Diode

Emitter

Collector

.3 to.9V

Diode

Collector

Emitter

OL

7 6

31

2

Location of Components (1) Bolt. (2) Bar. (3) Emitter wire #L64.

(4) Base wire #L63. (5) Transistor DTR1. (6) Screw.

(7) Bolts.

NOTICE Damage to the control panel could result.

To prevent further damage before a power transistor is replaced, complete the check list that follows:

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4 5

DTR1,DTR2 and PTR1 are all replaced in the same way. DTR1(5) is shown in the procedure that follows.

118

Testing And Adjusting

1. Disconnect the battery, discharge the head capacitor, and remove the logics.

Resistors (DR1, DR2 and PR1)

2. Remove bolt (1), bar (2) and emitter wire #L64 (3).

WARNING

3. Remove screw (6) and base wire #L63 (4).

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

4. Remove mounting bolts (7).

NOTE : Look for visual breaks or cracks on resistors.

1. Disconnect the battery, discharge the head capacitor, and remove the logics.

8 1

2 Transistor Removal (8) Contact surface.

4

5

3

6

5

8

Location of Components (1) DR1. (2) Wire #L67. (3) DR2.

(4) Wire #R67. (5) PR1. (6) Wire #77.

Transistor Removal (5) DTR1 transistor. (8) Contact surface.

2. Disconnect wire #L67 (2) from resistor DR1 (1) and disconnect wire #R67 from resistor DR2 (3).

5. The contact surface (8) of transistor (5) is coated with D557047 Thermal Joint Compound. Carefully remove the transistor.

3. Set the multimeter to the 200Ω range. Connect the multimeter leads to terminals on resistor (1) to check the resistance of DR1. Connect the multimeter leads to terminals on resistor (3) to check the resistance of DR2. Connect the multimeter leads to terminals on resistor (5) to check the resistance of PR1.

6. To Replace the transistor, wipe clean contact surfaces. Put a small amount of D557047 Thermal Joint Compound on the contact surface (8). Coat transistor so that compound covers only the contact area.

7. Install transistor (5) with mounting bolts (7). See Specifications section for proper torques.

4. The measurement for each resistor must be: 85 to 95 ohms.

8. Install base wire #L63 (4) with screw (6). See Specifications section for proper torques.

5. If the measurement is not correct, the resistor must be

9. Install bar (2) and emitter wire #L64 (3) with bolts (1). See Specifications section for proper torques.

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Testing And Adjusting

Thermal Switch The Thermal Switch (1) will open circuit if the temperature is 81 to 89°C (178 to 192°F) and close circuit at 69 to 77°C (156 to 171°F).

WARNING Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

If the thermal switch is removed from the heatsink, it can be tested in an oven.

See Troubleshooting Problem 20. Possible cause, pump or drive transistors overtemperature.

NOTICE Damage to the thermal switch will occur. Do not heat the thermal switch over an open flame.

Pump Motor and Drive Motor The Thermal Switch (1) will open circuit if the temperature is 144 to 156°C (291 to 313°F) and close circuit at 123 to 137°C (253 to 279°F).

If the thermal switch is removed from the motor, it can be tested in an oven.

Control Panel

See Troubleshooting Problems 21 and 22. Possible cause, drive or pump motors overtemperature.

1

5

5

Location of Components (1) Thermal switch-Drive. (5) Thermal switch-Hydraulic.

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Testing And Adjusting

Method B (Electrical)

Electrical System Adjustments

1. Enter diagnostics, through the specified procedure, the display is an “A0”.

Accelerator Control Linkage

2. Depress the accelerator slowly to stop. The speed symbols will increase from 0 to 10 on LCD.

Method A (Mechanical)

3. Release the accelerator, the display will be “A0”, disconnect the battery, and place the DIAG/RUN/SETUP switch back to RUN, and reinstall the line fuse.

1

4

Parking Brake Switch 63

2 WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible.

Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels that turn.

3

1. Disconnect the battery and discharge the head capacitor.

2. Adjust length of lever (1) to 63 L 2 mm and tighten the nut (2). Fully depress accelerator pedal (4) until stopped by accelerator stopper (3).

3. Release accelerator pedal (4). Check for dimension.

3 2

1

Parking Brake Switch Adjustment (1) Switch. (2) Plate. (3) Bolts.

