MITSUBISHI FORKLIFT GE SX Controls FBC35N 45N 55N Service Manual - PDF

Service Manual GE SX Controls

For use with FBC35N–FBC45N and FBC55N Chassis Service Manual.

WENB8473-02

Safety Precautions Mitsubishi Caterpillar Forklift America Inc. (MCFA) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not allinclusive. If a tool, procedure, work method or operating technique not specifically recommended by Mitsubishi Caterpillar Forklift America Inc. (MCFA) 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.

Safety Precautions

Mitsubishi Forklift Trucks Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules and 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, skills and tools to perform these functions properly.

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.

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

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

Mitsubishi forklift truck dealers have the most current information available.

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 “CAUTION” or “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 explains the hazard and 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.

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Table of Contents 1 — GENERAL INFORMATION AND FEATURES Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Motor Serial Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 Before Servicing Forklift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 GE SX Control System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Run-time Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Fault Code Display Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Programmable Truck Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Basics of Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 Motor Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 Solid-State Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 Flexible System Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 More Features with Fewer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 Features of SX Family of Transistor Motor Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11 Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Creep Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Control Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Regenerative Braking to Zero Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Pedal Position Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Auto Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Field Weakening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Speed Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Roll-Back Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Steer Pump Contactor Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Static Return to Off (SRO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Accelerator Volts Hold Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Pulse Monitor Trip (PMT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Thermal Protector (TP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Systems Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Standard Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Stored Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Hourmeter Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Maintenance Alert & Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Battery Discharge Indication (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Internal Resistance Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Display Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Circuit Board Coil Driver Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Truck Management Module (TMM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Hydraulic Pump Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15 GE Information for Separately Excited Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16 Premium Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17 Premium Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Battery Discharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

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Table of Contents Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 History Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Left Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Right Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Fault Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Monitoring System Action Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Setup Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Brush Wear Indicator Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20 Vehicle Monitoring System – Action Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21 Traction Control Logic Flow Chart For Normal Operating Conditions . . . . . . . . . . . . . . . . . . . .1-22 General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23 Cabling for Vehicle Retrofits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23 RF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23 Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23 Recommended Lubrication of Pins and Sockets Prior to Installation . . . . . . . . . . . . . . . . . .1-24 General Troubleshooting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25 BDI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25 Function 14 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26 2 — PROGRAMMING Handset General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Handset Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Handset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Function Set-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Accessing Stored Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Setup Functions for Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 1 - Adjustable Motor EMF For Plugging or Regen . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 2 - Creep Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 3 - Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 4 - Armature Current Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 5 - Counter EMF Trip Point For Auto Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 6 - Auto Calibration of Accelerator Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 7 - Min Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 8 - Max Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 9 - Regen Braking Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 10 - Max Field Current During Regen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Function 11 - Brake Switch Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Function 12 - Top Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Function 13 - Maintenance and Truck Management Speed Limit . . . . . . . . . . . . . . . . . . . . . .2-7 Function 14 - Internal Resistance Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 Function 15 - Battery Volts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 Function 16 - Stall Protection % On-Time Trip Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 Function 17 - Card Type Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 18 - Steer Pump Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 19 - Maintenance Code Tens and Units Hours Set . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 20 - Code Thousands and Hundreds Hours Set . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

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Table of Contents Function 21 - Auto Regen Braking Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 22 - Not Applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 23 - Regen Cancel Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 24 - Field Weakening Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 25 - Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 26 - Field To Armature Current Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 27 - Minutes Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 28 - Stored Status Code Count Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Function 29 - Power Steering Hours (Ones and Tens) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Function 30 - Power Steering Hours (Hundreds and Thousands) . . . . . . . . . . . . . . . . . . . . . 2-11 Function 48 - Mode 1 Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Function 49 - Mode 1 Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 50 - Mode 1 Auto Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 51 - Mode 1 Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 52 - Mode 2 Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 53 - Mode 2 Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 54 - Mode 2 Auto Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 55 - Mode 2 Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 56 - Mode 3 Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 57 - Mode 3 Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 58 - Mode 3 Auto Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 59 - Mode 3 Speed Limit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 60 - Mode 4 Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 61 - Mode 4 Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 62 - Mode 4 Auto Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 63 - Mode 4 Speed Limit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Setup Functions For Hydraulic Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 1 - Not Applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 2 - Internal Resistance Compensation Star. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 3 - Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 4 - Armature Current Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 7 - Internal Resistance Compensation Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 11 - Aux 1/Aux 2 Speed Limit (SL1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 12 - Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 13 - Tilt Speed Limit (SL3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 14 - Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 15 - Not Applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 16 - Speed/Torque Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 17 - Card Type Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 18 - Overcurrent Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 28 - Fault Count Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 Function 48 - Mode 1 – Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 Function 49 - Mode 1 – Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 Function 50 - Mode 1 – Tilt Speed Limit (SL3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 51 - Mode 1 – Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 52 - Mode 2 – Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 53 - Mode 2 – Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 54 - Mode 2 – Tilt Speed Limit (SL3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

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Table of Contents Function 55 - Mode 2 – Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 56 - Mode 3 – Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 57 - Mode 3 – Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 58 - Mode 3 – Tilt Speed Limit (SL3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 59 - Mode 3 – Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 60 - Mode 4 – Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 61 - Mode 4 – Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 62 - Mode 4 – Tilt Speed Limit 3 (SL3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 Function 63 - Mode 4 – Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 Setup Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 Controller Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 Traction Controller Settings Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 Traction Controller Settings Chart For UL EE Closed Motor Option . . . . . . . . . . . . . . . . . . .2-22 Pump Controller Settings Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Memory Maps – Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Accelerator Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Premium Display Speedometer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 3 — CHECKS AND REPAIRS General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Contactor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Brush Wear Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Motor Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Thermal Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Why is Thermal Transfer important? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 What determines “Good” Thermal Transfer?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Insuring Proper Thermal Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Mounting Instructions for Motor Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Necessary Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 The Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Vehicle Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Application of Thermal Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Mounting the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Troubleshooting Tips (Motors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Successful Commutation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Sparking At Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Insulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Armature Winding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Unsatisfactory Brush Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 Table One - Primary Sources of Unsatisfactory Brush Performance. . . . . . . . . . . . . . . . . . . 3-11 Table Two - Indications Appearing at Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 Table Three - Indications Appearing at Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 Table Four - Indications Appearing at Commutator Surface . . . . . . . . . . . . . . . . . . . . . . . . .3-15 Commutator Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

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Table of Contents 4 — SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM SX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Instructions for Removal of SX Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Table One - Failures That Cause Reduced or No Motor Torque . . . . . . . . . . . . . . . . . . . . . . .4-2 Table Two - Mis-operation of Other Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 Table Three - Mis-operation of Other Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 5 — ELECTRICAL Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Connections to Main Traction Plug P1 with Controller Hydraulics. . . . . . . . . . . . . . . . . . . . . .5-5 Connections to Main Traction Plug P5 with Controller Hydraulics. . . . . . . . . . . . . . . . . . . . . .5-6 Connections to Main Plug (23 Pin) and P2 or P4 Plug (12 Pin) . . . . . . . . . . . . . . . . . . . . . . .5-7 Pump Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Shorted or Open Field or Armature FET Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Armature FET Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Field FET Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 6 — DIAGNOSTIC STATUS CODES Basic Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Display Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Status Codes - Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 TRACTION STATUS CODE -NONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 TRACTION STATUS CODE -01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 TRACTION STATUS CODE -02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 TRACTION STATUS CODE -03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 TRACTION STATUS CODE -05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 TRACTION STATUS CODE -06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 TRACTION STATUS CODE -07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 TRACTION STATUS CODE -08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 TRACTION STATUS CODE -09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 TRACTION STATUS CODE -11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 TRACTION STATUS CODE -15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 TRACTION STATUS CODE -16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 TRACTION STATUS CODE -21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 TRACTION STATUS CODE -23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 TRACTION STATUS CODE -24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 TRACTION STATUS CODE -27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 TRACTION STATUS CODE -28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 TRACTION STATUS CODE -41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 TRACTION STATUS CODE -42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 TRACTION STATUS CODE -43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 TRACTION STATUS CODE -44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 TRACTION STATUS CODE -45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 TRACTION STATUS CODE -46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15 TRACTION STATUS CODE -47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

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Table of Contents TRACTION STATUS CODE -49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 TRACTION STATUS CODE -51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 TRACTION STATUS CODE -57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 TRACTION STATUS CODE -64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 TRACTION STATUS CODE -65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18 TRACTION STATUS CODE -66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18 TRACTION STATUS CODE -67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19 TRACTION STATUS CODE -69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19 TRACTION STATUS CODE -76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 TRACTION STATUS CODE -77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 TRACTION STATUS CODE -82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 TRACTION STATUS CODE -83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 TRACTION STATUS CODE -85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 TRACTION STATUS CODE -86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 TRACTION STATUS CODE -89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23 TRACTION STATUS CODE -90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23 TRACTION STATUS CODE -91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24 TRACTION STATUS CODE -94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24 TRACTION STATUS CODE -95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25 TRACTION STATUS CODE -99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25 TRACTION STATUS CODE -117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26 HYDRAULIC STATUS CODE -127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26 HYDRAULIC STATUS CODE -128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27 HYDRAULIC STATUS CODE -141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27 HYDRAULIC STATUS CODE -142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 HYDRAULIC STATUS CODE -143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 HYDRAULIC STATUS CODE -144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29 HYDRAULIC STATUS CODE -145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29 HYDRAULIC STATUS CODE -146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 HYDRAULIC STATUS CODE -150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 HYDRAULIC STATUS CODE -151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 HYDRAULIC STATUS CODE -157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 HYDRAULIC STATUS CODE -180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 HYDRAULIC STATUS CODE -181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 HYDRAULIC STATUS CODE -185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 HYDRAULIC STATUS CODE -189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

viii

GENERAL INFORMATION and FEATURES 1 — GENERAL INFORMATION AND FEATURES Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Motor Serial Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 Before Servicing Forklift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 GE SX Control System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Run-time Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Fault Code Display Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Programmable Truck Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Basics of Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 Motor Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 Solid-State Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 Flexible System Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 More Features with Fewer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 Features of SX Family of Transistor Motor Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11 Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Creep Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Control Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Regenerative Braking to Zero Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Pedal Position Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Auto Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Field Weakening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Speed Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Roll-Back Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Steer Pump Contactor Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Static Return to Off (SRO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Accelerator Volts Hold Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Pulse Monitor Trip (PMT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Thermal Protector (TP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Systems Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Standard Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Stored Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Hourmeter Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Maintenance Alert & Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Battery Discharge Indication (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Internal Resistance Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Display Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Circuit Board Coil Driver Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Truck Management Module (TMM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Hydraulic Pump Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15 GE Information for Separately Excited Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16 Premium Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17 Premium Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Battery Discharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

GENERAL INFORMATION and FEATURES Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 History Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Left Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Right Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Fault Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Monitoring System Action Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Setup Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Brush Wear Indicator Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20 Vehicle Monitoring System – Action Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21 Traction Control Logic Flow Chart For Normal Operating Conditions . . . . . . . . . . . . . . . . . . . .1-22 General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23 Cabling for Vehicle Retrofits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23 RF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23 Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23 Recommended Lubrication of Pins and Sockets Prior to Installation . . . . . . . . . . . . . . . . . .1-24 General Troubleshooting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25 BDI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25 Function 14 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

GENERAL INFORMATION and FEATURES Bus Bar

GENERAL INFORMATION AND FEATURES

Glossary

A heavy electrical conductor that carries high current from one point to another and to which other smaller wires are connected.