1. Close the seat switch and turn the key to ON. 2. Release the parking brake and put the truck in forward.

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Testing And Adjusting

3. Reposition plate (2) so the switch (1) actuator is against the bracket. Tighten bolts (3).

Valve Control Card Adjustment

4. Engage the parking brake and the park brake symbol will be displayed. Repeat the procedure until adjustment is correct.

WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible.

Safety lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels that turn.

Lift Sensor 1. Disconnect the battery and discharge the head capacitor.

1. Verify the lift sensor clearance is adjusted correctly.

1

2. Disconnect all tilt and auxiliary switch connectors.

3 3. Place the lift truck in “Quick” or “Self” diagnostics so that the display is flashing the lift speed.

4 2

Lift Sensor Adjustment (1) Lift Sensor(transducer) (2) Magnet. (3) Screw.

(4) Setscrew. (A) 1.0 mm (.039 in) Clearance.

1

NOTICE Lift sensor may be damaged. Do not allow the magnet (2) to make contact with the plastic bracket when the lift lever is activated.

2

Valve Control Card Adjustment (1) P1 Potentiometer. (2) P2 Potentiometer.

4. Turn potentiometer P1 (1) fully counterclockwise unitl a clicking sound is heard (roughly 20 turns).

2. Loosen setscrew (4).

5. Turn potentiometer P2 (2) fully counterclockwise until a clicking sound is heard (roughly 20 turns).

3. Adjust screw (3) to make clearance (A) 1.0mm (.039 in) between lift sensor (1) and magnet (2) when the lift lever is activated fully (pulled all the way back).

6. Turn potentiometer P2 (1) 15 full turns clockwise.

7. Position the lift lever just prior to the hydraulic valve opening. Adjust P1(1) clockwise until a flashing “1” is obtained on the display.

4. Tighten setscrew (4). Check lift sensor circuit. The valve control card may need adjusting.

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Testing And Adjusting

8. Pull the lift lever all the way back. A flashing “3” must be displayed.

Tilt and Auxiliary Switches

9. If a flashing “3” is not displayed, adjust P2 (2) clockwise until it is.

Because each tilt and auxiliary switch can turn on the pump motor, it is recommended that only one be connected to start with. After adjusting the first switch proceed with the next one.

10. Release the lift lever and adjust P1 counterclockwise until a “0” is displayed.

1. Disconnect the battery and discharge the head capacitor. Disconnect all but one switch connector.

11. Repeat steps 9 and 10 until “0” to “3” speeds correct.

12. Put the lift truck back in the run mode so the actual hydraulics can be tested.

13. Connect the battery, close the seat switch and turn the key to ON. 14. Pull the lift lever back until the pump motor turns on. The forks must not move. Adjust P1 so the motor starts just before the valve opens.

1

If the valve opens before the motor turns on, adjust P1 (1) clockwise.

2

If the motor turns on too far in advance of the valve opening, adjust P1 (1) counterclockwise.

Tilt and Auxiliary Switch Adjustment (1) Screw. (2) Screws.

2. With valve spool in neutral position, loosen screws (2) and adjust screw (1) to center the switch roller on cam.

3. After adjusting switch in or out to obtain correct switch point, tighten screws (1) and (2) to lock switch into position.

4. Connect the battery, close the seat switch and turn the key to on. Readjust switch if needed, so that the pump motor turns on before the control valve opens.

This must be adjusted for each lever direction (pushed or pulled).

5. Connect the next switch and repeat this proccdure.

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Testing And Adjusting

Rapid Tune-Up Procedure 3) VR6 : Bypass Dropout Current Potentiometer

5 4

Fully counterclockwise (CCW) and then slowly turn VR6 (20 full turns) clockwise (430A).

3 2 1

4. Make the final adjustments as specified in each of the Testing And Adjusting procedures before putting the truck into service. Perform these procedures in the order listed below:

Lacation of Potentiometers (1) Current limit potentiometer VR1.

(2) Plugging Current limit potentiometer VR2.

(3) BDI adjustment potentiometer VR5.

(4) Bypass drop out adjustment potentiometer VR6.

(5) Electric Assist Brake adjustment potentiometer VR8.

1) Battery Discharge Indicator (BDI) 2) Current Limit 3) Plugging Current Limit 5. Turn off the key switch.

The rapid tune-up procedure establishes a starting point for logic card adjustments. The following procedure allows the truck to run without damage to the truck or its components.

Battery Discharge Indicator (BDI) Adjustment

WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible.

Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels that turn.