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

Bypass (1A) Contactor, Traction Switch that connects A2 traction motor cable to battery negative and bypasses the main power MOSFETs.

Activate A 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.

Capacitor Device used to store electrical energy for short periods of time. Also used in filtering voltage noise and electrical spikes.

Ammeter An electric meter used to measure current flow in amperes.

Cathode The negative (–) side of a diode.

Ampere (or Amp) The unit of measure of current flow. The amount of current that one volt can push through a resistance of one ohm.

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.

Anode The positive (+) side of a diode.

Closed Circuit Armature

Wiring or components in a circuit that have continuity.

The rotating portion of an electric motor or generator.

Coil Battery

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

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

Commutator BDI (Battery Discharge Indicator)

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

An electrically controlled display showing the operator the state of battery charge.

Compound Motor BJT (Bipolar Junction Transistor) A transistor that is used to control voltage going to a motor or other electrical device.

A motor which has a field winding in series with the armature and a shunt field winding in parallel with the series winding and armature.

Brush

Conduct

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

To allow the flow of current.

Conductor A material that provides a path for current flow.

1-1

GENERAL INFORMATION and FEATURES Connector

Current Shunt

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

A precision low-value resistor connected in series with the armature of a motor. The logics uses the measured voltage drop across the shunt to control maximum current allowed in selected power circuits.

Contact Tips or Contacts Deactivate

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

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.

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.

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

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

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

Continuity Having the ability to allow current flow.

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

Control Circuits The wires and components carrying low current used to signal the logics unit, turn on main components, or support auxiliary circuits (indicated by thin lines on a schematic).

Drain Terminal of a MOSFET through which the main current flows.

Counter Electromotive Electric Motor

An opposing voltage set up by a collapsing or increasing magnetic field within a Force (CEMF) coil.

A device that changes electrical energy into mechanical energy to do work.

Current Electrical Braking

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

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

Current Limit Electromagnet

The maximum allowable current of a stalled drive motor.

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

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

Electromotive Force (EMF) The force that causes an electric current to flow in a circuit. This force is measured in volts.

1-2

GENERAL INFORMATION and FEATURES Field Effect Transistor (FET)

Horse Power

A transistor in which the output current is varied by varying the value of an electric field within a region of the device.

A measure of the time-rate of doing work. 1 HP is defined as the equivalent of raising 33,000 pounds, one foot, in one minute.

Linear Measure:

Field Windings

HP = Force X Distance 33,000 X Time

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.

Force in Pounds Distance in Feet Time in Minutes 33,000 is a Constant

Rotational Measure:

Fuse

HP = Torque X Speed 5252

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

• • • •

Gate Terminal of a MOSFET to which voltage is applied to turn the MOSFET on and off.

Force in Pounds Torque in Foot - Pounds Speed in revolutions per minute (RPM) 5252 is a Constant

Indicator Generator

A lamp or LED that gives an indication of some vehicle condition when it turns on or flashes.

A device that transforms non-electric energy (such as mechanical, thermal, etc.) into electrical energy.

Input Grounded

A voltage change at the incoming connection of a component.

A wire or wires that are in contact with the metal chassis of the vehicle (ground). Can be caused by a loss of insulation from the wire, or by connecting the wire to the vehicle.

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

Harness

LED

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

Light Emitting Diode - a diode that emits light (lights) when current flows in the forward direction.

Heat Sink

Logics or Logic Unit

A mounting frame used for semiconductor cooling.

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.

Heat Sink Pad Thin metal sheet sandwiched between the heatsink of a controller and the frame of the truck used to better transfer the heat away from the controller.

Magnetic Field Hour Meter

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

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

1-3

GENERAL INFORMATION and FEATURES Microprocessor

Output

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

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

MOSFET (Metal Oxide Semiconductor Field Effect Transistor)

PTC (Positive Thermal Coefficient Resistor) A resistor that is used in parallel with the tips of the line contactor to allow the main capacitors in the controller to charge quicker after the battery is plugged in. As the PTC conducts current, it heats up and its resistance increases. Each controller has an internal PTC that will slowly charge the main capacitors if the external PTC fails.

A fast switching transistor that is used to control voltage going to a motor or other electrical device.

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.

Resistance Opposition to the flow of current in a circuit. The unit of electrical resistance is the OHM. The lower the resistance, the greater the current flow for a given voltage.

Normally Closed (N.C.) A switch or relay whose contacts are closed in the normal condition.

Source Terminal of a MOSFET through which the main current flows.

Normally Open (N.O.) A switch or relay whose contacts are open in the normal condition.

Surface Voltage or Charge Generally present just after the battery is unplugged from the charger.

OFF-Time The amount of time a current does not flow through a semiconductor.

Terminal

Ohm

An electrical connection point on an electrical component.

The unit of measurement of resistance. The amount of resistance that will let one volt push only one ampere of current through it, where R = E / I.

Transistor A semiconductor device used as an electronic switch.

ON-Time The amount of time current flows through a transistor.

Torque The turning force or effect required to do work.

Open Circuit

Torque = Force X Distance

Wiring or components of a circuit that have no continuity.

• Force in Pounds • Distance in Feet to center of rotation

Optical Switch

Varistor

An electronic device made up of an infrared light signal generator and photosensitive signal receiver that changes an input digital voltage into an electrically isolated digital voltage output.

An electrical filter that is usually terminated across the horn connections of a mechanical horn to eliminate voltage spikes when the horn is activated.

1-4

GENERAL INFORMATION and FEATURES 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 protector.

1-5

GENERAL INFORMATION and FEATURES

Motor Serial Numbers MODEL

SERIAL #

TRACTION MTR

7 Ton, 8 Ton & 10 Ton

A2BC4-60200-up

330 mm (13")

279 mm (11")

12 Ton

A2BC5-60200-up

330 mm (13")

279 mm (11")

1-6

HYD PUMP MTR

GENERAL INFORMATION and FEATURES

Serial Number Locations

Chassis Serial Number Mast Serial Number

Traction Motor Serial Number

Hydraulic Motor Serial Number

Power Steering Motor Serial Number

For Illustrative Purposes Only

Before Servicing Forklift Truck WARNING Before doing any maintenance or adjustments on the forklift truck, always use the correct size blocks in order to prevent the unit from rolling or falling. Raise the drive wheels off the ground.

This can be done by tilting the mast all the way back, placing hard wood blocks under the mast then tilting the mast forward. Securely support with blocks.

1-7

GENERAL INFORMATION and FEATURES

GE SX Control System Features The GE SX control monitors over seventy different system functions. Run-time fault conditions, when sensed, are indicated on the steering console display.

Run-time Diagnostics

Mode/Fault Code Buttons

Fault Code Display Sequence When the truck key is switched off, the display shows truck hours, drive motor hours, and pump motor hours for four seconds each. At this point the mode buttons can be used to activate a display sequence of faults that caused the forklift truck to shut down.

For details see panel section.

Mode/Fault Code Button

During truck start up or operation, a diagnostic code could appear on the display instead of the battery state of charge. If the GE SX Control System detects a problem, the ! symbol glows in the monitoring system action lights at the same time. The codes indicate an improper operating sequence or a defect in the truck electrical system.

Mode Buttons

Programmable Truck Operating Modes

Run-time diagnostics cover the following areas of truck operation and protection:

•

Drive motor and pump motor hours

•

Service reminder hours

•

Battery discharge level

•

Motor brush wear (Premium Display Only)

•

Stall protection

•

Over-temperature protection of drive motor, pump motor, and the control panel

•

Brake fluid level

The GE SX Control System also allows users to modify how the truck operates for conditions where the truck is used. The operator can select from four operating modes.: 1. Economy – slowest travel speed and acceleration.

2. Moderate – travel speed and acceleration somewhat slower than standard.

3. Standard – travel speed and acceleration suitable for the broadest range of applications.

4. High – Highest travel speed and acceleration.

Each time the key is switched off then on again the controller remains in the previously selected mode.

1-8

GENERAL INFORMATION and FEATURES

Basics of Circuit Operation

For this reason, shunt motors are considered to be constant speed motors (Figure 2).

Motor Characteristics

FULL LOAD CURRENT

NO LOAD CURRENT

TORQUE

ARMATURE CURRENT Figure 2

In the separately excited motor, the motor is operated as a fixed field shunt motor in the normal running range. However, when additional torque is required, for example, to climb non-level terrain, such as ramps and the like, the field current is increased to provide the higher level of torque. In most cases, the armature to field ampere turn ratio can be very similar to that of a comparable size series motor (Figure 3.)