1

3

2

1. Turn off the key switch.

2. Place direction lever to reverse or forward or seat switch open.

Logic Board Layout (1) Jumper JP1. (2) Jumper JP2. (3) Potentiometer VR5

3. Turn on the key switch and then wait until display “EE” (SRO) or “EE” flashing shows on the LCD and the line contactor will be opened.

Accurate adjustment of the BDI is only possible with a battery of the same voltage that the truck is going to operate at, and at a voltage within the range of the display. If a lift interrupt has occurred, with a “EL” on the display, it may be necessary to reprogram Feature “10” to select TYPE1, and then make the necessary adjustments.

If 48 volt European tubular batteries are used, it is recommended that logic board is programmed TYPE1 on Programmable Feature “10”.

1) VRI : Drive Motor Current Limit Potentiometer Fully counterclockwise (CCW) and then slowly turn VR1 (8 full turns) clockwise (250A).

2) VR2 : Plugging Current Limit Potentiometer Fully counterclockwise (CCW) and then slowly trun VR2 (8 full turns) clockwise (250A).

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Testing And Adjusting

BDI Adjustment

Battery Table of the Closed Circuits Battery Terminal Voltage

1. Disconnect the battery and discharge the head capacitor. Remove logic cover and verify the DIAG/RUN/SETUP switch is in the RUN position.

Bar Symbols Display

2. Make sure the jumper connector is in the correct place for the lift truck battery used. Place the jumper on the following.

JP1=36V, JP2=48V 3. Set the multimeter to measure battery voltage.

Connect the multimeter positive lead to the battery positive cable at the line contactor. Connect the multimeter negative lead to the battery negative cable.

Type 1(OPT) : Closed Voltage 36V

48V

6

above 37.2

above 49.1

5

36.8 to 37.2

48.6 to 49.1

4

36.4 to 36.7

48.0 to 48.5

3

36.0 to 36.3

47.5 to 47.9

2

35.6 to 35.9

47.0 to 47.4

1

35.2 to 35.5

46.5 to 46.9

1*

25.8 to 35.1

33.8 to 46.4

0/EL

below 25.8

below 33.8

4. Put the direction lever in neutral and connect the battery.

1*=Display is flashing

5. Close the seat switch and turn the key to ON. The BDI display must show the correct bar for the voltage measured. To correct values are shown in the charts that follow.

Bar Symbols Display

Battery Terminal Voltage Type 1(STD) : Closed Voltage 36V

48V

EXAMPLE: If the measurement is 49.1 volts for a 48 volt battery, the bar display should be at “5”.

6

above 37.2

above 49.1

5

36.8 to 37.2

48.4 to 49.1

6. If the display is not correct, turn the key to OFF and make an adjustment to potentiometer VR5.

Turn VR5 clockwise to increase and counterclockwise to decrease the bar display.

Approximately a 1/2 turn of VR5 will change the display one bar. Turn the key to OFF between adjustments otherwise the display WILL NOT CHANGE.

4

36.4 to 36.7

47.7 to 48.3

3

35.9 to 36.2

47.1 to 47.6

2

35.4 to 35.8

46.4 to 47.0

1

35.0 to 35.3

45.9 to 46.3

1*

34.5 to 34.9

45.0 to 45.8

0/EL

below 34.5

below 45.0

1* = Display is flashing 7. If the voltage was 49.1V, VR5 should be turned to find the transition point between 6 and 5 on the bar display. This will assure that the BDI is calibrated at a high 5.

6 : The highest position

Battery Terminal Voltage Bar Symbols Display

: Max. Charged Status

5: 4: 3: 2: 1:

: (A) Not flashing (B) Flashing - 80% discharge warning

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Type 1(OPT) : Closed Voltage 36V

48V

6

above 37.2

above 49.1

5

36.9 to 37.2

48.3 to 49.1

4

36.6 to 36.8

47.4 to 48.2

3

35.3 to 36.5

46.6 to 47.3

2

35.9 to 36.2

45.7 to 46.5

1

35.6 to 35.8

44.9 to 45.6

1*

35.3 to 35.5

44.0 to 44.8

0/EL

below 35.3

below 44.0

Testing And Adjusting

NOTE: Closed Voltage means that line contactor close and idle operation in hydraulic system.