STARTING CURRENT

TORQUE

ARMATURE CURRENT Figure 1 NO LOAD CURRENT

As shown from the typical performance curves in Figure 1, the high torque at low speed characteristic of the series motor is evident.

In a shunt motor, the field is connected directly across the voltage source and is therefore independent of variations in load and armature current. If field strength is held constant, the torque developed will vary directly with the armature current. If the mechanical load on the motor increases, the motor slows down, reducing the back EMF (which depends on the speed, as well as the constant field strength).

The reduced back EMF allows the armature current to increase, providing the greater torque needed to drive the increased mechanical load. If the mechanical load is decreased, the process reverses. The motor speed and the back EMF increase, while the armature current and the torque developed decrease. Thus, whenever the load changes, the speed changes also, until the motor is again in electrical balance.

STARTING CURRENT

SPEED FULL LOAD CURRENT

SPEED

FULL LOAD CURRENT

NO LOAD CURRENT

Historically, most electric vehicles have relied on series motor designs because of their ability to produce very high levels of torque at low speeds. But, as the demand for high efficiency systems increases, i.e., systems that are more closely applied to customers’ specific torque requirements, shunt motors are now often being considered over series motors. In most applications, by independently controlling the field and armature currents in the separately excited motor, the best attributes of both the series and the shunt wound motors can be combined.

STARTING CURRENT

SPEED

TORQUE

ARMATURE CURRENT Figure 3

Aside from the constant horsepower characteristics described above, there are many other features that provide increased performance and lower cost. The following description provides a brief introduction to examples of some of these features.

In a shunt motor, the variation of speed from no load to normal full load on level ground is less than 10%.

1-9

GENERAL INFORMATION and FEATURES

Solid-State Reversing

Flexible System Application

The direction of armature rotation on a shunt motor is determined by the direction in which current flows through the field windings. Because the shunt motor field only typically requires about 10% of the armature current at full torque, it is normally cost effective to replace the double-pole, double-throw reversing contactor with a low power transistor H-Bridge circuit (Figure 4).

Because the shunt motor controller has the ability to control both the armature and field circuits independently, the system can normally be adjusted for maximum system efficiencies at certain operating parameters. Generally speaking, with the ability of independent field and armature, the motor performance curve can be maximized through proper control application.

More Features with Fewer Components

LINE POS FUSE Q3

Field weakening with a series wound motor is accomplished by placing a resistor in parallel with the field winding of the motor. Bypassing some of the current flowing in the field into the resistor causes the field current to be less, or weakened. With the field weakened, the motor speed will increase, giving the effect of “overdrive”. To change the “overdrive speed”, it is necessary to change the resistor value.

In a separately excited motor, independent control of the field current provides for infinite adjustments of “overdrive” levels, between motor base speed and maximum weak field. The desirability of this feature is enhanced by the elimination of the contactor and resistor required for field weakening with a series motor.

Q5

A1 + ARM CAP

Q2

F1

F2

A2 Q4

Q6

Q1

NEG Figure 4

By energizing the transistors in pairs, current can be made to flow in either direction in the field. The armature control circuit typically operates at 12KHZ to 15KHZ, a frequency range normally above human hearing. This high frequency coupled with the elimination of directional contactors, provides very quiet vehicle operation. The field control circuits typically operate at 2 KHZ.

With a separately excited motor, overhauling speed limit, or downhill speed, will also be more constant.

By its nature, the shunt motor will try to maintain a constant speed downhill. This characteristic can be enhanced by increasing the field strength with the control. Overhauling load control works in just the opposite way of field weakening, armature rotation slows with the increase of current in the field.

The line contactor is normally the only contactor required for the shunt motor traction circuit. This contactor is used for both pre-charge of the line capacitors and for emergency shut down of the motor circuit, in case of problems that would cause a full motor torque condition. The line can be energized and de-energized by the various logic combinations of the vehicle, i.e. activate on key, seat or start switch closure, and de-energize on time out of idle vehicle.

Again, these options add to the quiet operation of the vehicle.

Regenerative braking (braking energy returned to the battery) may be accomplished completely with solidstate technology. The main advantage of regenerative braking is increased motor life. Motor current is reduced by 50% or more during braking while maintaining the same braking torque as electrical braking with a diode clamp around the armature. The lower current translates into longer brush life and reduced motor heating. Solid state regenerative braking also eliminates a power diode, current sensor and contactor from the circuit.

1-10

GENERAL INFORMATION and FEATURES

Features of SX Family of Transistor Motor Controllers

Current Limit This circuit monitors motor current by utilizing sensors in series with the armature and field windings. The information detected by the sensor is fed back to the card so that current may be limited to a pre-set value.

If heavy load currents are detected, this circuit overrides the oscillator and limits the average current to a value set by Function 4 and Function 8 of the Handset. The C/L setting is based on the maximum thermal rating of the control. Because of the flyback current through Q2, the motor current is usually greater than battery current, except at 100% ON time.

Standard Operation With the accelerator at maximum ohms or volts, the creep speed can be adjusted by Function 2 of the Handset or a trimpot. The field control section allows the adjustment of the field weakening level in order to set the top speed of the motor. This top speed function (Minimum Field Current) is enabled when the armature current is less than the value set by Function 24 and the accelerator pedal is fully depressed.

Top Speed can be adjusted by Function 7 of the Handset or a trimpot.

Regenerative Braking to Zero Speed Slow down is accomplished when reversing direction by providing a small amount of torque for deceleration. If the Q2 vehicle is moving, and the ARM directional lever is moved from one direction to the other, the regen signal is initiated. Once the regen signal has been initiQ1 ated, the field current is Figure 5 increased (armature circuit shown in Figure 5). Armature current is regulated to the regen current limit as set

by Function 9. As the vehicle slows down, the field current continues to increase, and transistor Q2 begins to chop. The field current will increase until it reaches a preset value set by Function 10, and transistor Q2 on-time will increase until it reaches 100% on-time. Once both of the above conditions have been met, and regen current limit can no longer be maintained, the braking function is canceled. The fields will then reverse, and the control reverts back to motoring.

The percent on-time has a range of approximately 0 to 100 percent. The SX controllers operate at a constant frequency and the percent on-time is controlled by the pulse width of the voltage / current applied to the motor circuits.

Creep Speed With the accelerator at minimum volts, the creep speed can be adjusted by Function 2 of the Handset.

At creep speed, the ON time can decrease to approximately 5%, with the OFF time at approximately 95%. At full transistor operation, this condition will be reversed (short OFF time, long ON time). This variation of ON and OFF time of the oscillator varies the voltage applied to the motor, thereby varying the speed of the motor for a given load.

Control Acceleration This feature allows for adjustment of the rate of time it takes for the control to accelerate to 100% applied battery voltage to the motor on hard acceleration.

Armature C/A is adjusted by Function 3 from 0.1 to 22 seconds.

Part of the energy produced by the motor during regen is returned to the battery, and part is dumped in the motor as heat.

Pedal Position Regenerative Braking This feature allows control of the stopping distance based on pedal position when there has been a “directional switch” change. Pedal position will reduce the regenerative current to as the accelerator is returned to the creep speed position. Maximum regenerative current is obtained with the accelerator in the top speed position.

1-11

GENERAL INFORMATION and FEATURES

Auto Braking

Roll-Back Control

This feature is enabled by initiating a “neutral position” using either the directional switch or the accelerator switch. Once activated, Auto Braking operates similar to Pedal Position Regenerative Braking and is adjusted by using Function 21 of the Handset.

This feature provides retarding torque to limit rollback speed in the non-travel direction when the accelerator pedal is released when stopping on a grade, or when the brake pedal is released when starting on a grade. This feature forces the vehicle to roll very slowly down the grade when the accelerator or brake is released. Because the vehicle can gain significant speed during roll-back, the torque needed to re-start on the ramp is lower than an unrestricted roll-back speed.

Field Weakening This function allows the adjustment of the field weakening level in order to set the top speed of the motor.

The function is enabled when the armature current is less than the value set by Function 24 and the accelerator pedal is fully depressed. It is important to note that this function is used to optimize motor and control performance, and this setting will be determined by engineers at the time of vehicle development. This setting must not be changed by field personnel, without the permission of Service Engineering.

Steer Pump Contactor Time Delay This feature provides two options for SP time delay.

Option 1 provides a 0.5 to 63 second time delayed drop out of the steer pump contactor when the Forward or Reverse directional switch is opened. This is the default option for function 18. This Option 1 is overridden by a 1.5 second time delayed drop out whenever the seat switch is opened. Option 2 provides a 0.5 to 63 second time delayed drop out of the SP contactor when the seat switch is opened.

Speed Limits This feature provides a means to control speed by limiting motor volts utilizing three “adjustable speed limits. This motor volt limit regulates top speed of the transistor controller, but actual truck speed will vary at any set point depending on the loading of the vehicle. Each speed limit can be adjustable with the Handset using Functions 11, 12, and 13.

Static Return to Off (SRO) This inherent feature of the control is designed to require the driver to return the directional lever to the neutral position anytime he leaves the vehicle and returns. Additionally, if the seat switch or key switch is opened, the control shuts off and cannot be restarted until the directional lever is returned to neutral. A time delay of approximately 2 seconds is built into the seat switch input to allow momentary opening of the seat switch, if a bump is encountered.

Ramp Start This feature provides maximum control torque to restart a vehicle on an incline. The memory for this function is the directional switch. When stopping on an incline, the directional switch must be left in its original or neutral position to allow the control to initiate full power when restarted. The accelerator potentiometer input will modulate ramp start current.

Accelerator Volts Hold Off This feature checks the voltage level at the accelerator input whenever the key switch or seat switch is activated. If, at start up, the accelerator is calling for more than 20% of full speed, the control will not operate. This feature assures that the control is calling for low speed operation at start up.

1-12

GENERAL INFORMATION and FEATURES

Pulse Monitor Trip (PMT)

Systems Diagnostics

The PMT design contains three features which shut down, or lock out, control operation if a fault conditions occurs that would cause a disruption of normal vehicle operation:

The control detects the system’s present operating status and can be displayed to either the Dash Display or the Handset. There are currently over 70 status codes that are available with SX systems using Traction and Pump controls and Truck Management Module (TMM). Along with the status code display from the TMM, the SX control is capable of reducing the current to the motor, alerting the operator of a critical fault condition.

•

Look ahead

•

Look again

•

Automatic look again and reset

The PMT circuit will not allow the control to start under the following conditions:

•

The control monitors both armature and field FET’s at start-up and during running.

•

The control will not allow the line contactor to close at start-up, or will drop it out during running, if either the armature or field FET’s are defective, so as to cause uncontrolled truck movement.

Standard Status Codes The SX traction control has over 30 Status Codes that assist the service technician and operator in trouble shooting the vehicle. If mis-operation of the vehicle occurs, a status code will be displayed on the Dash Display for vehicles so equipped, or be available by plugging the Handset into the “P2 or P4” plug of the logic card.

With the status code number, follow the procedures outlined in DIAGNOSTIC STATUS CODES to determine the problem and a solution.

Thermal Protector (TP) This temperature sensitive device is mounted to the heat sink of the power transistor (Q1). If the transistor’s temperature begins to exceed the design limits, the thermal protector will lower the maximum current limit, and maintain the transistors within their temperature limits. Even at a reduced current limit, the vehicle will normally be able to reach sufficient speed. As the control cools, the thermal protector will automatically reset, returning the control to full power.

Note: The Status Code Instruction Sheets do not claim to cover all possible causes of the display of a “status code”. They do provide instructions for checking the most direct inputs that can cause status codes to appear.

Stored Status Codes This feature records the last 16 “Stored Status Codes” that have caused a PMT controller shut down and/or disrupted normal vehicle operation. (PMT type faults are reset by cycling the key switch). These status codes, along with the corresponding BDI and hourmeter readings, can be accessed with the Handset, or by using the RS 232 communications port and dumping the information to a Personal Computer terminal.

Low Voltage Batteries under load, particularly if undersized or more than 80 percent discharged, will produce low voltages at the control terminals. The SX control is designed for use down to 50 percent of a nominal battery voltage of 36-84 volts, and 75 percent of a nominal battery voltage of 24 volts. Lower battery voltage may cause the control to operate improperly, however, the resulting PMT should open the Line contactor, in the event of a failure.

Hourmeter Readings This feature will display the recorded hours of use of the traction and pump control or contactor to the Dash Display each time the key switch is turned off.

1-13

GENERAL INFORMATION and FEATURES

Maintenance Alert & Speed Limit

Display Modes

This feature is used to display Status Code 99 and/or activate a speed limit when the vehicle operating hours match the hours set into the maintenance alert register. This feature is set with the Handset using Functions 19 and 20. The operator is alerted that maintenance on the vehicle is required. This function can be disabled be setting functions 19 & 20 to a value of 255.

The Dash Display allows the operator to select the best vehicle performance for changing application (task) conditions. There are four (4) modes that can be selected by depressing a push button on the dash display. (SEE SECTION ON DISPLAY) From the display, the operator may select any of the four pre-set interactive modes for either the drive system or the pump system. For the drive controller these modes consist of (4) Controlled Acceleration levels, (4) Auto Regen levels, (4) Lever Regen Levels and (4) Speed Limits.

Battery Discharge Indication (BDI) The latest in microprocessor technology is used to provide accurate battery state of charge information and to supply passive and active warning signals to the vehicle operator. Features and functions:

•

Displays 100 to 0 percent charge.

•

Display blinks with 20% charge. Disables pump circuit with 10% charge. Auto ranging for 36/48 volt operation. Adjustable for use on 24 to 80 volts.

These interactive modes are “pre-set” using the Handset (Functions 48-63) or a personal computer (Functions 97-112). This feature allows the operator to select the best vehicle performance for changing application (task) conditions.

Circuit Board Coil Driver Modules Coil drivers are internal to the control card, and are the power devices that operate the Traction Line, Pump Line, A1, and SP contactor coils. On command from the control card, these drivers initiate opening and closing the contactor coils. All driver modules are equipped with reverse battery protection, such that, if the battery is connected incorrectly, the contactors cannot be closed electrically.

Internal Resistance Compensation This feature is used when the Battery Discharge Indicator is present. Adjustment of this function will improve the accuracy of the BDI. Improper adjustment can cause the battery to be over discharged.

For the pump controller, these modes consist of (4) Controller Acceleration levels, (4) Lift Speed Limit levels, (4) Tilt Speed Limit levels and (4) Lift 2 Speed Limit levels.

Truck Management Module (TMM) The Truck Management Module is an integral function of the GE Pump controls when used with the SX Traction control. The Module provides the OEM the ability to initiate status codes or operator warning codes to be displayed on the Dash Display, whenever a normally open switch or sensor wire provides a signal to the Module.

The TMM Module can be used to display a separate status code indicating over-temperature of traction motors, hydraulic motors, or any other device or system that can activate a switch that closes.

The TMM Module can also be used as a Brush Wear Indicator (BWI). The Brush Wear Indicator is designed to detect a “worn out brush” and display a fault code on the Dash Display to warn maintenance personnel that the motor brushes need to be replaced before they wear to the point of causing destructive damage to the motor commutator surface.

1-14

GENERAL INFORMATION and FEATURES

Hydraulic Pump Control

The controlled acceleration circuit is adjustable and operates the same as the traction circuit. Adjustment range is from 0.1 to 22.0 seconds.

This hydraulic motor controller consists of the following features:

•

Four speeds, adjustable from 0 to 100% motor volts. Fixed speeds actuated by switch closure to negative.

•

Current limit and controlled acceleration adjustable.

•

Battery Discharge Indicator interrupt compatible.

The Battery Discharge Indicator (BDI) interrupt will disable the hydraulic controller if the connection at P10 loses the 12 volt signal from the traction control.

BDI interrupt can be disabled by Function 17 using the Handset. Select card type with or without BDI function.

Operation of voltage regulator card: This card provides the basic functions required for controlling the pump control and PMT functions. Battery positive is applied through a main control fuse to the key switch, energizing the control card power supply input to P1.

PMT operation is the same as outlined for the traction controllers, except with the pump line contactor (PL).

The four speed (motor volts) reference points P12, P19, P20 and P21 are selected by connecting these points independently to battery negative.

The speed for the Auxiliary functions (Aux1/Aux2) is obtained by closing speed limit 1 (SL1) at P1-12 to control negative. SL1 is adjustable by Function 11 using the Handset to adjust motor voltage from 0 to 100%. The specified motor volts will be regulated, however, the magnitude of motor current will vary depending on the loading of the vehicle.

The speed for the first lift function is obtained by closing Speed Limit 2 (SL2) at P1-19 to control negative.

SL2 is adjusted using the Handset and Function 12, similar to SL1.

The speed for the tilt function is obtained by closing speed limit 3 (SL3) at P1-20 to control negative. SL3 is adjusted using the Handset and Function 13, similar to SL1.

The speed for the second lift function is obtained by closing speed limit 4 (SL4) at P1-21 to control negative. SL4 is adjusted using the Handset and Function 14, similar to SL1.

If more than one Speed Limit is activated, the selected speed with the highest motor volts will override the low motor volt speed. The current limit circuit is adjustable and operates the same as the traction current limit.

1-15

GENERAL INFORMATION and FEATURES

GE Information for Separately Excited Controls Example: Part Number:

IC3645

Argument Number: 01 Argument 01:

Basic Electric Vehicle Control Number

Argument 02:

Control Type:

Argument 03:

Argument 04:

Argument 05:

D

33

02

03

04 05

=

Series Control (Pump)

SH

=

Separately Excited Control (Plugging)

SR

=

Separately Excited Control (Regen to Zero)

1

=

120 volts

4

=

48 volts

2

=

24 volts

5

=

36/48 volts

3

=

36 volts

6

=

24/36 volts

7

=

72/80 volts

D

=

174.24 mm (6.86")

X

169.42 mm (6.67")

R

=

174.24 mm (6.86")

X

207.01 mm (8.15")

U

=

225.04 mm (8.66")

X

206.50 mm (8.13")

W

=

225.04 mm (8.66")

X

275.08 mm (10.83")

22

=

220 Amps

33

=

330 Amps

40

=

400 Amps

2

=

20 Amps

3

=

30 Amps

4

=

40 Amps

Operating Voltage:

Package Size:

Armature Current

etc.

Field Current (1 character)

etc.

Argument 07:

4

SP

(2 characters)

Argument 06:

SE

Customer / Revision A1

=

Customer A / Revision 1

B1

=

Customer B / Revision 1

etc.

1-16

2

C3

06 07

GENERAL INFORMATION and FEATURES

Premium Display Operation

NOTE When the battery reaches a 20% state of charge the battery action light will flash continuously. At 10% charge the light remains on.

If the display shows a fault code instead of the battery state of charge, this means a run-time fault has been detected. The fault must be corrected before you use the forklift truck. See the sections on the Premium Display for more information on run time fault codes.

All segments on the LCD display and the Vehicle Monitoring System Action Lights should light in a chaser pattern from left to right. The seat belt icon should flash for 10 seconds (regardless of whether the seat belt is fastened or not). The time display area should show the currently selected operating mode for the drive motor controller and pump motor controller, D1-4 and P1-4.

The battery charge display area should show the battery state of charge, and the time display area should display either the time or date, whichever is selected.