7. If the voltage is higher than 49.1V, adjust the BDI as example.

EXAMPLE: If the measurement is 50.7V, adjust bar display at a low 6 and then turn VR5 to 1 TURN CW. (1 TURN CW = 1.6V increase)

BDI Adjustment with display at “EL” If the logics has already gone into lift interrupt (display = “EL”) it is not possible to adjust the BDI until a battery above a certain programmed voltage is connected to the vehicle.

The factory default setting to reset the lift interrupt is any voltage equivalent to a bar display of 3 or higher.

This level can be adjusted.

See Program Feature “3”.

By reprogramming Feature “3”, from the factory default code of 3, to a temporary code of 0, it will become possible to adjust the BDI with a battery with a voltage less than a 3 on the bar display .

After adjustment of the BDI, reprogram Feature “3” back to the default setting of 3.

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Current Limit Test and Adjustment 4. Engage the park brake. Connect the park brake connector of harness to hold the closed circuit.

5. Connect the battery. Close the seat switch and turn the key to ON. 6. Select a direction and depress the service brake so that the wheels do not turn. Depress the accelerator to 80% pulsing.

To prevent bypass operation ensure that the accelerator is not depressed all the way down. To get an accurate current reading the wheels must not slip.

1

Ammeter Connection (1) Digital Ammeter.

NOTICE Damage to the drive motor will result. Do not stall the drive motor for longer than absolutely necessary. To protect the drive motor from excessive currents, and “F0” can occur during current limit setting. Allow for the motors to cool between stalls, and let the motor run between stalls.

WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible.

Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels that turn.

7. The current measurement must be within specification. Adjust logic potentiometer VR1 clockwise to increase the current and counterclockwise to decrease the current.

48V between 240 and 260 amps.

NOTE : Current limit is preset at the factory and should not be adjusted unless the truck malfunctions, or the logic board is replaced.

Only qualified service personnel with the correct instrumentation should adjust current limits.

8. Repeat steps 6 and 7 until setting is correct.

9. Don’t forget to re-engage the service brake switch and park brake switch prior to putting the vehicle back into operation.

1. Put blocks of wood under the frame so both drive wheels are free to turn.

2. Connect clamp-on ammeter (1) around the LA1 cable to measure drive motor current. Use multimeter to read current remotely from the operator’s seat. Ensure that option feature “9” is default setting to prevent bypass operation.

3. Remove the floor plate, and disconnect the service brake switch connector.

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Electrical Braking (Plugging) Current Test and Adjustment

Bypass Dropout Adjustment - Stall Protection WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible.

Safely lift the drive wheels off the floor. Put blocks of wood under the frame so both drive wheels are free to turn. Keep away from drive wheels that turn.

1

The stall protection feature helps protect the drive motor from abuse, and can also prevent unnecessary line fuse failures. Adjustment or checking of this current setting is not recommended unless drive motor or fuse failures have occurred, or an “F0” occurs during bypass operation. Factory settings are as follows:

Ammeter Connection (1) Digital Ammeter.

1. Make sure current limit is adjusted to specification before adjusting Electrical Braking current.

2. Connect clamp-on current probe (1) around LA1 cable to measure drive motor current. Use multimeter to read current remotely from the operator’s seat.

48V between 420 and 440 amps Fully counterclockwise (CCW) and then slowly turn VR6 (20 full turns) clockwise (430A).

3. Move the lift truck FORWARD at full speed. Keep the accelerator pedal fully depressed and change the direction to REVERSE.

If “F0” occurs during bypass operation, the application should be investigated for incorrect operation, and maximum currents should be measured. Adjusting VR6 clockwise will increase the maximum current allowed in bypass. For maximum motor protection, VR6 can be adjusted counterclockwise, until a “F0” occurs in bypass, then adjust the potentiometer clockwise 1 turn.

4. The current measured during the electircal braking (plugging )must be 250 amps L 5%.

5. If the correct current is not measured, disconnect the battery and discharge the head capacitor.

Remove the logic cover and adjust potentiometer VR2. Turn the potentiometer adjustment screw counterclockwise to decrease the plugging current.

NOTE : Though the plugging distance (Recommended plugging distance is approximately 5 meters) is an application specific adjustment, plugging current should not exceed 250 amps. If the recommended current produces a short stopping distance, the distance may be lengthened by turning potentiometer VR2 counterclockwise to reduce plugging current.

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Programmable Features There are 17 programmable features that effect the operation of the lift truck. A table of these features, the default setting, the minimum setting and the maximum setting are shown below: Default Feature Minimum Maximum Setting Number Setting

With the desired Feature Number being shown, move the direction lever to forward or reverse and then neutral. The display will flash the preset data value.