1-17

GENERAL INFORMATION and FEATURES

Premium Display Brush Wear Indicator

Drive Motor Icon Pump Motor Icon Battery Discharge Indicator

Speed Display/ Performance Mode Indicator/Fault Code Indicator

Truck Icon

Monitoring System Action Lights

History/Date/ Time Display Right Mode Button

Left Mode Button

Battery Discharge Indicator

Speed Display

The Battery Charge Display Area shows the current battery state of charge on its bar graph in 10% increments.

The Speed Display Area shows the current speed in either MPH or KPH depending on the unit mode. The appropriate MPH or KPH symbol is also lit to indicate which mode is active. For details on how to select a desired system of units, see the Setup Mode section.

Time Display The Time Display Area can either show the time or date. Simultaneously depressing both Mode Buttons will switch the display between the time and date. For details on how to set the time and date see the Setup Mode section.

Hour Meter Immediately after the key is turned to the off position, the numeric display enters the Hour Display Mode for 12 seconds. Truck hours, drive motor hours, and pump motor hours are consecutively displayed along with their corresponding icon for 4 seconds each.

1-18

GENERAL INFORMATION and FEATURES

History Display

Right Mode Button

After the hour display cycle is complete the truck enters Silent Mode. No activity is shown on the display or indicators when the truck is in this mode. By pressing the left or right buttons, History Display can be accessed for either the drive motor control or the pump motor control respectively. The corresponding motor icon illuminates to indicate which history folder is being accessed. Regardless of which is accessed, the display behaves the same way. The Speed Display Area displays the most recent fault code. The time display area cycles through 4 different items: battery state of charge, truck or pump hours, time, and date of the displayed fault. Pressing either button will cycle to the next fault in the history folder, and the display will blink briefly each time a button is pressed.

This button allows the user to change the current performance mode. By holding down this button while in either the drive performance display mode or pump performance display mode the unit will cycle through each available mode. Releasing the button while the desired mode is displayed will switch the unit to that mode. This button has several other functions described in other sections.

Fault Code Indicator A fault code will be displayed in the Speed Display Area if a run-time fault is detected by the monitoring system. In addition, the Fault Code Indicator and any applicable icons will light.

Monitoring System Action Lights

Start-Up

These symbols light when specific problems are detected. The truck should be stopped and corrective action should be taken immediately. These lights are detailed on the following page of this manual.

Once the key is turned on, the display enters a self test mode. All segments on the Liquid Crystal Display (LCD) and indicators are turned on in a left-to-right chaser pattern. After the self test is complete, the seat belt light will blink for 10 seconds regardless of whether the seat belt is fastened. Also, the currently selected drive controller and pump controller performance modes are displayed in an “dx_Py” format where “x” and “y” are numeric values between 1 and 4. If the performance mode information from either controller is outside of this range, “=” will be displayed instead of a number. If the performance mode information cannot be read, “dC” or “PC” will be displayed.

Setup Modes Setup Mode is accessed by pressing both mode buttons simultaneously while the display is in Silent Mode. If the buttons are released within 10 seconds, Regular Setup Mode is accessed. If the buttons are held for longer than 10 seconds, the display blanks for 5 seconds and then enters Speed Sensor Setup Mode.

In Regular Setup Mode the units system (imperial or metric) and the date and time can be set. Pressing the right button toggles between metric (indicated by KPH icon) and imperial (MPH icon). Pressing the left button selects the currently flashing mode and advances to the time setup mode. The time is displayed in the Time Display Area with the hours flashing. The right mode button changes the hour and the left mode button accepts the currently displayed hour. The minutes will then flash and can be set in the same manner. AM and PM are set next if the unit is in imperial mode. Once the time is set, the display switches to the current date. Date setup is identical to time setup, cycling through year, month, and day respectively. To exit Regular Setup Mode, press both the left and right buttons simultaneously.

Left Mode Button Pressing this button accesses the drive performance display mode. The drive motor icon illuminates and the current drive motor mode is displayed in the Speed Display Area. Pressing this button a second time within 4 seconds accesses the pump performance display mode and lights the pump motor icon.

To return to normal operating mode press this button again. After 4 seconds, the performance display mode is exited automatically if no other buttons are depressed. This button also has several other functions described in other sections.

In Speed Sensor Setup Mode the current speed sensor setting flashes in the Speed Display Area. To scroll through the available speed settings, press and 1-19

GENERAL INFORMATION and FEATURES release the right mode button. Press the left mode button when the desired speed setting is displayed.

The selected setting will stop flashing and both mode buttons must then be depressed to select the setting.

The Speed Sensor mode must be adjusted according to the tire diameter. The available range of usable settings is 1 through 12. Any setting outside of this range may cause the speed to be displayed incorrectly. If the truck has new, standard tires with no wear yet, a setting of 5 should be used.

Brush Wear Indicator Icon This icon lights if the system detects that either the drive or pump motor brushes are worn and need to be replaced. The corresponding motor icon (drive or pump) is illuminated with this icon.

1-20

GENERAL INFORMATION and FEATURES

Vehicle Monitoring System – Action Lights 1

2

3

4

5

6

7

1. Service Due Action Light

4. Battery Charge Action Light

The wrench symbol lights when it is time for planned maintenance. The maintenance interval can be programmed into the GE SX Control System tp provide reduced drive performance when activated.

The battery symbol flashes if the battery reaches the 20% charge level. If the charge level drops below 10%, the symbol glows solid. Reduced truck drive and/or lift performance can be programmed into the GE SX Control System.

2. Seat Belt Warning Action Light The seat belt symbol flashes for the first 10 seconds after the key is turned on regardless of whether the seat belt is fastened.

5. Brake Fluid Action Light

3. Over Temperature Action Light

6. Park Brake Action Light

The thermometer symbol glows if an over-temperature condition develops in the drive motor, pump motor, or the controller. Reduced truck drive performance can be programmed into the GE SX Control System.

The park brake symbol lights when the park brake is applied. Do not drive the forklift truck with the park brake applied.

The brake fluid symbol lights if the brake fluid reaches a predetermined low level.

7. Fault Detection Light The fault code symbol lights whenever a fault code is being displayed. When some faults are detected, the truck shuts downs and cannot be operated until the cause of the fault is repaired.

1-21

GENERAL INFORMATION and FEATURES

Traction Control Logic Flow Chart For Normal Operating Conditions Connect Battery

Battery Positive @ P1-1

Close Key Switch

Battery Positive @ P1-2

Close Seat Switch

Line contactor closes and battery positive @ control P, A1, A2 and F1

Circuit is energized to allow inputs from direction lever and accelerator

Select forward or reverse

Power Steer contactor closes

Depress accelerator which closes accelerator start switch

Voltage from accelerator potentiometer is applied to controller

The appropriate H-bridge transistors are turned on to apply voltage to the field

Q1 transistor turns on and voltage is applied to the armature

Truck moves in chosen direction

1-22

GENERAL INFORMATION and FEATURES

General Maintenance Instructions

80 percent discharged with periodic equalizing charges.

Visual inspection of GE contactors contained in the traction and pump systems is recommended to occur at every maintenance interval or anytime the rear door is opened.

The transistor control, like all electrical apparati, does have some thermal losses. The semiconductor junctions have finite temperature limits, above which these devices may be damaged. For these reasons, normal maintenance should guard against any action which will expose the components to excessive heat and/or those conditions which will reduce the heat dissipating ability of the control, such as restricting air flow.

Inspection is recommended to verify that the contactors are not binding and that the tips are intact and free of contaminants.

It is not recommend that any type of welding be performed on the vehicle after the installation of the control(s) in the vehicle. MCFA will not honor control failures during the warranty period when such failures are attributed to welding while the control is installed in the vehicle.

The following Do’s and Don’t’s should be observed: Any controls that will be applied in ambient temperatures over 100° F (40° C) should be brought to the attention of MCFA Service Engineering.

Cabling for Vehicle Retrofits

All external components having inductive coils must be filtered. Refer to vehicle manufacturer for specifications.

If an additional control or electronic device is added to the vehicle in the field, only MCFA recommended wires and cables should be used.

The wiring should not be directly steam cleaned. In dusty areas, blow low-pressure air over the control to remove dust. In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used to wash the control, and then low-pressure air should be used to completely dry the control.

RF Interference To prevent radio frequency (RF) interference, care should be taken in routing power cables in the vicinity of radio-controlled devices.

For the control to be most effective, it must be mounted against the frame of the vehicle. The metal vehicle frame, acting as an additional heat sink, will give improved vehicle performance by keeping the control package cooler. Apply a thin layer of heattransfer grease such as Dow Corning 340, and a metal heatsink pad between the control heat sink and the vehicle frame.

Suppression Unless specifically noted otherwise, suppression (for example, a snubber) is required on all inductive devices. This suppression minimizes noise and prevents damage caused by electrical surges.

Control wire plugs and other exposed transistor control parts should be kept free of dirt and paint that might change the effective resistance between points.

CAUTION Electric braking should not be used when the vehicle is jacked up and the drive wheels are in a free wheeling position. The higher motor speeds can create excessive voltages that can be harmful to the control.

Do not hipot (or megger) the control.

Use a lead-acid battery with the voltage and ampere hour rating specified for the vehicle. Follow normal battery maintenance procedures, recharging before 1-23

GENERAL INFORMATION and FEATURES

Recommended Lubrication of Pins and Sockets Prior to Installation

WARNING Do not use any other cleaners or lubricants other than the ones specified.

WARNING

1. Disconnect plug from controller or mating plug.

Before conducting maintenance on the vehicle, jack up the drive wheels, disconnect the battery and discharge the capacitors. To discharge the capacitors, connect a 150 ohm, 25 watt resistor (Part No. 358280) between the positive and negative terminals on the control panel for at least 20 seconds. Activating the horn will also discharge the capacitor.