To increase the value, cycle the direction lever to forward and then back to neutral. The display will increment number. Repeat this cycle until the desired value for this feature is flashed.

Description

Setting 36(V) 48(V)

0

1

5

4

4 Creep Speed

1

1

6

4

2 Maximum Steering Speed

2

1

2

0

1 Electrically Assisted Braking

3

0

6

3

3 Discharged Battery Reset Value

4

0

6

5

0

0 Top Travel Speed Limit

P

P Auto Plugging

6

0

4

2

2 Wait Timer (seconds)

7

1

2

1

1 Discharged Battery Drive Speed

8

1

5

4

4 Acceleration Travel Speed Time

9

1

3

1

1 Excessive Drive Motor Current

10

1

3

2

2 Battery Type Selection

11

1

6

3

3 Maximum Idle Speed

12

1

6

3

3 Maximum Lift1 Speed

13

1

6

1

1 Maximum Lift2 Speed

14

1

6

3

3 Maximum Tilt Speed

15

1

9

4

4 Maximum Auxiliary Speed

16

1

5

3

3 Hydraulic Ramp Timer

To save a new setting, pull the tilt lever to maximum position and then release slowly while holding a wanted setting.

The display will show the next feature number.

3. Repeat again on the above NO.2 until static display, 16 will show.

A “PE” indicates the end of the feature list and can be cycled to return to the beginning of the feature list.

Activating Default Settings All of the programmable features can be set to the factory default settings by the following procedure.

1. Turn the key switch to OFF.

Setting Procedure Option Features

2. Seat switch must be open.

The programming procedures are described on the following.

3. Move the direction lever to reverse.

4. Place the DIAG/RUN/SETUP switch to SETUP.

1. Initial conditions 5. Park brake must be released.

Move the DIAG/RUN/SETUP switch to “SETUP” and then turn on the key switch.

6. Depress the accelerator pedal to maximum.

Wait until display “0” shows on the LCD. This code indicates that truck is in the SETUP mode.

7. Turn the key switch to ON. 8. After the display performs the LCD test, a “d” (Flashing) will be displayed. This indicates that the default settings have been programmed.

2. Programming methods To change the Programmable Feature Numbers, pull the tilt lever to maximum position and then release once. The display will show Feature Number 1.

NOTE: When you change voltage jumper (JP1 JP2), you should do the default setting on page 129

Cycling the tilt switch advances the display to the next Feature Number. Cycle the tilt switch until the Feature Number of the parameter to be programmed is shown on the display.

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Programmable or Settable Option Features The logics contains a number of features which are either settable or programmable.

The following is a list of the features, however the “Service Manual” or your Daewoo Dealer should be consulted in determing which options may be beneficial to the application.

Note : Marked

means default setting.

FEATURE NO.

DESCRIPTIONS • • Creep Speed •B •

0

Creep Speed Selection provides for slower creep speed control, especially at high mast application. Depending on truck chassis configuration and customer preference, the creep speed can be selected. The default setting of 2 gives improved creep speed control, especially at higher mast. The higher “number” makes more faster creep speed.

Data Codes

1

2

3

4

5

On-Duty (%)

20

23

26

29

32

• • Maximum Steering Speed •B • This can be used to limit the maximum steering speed of the truck.

These values are on-duty ratio of the pump main transistor base.

1

Data Codes

36(V)

1

2

3

4

5

6

48(V)

1

2

3

4

5

6

17

20

23

26

29

32

On-Duty (%)

• • Electrically Assisted Braking B •

2

To automatically activate plugging braking when the service brake is depressed and accelerator pedal is released.

Data Codes

36(V)

0

1

48(V)

0

1

Not used

Used

Comments • •B • • Discharged Battery Reset Value

3

4

This feature sets the level of battery charge required to enable the hydraulics after a lift interrupt occurs. The battery discharge indicator (BDI) must read a level greater than the value set in this feature to enable the hydraulics after a lift interrupt occurs.

(1* = Display is flashing) Data Codes

0

1

2

3

4

5

6

On-Duty (%) • •B • • Top Travel Speed Limit

1*

1

2

3

4

5

6

The value of this feature is set to select the drive motor top speed.

Values between 1 and 5 allow for varying speeds, 1 being the slowest and 5 being the fastest without using the bypass contactor.

0 being the normal travel and bypass operation.