2. Locate the plug that contains the socket (female) terminals. Maintenance needs only to be performed on the plug containing the socket (female) type terminals. Reconnecting the plugs will lubricate the pin (male) terminals.

3. Clean each terminal using contact cleaner as shown in Figure 1.

Cleaner and lubricant are provided in the terminal maintenance kit SE000003.

Figure 1

Corrosion occurs during microscopic movement at the contact points of the connection. This movement exposes the base metal of the connector pin which, when oxygen is present, allows oxidation to occur.

Sufficient build up of the oxidation can cause intermittent contact and intermittent vehicle operation. This can occur at any similar type of connection, whether at the control or in any associated vehicle wiring, and the resultant intermittent contact can provide the same fault indication as actual component failure.

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ane

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The addition of lubricant will prevent the oxidation process by eliminating the access of oxygen to the contact point. Add this lubricant to the 12 pin and 23 pin plugs of all new SX controls at the time of their installation into a vehicle.

4. Lubricate each terminal using lubricant as shown in figure 2. Apply enough lubricant to each terminal opening to completely fill each opening to a depth of .125" minimum.

When servicing existing vehicles exhibiting symptoms of intermittent mis-operation or shutdown by the control, add this lubricant to all 12 and 23 pin plugs, after proper cleaning of the connectors, as a preventative measure to insure fretting is not an issue before control replacement. Also, for long term reliable control operation, the plug terminals must be maintained per these instructions with the recommended contact cleaner and lubricant which provides a high degree of environmental and fretting protection.

Figure 2

B LU A IC R T N

New and re-manufactured control plugs are cleaned and lubricated prior to shipment from the factory.

However, in applications where severe vibration or high temperature cycling and excessive humidity, such as freezers are present, it is recommended that the plug terminals be cleaned and lubricated every year, per these instructions. In normal applications, plug maintenance should be performed every two years, unless intermittent problems arise with the plugs, requiring more immediate attention.

5. Reconnect plugs.

1-24

GENERAL INFORMATION and FEATURES

General Troubleshooting Instructions

Resistance less than 1000 ohms should be corrected first.

Before proceeding, visually check for loose wiring, mis-aligned linkage to the accelerator switch, signs of overheating of components, etc.

Trouble-shooting the SX control should be quick and easy when following the instructions outlined in the status code instruction sheets.

Tools and test equipment required are: clip leads, volt-ohm meter (20,000 ohms per volt) and basic hand tools.

WARNING Before trouble-shooting, jack up the drive wheels, disconnect the battery and discharge the capacitors. Capacitors should be discharged by connecting a 150 ohm, 25 watt resistor (Part No 358280) between the positive and negative terminals on the control panel for at least 20 seconds.

Reconnect the battery as needed for specific checks. Activating horn will also discharge the capacitor.

BDI Operation BDI is only monitored by the GE Traction controller, not the pump controller. The separate pump controller has no way of tracking the charge of battery. In order to tell the truck display what the state of charge of the battery is so that it can show the operator, the traction controller uses a specific algorithm to more accurately determine the voltage on the battery. The information that is sent to the display is just a percentage value, but this percentage is linked to a specific battery voltage by the controller.

If mis-operation of the vehicle occurs, a status code will be displayed on the Dash Display or made available by plugging a Handset into the plug P2 location, and then reading the status code.

The GE controller uses a value of 2.14 volts per cell or higher to indicate a fully charged battery (100%) and a value of 1.94 volts per cell or lower to indicate a fully discharged battery (0%). As an example, a 36V battery with 18 cells would have a fully charged voltage of 38.52V and a fully discharged voltage to a percentage value that is then sent to the display.

NOTE Status code numbers from 00 to 99 are traction control status codes. Status codes with the prefix 1 (101 to 199) are pump control status codes.

The controller must know how many cells are present to properly make this association, so there is a setting (setting number 15) that can be adjusted to do this. Because the voltage difference is great enough between a 36V and 48V battery, there is a value that setting number 15 can be set to that allows the controller to determine which of these two voltages is connected. If this setting is used, the controller can sometimes be fooled by a 36V battery with a high surface voltage (generally present just after the battery is unplugged from the charger) or an over discharged 48V battery. Another problem can arise if a battery is plugged into the truck that has a different voltage than the previous battery, without letting the head capacitors in the controller discharge. Until the capacitors completely discharged, the controller still holds memory of the voltage of the first battery and will not automatically adjust to the new particular voltage of the battery to be used in the truck.

With the status code number, follow the procedures outlined in the status code instruction sheets to determine the problem.

NOTE Important: Due to the interaction of the controller with all vehicle functions, almost any status code or control fault could be caused by the controller. After all other status code procedures have been followed and no problem is found, the controller should then be replaced as the last option to correct the problem.

The same device designations have been maintained on different controls but the wire numbers may vary. Refer to the schematic for your specific control.

The wire numbers shown on the schematic will have identical numbers on the corresponding wiring diagrams for a specific vehicle.

Whenever the controller is powered up and the key switch is turned on after having the capacitors completely discharged, the controller must start with a new battery discharge level based on the voltage that

Check resistance on R x 1000 scale from frame to power and control terminals. A resistance of less than 20,000 ohms can cause misleading symptoms.

1-25

GENERAL INFORMATION and FEATURES is measured at that time. This discharged voltage is stored and sent to the display to be shown to the operator.

information is difficult, it can sometimes cause the voltage measurement to be off by as much as a couple of volts.

Once the controller knows how many cells the battery should have and the current discharge state of the battery, it must then start taking samples of the battery voltage to monitor any changes in the battery’s state of charge. These samples are taken only during operation of the traction motor by the traction controller and only when the current in the traction motor is between 50 amps and 400 amps. Each sample is at least 4 seconds apart. As the values of the sample voltages start changing, the controller waits until the measured voltage value is lower than the stored voltage value 6 times in a row before it will decrement the stored battery state of charge by 1%.

This means that it will take a minimum of 4 minutes for the BDI to drop 10%

A simpler method of obtaining the correct values that are at least 100 amps apart and extrapolate. The voltage drop that is given in the function 14 table is based on how much the voltage with battery current is assumed to be linear, so once the current and voltage are known for any 2 points, any third point on the same line can be calculated. If the third point is chosen as being exactly 100 amps above or below one of the other points, then the voltage difference between should work for the function 14 table.

Function 14 Setting

Find the voltage difference (X) for a current difference of 100 amps.

Example: Operated unloaded lift >36.5V on the battery with 120 amps out of the battery Operated loaded lift >34.4V on the battery with 275 amps out of the battery

In order for the controller to know what the true state of discharge of the battery is by measuring the voltage while the battery is supplying current, there must be a relationship established that will give the static voltage of the battery based on the voltage of the battery under a load. This relationship is based on the internal resistance of the battery and can vary between different batteries based on battery quality, capacity and voltage. This compensation factor can be adjusted using setting 14 in the GE traction controller.

Slope= voltage difference / current difference = (36.5-34.4)/(275-120) = 0.0135 = X / 100 X = 0.0135 * 100 = 1.35 Since 1.35 is between a setting of 16 (1.43) and 17 (1.34), choose the higher setting (17) to be sure that the battery is not over-discharged.

The setting for function 14 should be adjusted for each different battery that is used in a truck to insure the proper amount of discharge per cycle. If a battery is still not being discharged properly (over or under discharged), even after properly adjusting function 14, the function 14 setting can be raised to decrease the depth of discharge or lowered to increase the depth of discharge.

See Function 14 in the Handset section, there is a table titled Internal Resistance Compensation Table.

This table gives the appropriate setting for a given voltage drop. This voltage drop value is the difference between the voltage on the battery while providing 0 amps of current (static voltage) and the voltage on the battery while providing 100 amps of currents. From this given voltage, the logic in the controller can determine the static voltage of the battery when the traction motor current is at any value between 50 amps and 400 amps.

To obtain the correct voltage drop for the function 14 table, the battery voltage when the battery current is 100 amps can be subtracted from the static battery voltage. A true static voltage of the battery can be difficult to obtain if there is some surface charge still on the battery right after charging or if the battery voltage is still rising after heavy usage. In addition, getting the current to be exactly 100 amps out if the battery can be difficult as well. Because getting this 1-26

PROGRAMMING 2 — PROGRAMMING Handset General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Handset Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Handset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Function Set-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Accessing Stored Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Setup Functions for Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 1 - Adjustable Motor EMF For Plugging or Regen . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 2 - Creep Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 3 - Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 4 - Armature Current Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Function 5 - Counter EMF Trip Point For Auto Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 6 - Auto Calibration of Accelerator Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 7 - Min Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 8 - Max Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 9 - Regen Braking Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Function 10 - Max Field Current During Regen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Function 11 - Brake Switch Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Function 12 - Top Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Function 13 - Maintenance and Truck Management Speed Limit . . . . . . . . . . . . . . . . . . . . . .2-7 Function 14 - Internal Resistance Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 Function 15 - Battery Volts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 Function 16 - Stall Protection % On-Time Trip Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 Function 17 - Card Type Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 18 - Steer Pump Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 19 - Maintenance Code Tens and Units Hours Set . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 20 - Code Thousands and Hundreds Hours Set . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 21 - Auto Regen Braking Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 22 - Not Applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Function 23 - Regen Cancel Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 24 - Field Weakening Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 25 - Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 26 - Field To Armature Current Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 27 - Minutes Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Function 28 - Stored Status Code Count Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Function 29 - Power Steering Hours (Ones and Tens) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Function 30 - Power Steering Hours (Hundreds and Thousands) . . . . . . . . . . . . . . . . . . . . . 2-11 Function 48 - Mode 1 Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Function 49 - Mode 1 Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 50 - Mode 1 Auto Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 51 - Mode 1 Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 52 - Mode 2 Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 53 - Mode 2 Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 54 - Mode 2 Auto Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 55 - Mode 2 Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 56 - Mode 3 Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Function 57 - Mode 3 Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 58 - Mode 3 Auto Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