Data Codes

0

1

2

3

4

5

Speed(%)

100 : Bypass operation

43

50

60

75

90

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Testing And Adjusting

FEATURE NO.

DESCRIPTIONS • • Auto Plugging •B •

5

If selected, this feature will automatically activate auto plugging braking when the accelerator is released during driving.

Data Codes

P

Time (Sec)

Pass

• • Wait Timer •B •

6

This feature varies the time before the line contactor drops out after the truck has been inactive (wait mode-no operator requests, and direction lever in neutral).

The delay may be set in 6 second increments between 0 and 12 seconds.

Data Codes

0

1

2

3

4

Time (Sec)

0

3

6

9

12

• • Discharged Battery Drive Speed •B •

7

This feature sets the drive motor top speed during lift interrupt, battery lock-out. If the display shows “EL”, the logics limits the drive motor top speed to the value set in this feature.

Data Codes Comments

1

2

1. Max.speed=70%

1. Normal operation.

2. No bypass operation.

2. Bypass operation.

• • Acceleration Travel Speed Time •B •

8

This feature allows for varying amounts of time until the bypass contactor close when accelerator pedal has been depressed from zero to max. position.

Data Codes

1

2

3

4

5

Time (Sec)

Slowest

Slower

Normal

Faster

Fastest

• • Excessive Drive Motor Current •B •

9

This prevents the truck from entering bypass when the truck is in current limit, thus extending the life of the bypass contactor tips, reducing line fuse failures, and extending drive motor brush life.

If the motor is stalled for longer than the timer is set for, the vehicle will failsafe to prevent motor damage and an “F0” will be displayed.

Data Codes

Comments

1

2

3

This is to protect drive

This is to protect drive

motor from excessive

motor from excessive

current in either pulsing

current in only bypass

or bypass modes.

modes.

Not used

• • Battery Type Selection •B •

10

Due to different voltage characteristics of battery technologies, specifically european tubular designs, it may be necessary to use a battery voltage chart with a reduced voltage range.

Data Codes

1

2

3

Battery Voltage (Volt)

Max.49.1/Min.33.8

Max.49.1/Min.45.0

Max.49.1/Min.44.0

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FEATURE NO.

DESCRIPTIONS • • Maximum Idle Speed •B •

11

This can be used to limit the maximum idle speed of the truck.

These values are on-duty ratio of the pump main transistor base.

Data Codes

1

2

3

4

5

6

On-Duty (%)

7

9

11

13

15

17

• • Maximum Lift 1 Speed •B • 12

This can be used to limit the maximum lift 1 speed of the truck.

These values are on-duty ratio of the pump main transistor base.

Data Codes

1

2

3

4

5

6

On-Duty (%)

25

30

35

40

45

50

• • Maximum LIft 2 Speed •B • 13

This can be used to limit the maximum lift 2 speed of the truck.

These values are on-duty ratio of the pump main transistor base.

Data Codes

1

2

3

4

5

6

On-Duty (%)

50

60

70

80

90

95

• • Maximum Tilt Speed •B • 14

This can be used to limit the maximum tilt speed of the truck.

These values are on-duty ratio of the pump main transistor base.

Data Codes

15

1

2

3

4

5

6

On-Duty (%) 30 • •B • • Maximum Auxiliary Speed

40

50

60

70

80

This can be used to limit the maximum aux. speed of the truck.

These values are on-duty ratio of the pump main transistor base.

Data Codes

1

2

3

4

5

6

7

8

9

Time (Sec)

30

35

40

45

55

65

75

85

95

• • Hydraulic Ramp Timer •B • 16

When the hydraulic switches are activated, the time which is to take to maximum pulsing can be adjusted.

Data Codes

1

2

3

4

5

On-Duty (%)

Slowest

Slower

Normal

Faster

Faster

Quick Procedure for Programmable Features An alternative method of entering option programmable features has been programmed into the logics. This will enable quick option programmable features without removing the controller room, line fuse, or placing the DIAG/RUN/SET switch to the “Set Up” position.

To enter quick option programmable features, open the seat switch and place the direction lever to reverse and ensure that the park brake is released. While depressing the accelerator to maximum position other than OFF, and key switch to ON. Display will go to a solid “O”, indicating that you have entered option programmable features and you are ready for setting: Place the direction lever to neutral and release accelerator pedal.You can set the option programmable features.

See programmable or Settable Option Features on page 129-132.

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Testing And Adjusting