PROGRAMMING Function 59 - Mode 3 Speed Limit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 60 - Mode 4 Armature Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 61 - Mode 4 Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 62 - Mode 4 Auto Regen Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Function 63 - Mode 4 Speed Limit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 Setup Functions For Hydraulic Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 1 - Not Applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 2 - Internal Resistance Compensation Star. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 3 - Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 4 - Armature Current Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 7 - Internal Resistance Compensation Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 11 - Aux 1/Aux 2 Speed Limit (SL1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 12 - Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 13 - Tilt Speed Limit (SL3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Function 14 - Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 15 - Not Applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 16 - Speed/Torque Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 17 - Card Type Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 18 - Overcurrent Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Function 28 - Fault Count Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 Function 48 - Mode 1 – Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 Function 49 - Mode 1 – Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 Function 50 - Mode 1 – Tilt Speed Limit (SL3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 51 - Mode 1 – Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 52 - Mode 2 – Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 53 - Mode 2 – Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 54 - Mode 2 – Tilt Speed Limit (SL3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 55 - Mode 2 – Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 56 - Mode 3 – Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 57 - Mode 3 – Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 58 - Mode 3 – Tilt Speed Limit (SL3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 59 - Mode 3 – Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 60 - Mode 4 – Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 61 - Mode 4 – Lift 1 Speed Limit (SL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Function 62 - Mode 4 – Tilt Speed Limit 3 (SL3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 Function 63 - Mode 4 – Lift 2 Speed Limit (SL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 Setup Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 Controller Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 Traction Controller Settings Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 Traction Controller Settings Chart For UL EE Closed Motor Option . . . . . . . . . . . . . . . . . . .2-22 Pump Controller Settings Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Memory Maps – Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Accelerator Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Premium Display Speedometer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

PROGRAMMING The Handset can access the registers that control the operation of the forklift truck. The values for the limits on the control card functions must be set with either the Handset or a PC. The Handset has a Light Emitting Diode (LED) display, a keypad for data entry and an adjustment knob for changing function values. See FIGURE 1.

PROGRAMMING

Handset General Information

NOTE The vehicle will operate with the Handset connected, however, the adjustment knob MUST BE SET FULLY CLOCKWISE to make sure the control can operate at maximum speed.

This section has the control card checks and adjustments that can be made using the Handset. The control card checks and adjustments are usually made with the controller installed in the forklift truck. Bench checks and adjustments can also be made with the control card connected. The checks show the stored setting numbers that have been stored for the different controller functions. This section also includes a description of each of the different functions. Use the adjustment knob on the Handset to adjust the function settings. See FIGURE 1.

The Handset with a cord is available through your forklift truck dealer under part #97E57-00100. The handset is the same for all GE controls, however, the cord is different for the SX series motor controllers.

The SX controller Handset cord is available from MCFA under part # 97E57-00111.

1. Adjustment Knob

4. Coil Cord

2. LED Display

5. Plug P2 or P4 (12 Pin)

3. Keypad

6. Modular Plug (8 Pin Hand Set)

Figure 1. Handset The Handset is a multifunctional tool to be used with the SX series motor controllers. The Handset is used to access the memory elements called “Registers” which have electronic data stored in them to control an operation. There are 128 Registers in the SX series of Control Cards. The Handset will access the registers for the traction or pump motor functions, indicate Status Codes (possible faults) and make adjustments to the operating limits set in the Control Cards. Some of the registers in the “SX” series of control cards can not be accessed with the Handset.

2-1

PROGRAMMING

Handset Functions

Handset Operation

The purpose of the Handset is to permit authorized personnel to perform checks and adjustments: •

Monitor existing system fault codes for both traction and pump controllers.

•

Monitor intermittent random status codes

•

Monitor battery state of charge

•

Monitor hourmeter reading on traction and pump controllers.

•

Monitor or adjust the following control functions:

•

-

Creep speed

-

Controlled acceleration and 1A time

-

Armature and field current limit.

-

Steer pump time delay and define signal input (seat switch or directional switch)

-

Regenerative braking current limit

-

Speed limit points (SL1, SL2, and SL3)

-

Truck management fault speed limit

-

Internal resistance compensation for battery state of charge indication

-

Battery voltage (36/48 volts can be auto ranging)

WARNING Before connecting or disconnecting the Handset tool, 1) Jack up the drive wheels of the vehicle, 2) Turn off the key switch, 3) Unplug the battery and 4) Discharge the capacitors.

At the Traction Controller, unplug the P2 plug” and plug in the Handset to the plug location P2 on the controller. After installing the Handset tool, plug in the battery and turn on the key switch. The following is the start-up display sequence that will occur: START-UP DISPLAY SEQUENCE Key Switch On Verify each LED Segment 8888 If Maintenance Code is active

If Maintenance Code is not active

Display Code -99 for four seconds and activate speed limit (if selected)

Selection of card operation type: -

Standard traction card selection: -

1A enabled/disabled

Diagnostics override with fault

BDI Display

Auto braking enabled/disabled

Run Mode

Diagnostics override with fault

BDI Display

Key Switch Off Display steer pump hourmeter for four seconds Display traction Hourmeter for four seconds Display pump Hourmeter for four seconds

Figure 2. Start up display 2-2

PROGRAMMING WARNING Before making any adjustments to the control, consult the function settings on page 4. Failure to use the proper settings could result in misoperation or damage to the control system.

Example for function 18:

CONT and keypad #3

Example for function 48: CONT and keypad #1

With the Handset connected, hold down the CONT button while turning on the Key Switch. The Handset will now show the segment checking display. This accesses the set up mode, ready to monitor or adjust control function settings. If a fault code is displayed simply push the CONT button to clear.

When programming is finished, press the ESC button when the (8888) is showing and press it again for 1 second. The display now shows the battery state of charge. This means the control is in run mode.

Push down one of the function numbers on the keypad to check that setting. For example, push down on function key : the corresponding function code will be displayed.

U 05

After one second we will see the value which is stored under this function: Example:

CONT and keypad #1

To access functions 48 and up, the seat switch must be closed for the traction controller, and turn the key switch off for the pump controller. Then press the CONT button and the appropriate number on the keypad at the same time.

Function Set-Up Procedures

Example:

Example for function 16:

105

If this value needs to be reset, push again on the CONT button and the value will blink. The number on the Handset will no longer be the original value but will correspond to the position the adjustment knob was left.

Now turn the adjustment knob to the desired setting (the values will continue to blink). When the desired setting is reached, push STORE. This value will be displayed but will no longer be blinking. Next push the ESC button and get the Segment Check display again. This indicates the programming mode is still accessed. Continue this process to check or set all the functions. Each time a value is changed, go back and verify that the setting is correct. The value adjustment range available on the Handset is 0 to 255. However, some functions do not use the entire range.

There are 15 numbers on the keypad but many more functions available. For the first 15 functions on the keypad simply press the appropriate number. To access functions 16 through 30 press the CONT button and the appropriate number on the keypad at the same time. For the traction controller, the seat switch must be open and for the pump controller, the key switch must be on.

2-3

PROGRAMMING

Accessing Stored Fault Codes

and then to the ON position. The first of the 16 status codes will be overwritten each time a new status code occurs. The stored status can be cleared from the register by using the Handset. Use the procedure in FIGURE 3 to access and clear the fault code registers for the traction and pump controllers with the Handset.

The SX Traction and Pump Motor Controllers have function registers (31 through 47) that store the last 16 Status Codes that caused the operation of the forklift truck to stop, the battery charge and the power steer hours at the time the fault occurred. A PMT fault is reset by turning the key to the OFF position

Key to OFF position Push ESC and CONT at the same time Release ESC and CONT Status Code Displayed

Push ESC to erase stored data

Push CONT Key Displays Battery Stare-of Charge When Fault occurred

Push ESC to erase stored data

Push CONT Button Display hourmeter reading when fault occurred

Push ESC to erase stored data

Push CONT Button FIGURE 3. Accessing Fault Codes

2-4

hold both the ESC and CONT Keys down to erase all 16 Stored codes

PROGRAMMING

Setup Functions for Traction Controller

WARNING Please contact MCFA before making changes to any function settings. Failure to properly adjust the settings could result in misoperation or damage to the motor and/or controller.

Function 1 - Adjustable Motor EMF For Plugging or Regen (Push 1) This function allows for the adjustment of the level of motor EMF required for plugging or regenerative braking. The control will default to standard regen functionality if the setting is higher than a value of 60.

Range Set Resolution Example:

0 to 95.6 volts 0 to 255 0.375 volts per set unit Setting of 20 = 7.5 volts

Function 2 - Creep Speed (Push 2) This function allows for the adjustment of the creep speed of the vehicle. Creep speed can add 13% to the percent on time at the slowest speed range.

Range Set Resolution Example:

2% to 15% on time 0 to 255 0.05% per set unit Setting of 20 = 3% on time

Function 3 - Armature Controlled Acceleration (Push 3) This function allows for the adjustment of the rate of time it takes for the control to accelerate to 100% applied battery voltage to the motor on hard acceleration. This function can be changed by the dash display mode selection button.

Range Set Resolution Example:

0.025 to 6.3 seconds 0 to 255 0.025 seconds per set unit Setting of 20 = 0.5 seconds

Function 4 - Armature Current Limit (Push 4) This function should always remain set at 255 (maximum current limit) for this family of controls.

2-5

PROGRAMMING

Function 5 - Counter EMF Trip Point For Auto Braking

Function 7 - Min Field Current (Push 7)

(Push 5)

This function allows the adjustment of the field weakening level in order to set the top speed of the motor.

This function allows for the adjustment of the speed at which the truck will activate auto braking, after the accelerator pedal is released. The truck speed correlates to the amount of voltage produced by the traction motor when it is coasting. The setting of this function represents the motor voltage.

Range Set Resolution Example:

Volts

Min

Resolution Example Per unit value If set at 71

Max

Set

36/48 0

20

51 to 115 0.314

6.28A

1000A 0

20

51 to 90 0.507 amps

10.13A

MIN IF = (VAL-51) X 0.314 (at 36/48 VOLTS) MIN IF = (VAL-51) X 0.507 (at 1000 AMPS)

0 to 100 volts 0 to 255 0.392 volts per set unit Setting of 20 = 7.84 volts

NOTE Important: This function is used to optimize motor and control performance, and this setting was determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

Function 6 - Auto Calibration of Accelerator Potentiometer (Push 6) This function allows for the auto calibration of the accelerator potentiometer. This function should be left set to a value of zero during normal truck operation. To activate accelerator the auto calibration routine, set this function to a value between 15 and 20, and refer to accelerator setup of this manual for detailed instructions covering the auto calibration procedure, on page 2.

Function 8 - Max Field Current (Push 8) This function allows for the adjustment of the maximum field current in order to obtain the maximum torque of the motor. This function should always be set to 255.

NOTE

Function 9 - Regen Braking Current Limit

Important: This function must be used to recalibrate the accelerator every time the traction controller or accelerator is replaced. The GE Sentry cannot be used to calibrate the accelerator.

(Push 9) This function allows for the adjustment of the maximum current seen by the motor during regenerative braking; the higher the current, the shorter the stopping distance. This function can be changed by the dash display mode selection button.

Volts

Min

Max

Set

Resolution Example Per unit value If set at 100

36/48 182A 591A 0 to 255 1.625

344 amps

REGEN BRAKE IA = (VAL X 1.625) + 182 at 36/48 volts

2-6

PROGRAMMING

Function 10 - Max Field Current During Regen

Function 12 - Top Speed Limit (Push 12)

(Push 10)

This function allows for the adjustment of the motor speed limit (maximum battery volts to the motor).

This speed limit is the same as function 11, however it is always active. This function can be changed by the dash display mode selection button.

This function allows for the adjustment of the maximum field current attainable during the regenerative braking mode.

Volts

Min

Resolution Example Per unit value If set at 220

Max

Set

36/48 0

64

51 to 255 0.314

52 amps

1000A 0

103

51 to 255 0.507

85 amps

Range Set Resolution Example:

Factory Default Value 0

IF = (VAL-51) x 0.314 (at 36/48 volts)

SPEED LIMIT = 100% - ((VAL-46) x 0.75%)

NOTE Important: This function is used to optimize motor and control performance and this setting was determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

Function 13 - Maintenance and Truck Management Speed Limit (Push 13) This function is the same as function 11, however it is active based on maintenance hours (function 19 and 20), or traction motor overheating (Status Code 90) or on low BDI value.

Function 11 - Brake Switch Current Limit

Range Set Resolution Example:

(Push 11) This function allows for the adjustment of the maximum motor armature current when the voltage at Pin 12 is less than 50% of battery voltage. The 1A contactor will not close, if the brake switch current is active.

Range Set Resolution Example:

100% to 0% battery volts 46 to 180 0.75% per set unit Setting of 80 = 75% of battery volts

100% to 0% battery volts 46 to 180 0.75% per set unit Setting of 80 = 75% of battery volts

SPEED LIMIT = 100% - ((VAL-46) x 0.75%)

160 amps to 575 amps 0 to 255 160 amps + (VALUE x 1.63 amps) Setting of 100 = 323 amps

2-7

PROGRAMMING

Function 14 - Internal Resistance Compensation

Function 15 - Battery Volts (Push l5)

(Push 14)

This function allows for the adjustment of voltage range. In order for the BDI to operate properly, the setting as shown in the table must be entered:

This function is used when the Battery Discharge Indicator is present. Adjustment of this function will improve the accuracy of the BDI. In order to determine this setting the voltage drop of the battery under load must first be calculated by the following method.

1. On a fully charged battery, record the open circuit voltage (Vo) by measuring the voltage at the control positive and negative power terminals.

3. Calculate voltage drop (VDrop) as follows: VDrop = VO - VL 4. Use the table below to determine the appropriate setting using the calculated VDrop as a reference. (See Function 14 settings in General Information & Features)

Setting 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

36 volts 48 volts 36/48 volts No BDI

Between 32 and 44 Factory Default Between 45 and 69 Between 184 and 250 Between 251 and 255

Function 16 - Stall Protection % OnTime Trip Point

INTERNAL RESISTANCE COMPENSATION TABLE VDrop 11.44 07.60 05.72 04.57 03.81 03.27 02.86 02.54 02.28 02.08 01.90 01.76 01.63 01.52 01.43

Set units

The following functions have function numbers larger than the numbers on the Handset keyboard. To access these functions. Push the CONT key and the number shown in the following instructions at the same time. THE SEAT SWITCH MUST BE OPEN.

2. Load the traction motor to 100 amps in the battery cable and record the voltage (VL) at the control positive and negative power terminal.

Setting 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Battery volts

(Push CONT 1) This function allows for the adjustment of the stall motor protection, as well as the display and storing of an 82 fault code. This function adjusts the percent on time at which the fault occurs when the accelerator is calling for greater than 50% speed and the armature current is above 500 amps at 36/48V (or above 370 amps at 72/80V).

VDrop 01.34 01.27 01.20 01.14 01.09 01.04 00.99 00.95 00.91 00.88 00.85 00.82 00.79 00.76 00.74

Range Set Resolution Example:

100% to 0% battery volts 46 to 180 0.75% per set unit Setting of 125 = 41% on-time

% ON TIME = 100% - ((VAL-46) x 0.75%)

NOTE Important: This function is used to optimize motor and control performance, and this setting will be determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

2-8

PROGRAMMING

Function 17 - Card Type Selection

Function 19 - Maintenance Code Tens and Units Hours Set

(Push CONT 2)

(Push CONT 4)

This function allows the user to enable or disable the vehicle’s auto braking routine by setting the function within the ranges outlined below.

Control 740A, 36/48V

Function

This function allows for the adjustment of the tens and units hours of the maintenance code activation time. If the replacement of the SX controller is required, record this value.

Setting

1A enabled, auto braking enabled

128 to 255

740A, 36/48V

1A enabled, auto braking disabled

64 to 127

740A, 36/48V

Without 1A, auto braking enabled

50 to 63

740A, 36/48V

Without 1A, auto braking disabled

0 to 49

600A, 36/48V

Auto braking enabled

50 to 255

600A, 36/48V

Auto braking disabled

0 to 49

1000A

1A enabled, auto braking enabled

128 to 255

1000A

1A enabled, auto braking disabled

64 to 127

1000A

Without 1A, auto braking enabled

50 to 63

1000A

Without 1A, auto braking disabled

0 to 49

Range Set Resolution Example:

0 to 99 0 to 99 9999 Hours 255

Function 20 - Code Thousands and Hundreds Hours Set (Push CONT 5) This function allows for the adjustment of the thousands and hundreds hours of the maintenance code activation time. Same as Function 19.

Function 18 - Steer Pump Time Delay (Push CONT 3)

Range Set Resolution Example:

This function allows for the selection of steer pump contactor pick up input, either seat switch or directional switch closing, as well as the adjustment of the time delay for the contactor drop out.

•

Pick up steer pump contactor on seat switch closure and drop out steer pump contactor on seat switch opening, after a delay determined by the following: Range Set Resolution Example:

•

Function 21 - Auto Regen Braking Current Limit (Push CONT 6)

1.5 to 65 seconds Between 0 and 127 0.5 seconds per set unit Setting of 20 = (20 x 0.5) + 1.5 = 11.5 seconds

This function allows for the adjustment of the braking torque applied when the start or directional switch is opened, and the counter EMF is above the setting of Function 5. A higher current correlates to a shorter stopping distance. This function can be changed by the dash display mode selection button.

Pick up steer pump contactor on directional switch closure and drop out steer pump contactor on directional switch opening, after a delay determined by the following: Range Set Resolution Example:

0 to 240 0 to 240 9999 Hours 255

Current = (Value of Setting /4) x 6.5 Note, if the result is less than 52 amps, the control will default to 52 amps.

0.5 to 63 seconds Between 128 and 255 0.5 seconds per set unit Setting of 149 = ((149-128) x 0.5) + 1.5 = 11.5 seconds

Function 22 - Not Applicable This value changes with operating mode selected, and should not be adjusted in the field.

NOTE If the seat switch opens, the steer pump contactor will open immediately. If a foot directional control option is installed on a truck, only the settings for the seat switch input should be used.

2-9

PROGRAMMING

Function 23 - Regen Cancel Current

Function 26 - Field To Armature Current Ratio

(Push CONT 8)

(Push CONT 11)

This function allows for the adjustment of the armature current at which regenerative braking cancels, and is specific to each motor design.

This function sets the ratio between armature and field current when operating below the maximum field current and above the Field Weakening Start point. The setting represents the quantity of field current changed for each 1 amp of armature current changed.

NOTE Important: This function is used to optimize motor and control performance, and this setting will be determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

For a 36/48V control: Range Setting Resolution Example:

Function 24 - Field Weakening Start (Push CONT 9)

For a 1000A control:

This function allows for setting the armature current at which minimum field current will be achieved.

Range Setting Resolution Example:

0 to 0.314 field amps/armature amp 0 to 13 0.024 field amps/armature amp Setting of 10 = 0.24 field amps armature amp

Range

0 to 414 Amps 0 to 255 1.625 per set unit Setting of 20 = 32.5 amps

Setting Resolution Example:

I motor FWS = VAL. x 1.625

0 to 0.507 field amps/armature amp 0 to 13 0.038 field amps/armature amp Setting of 10 = 0.38 field amps armature amp

NOTE

NOTE

Important: This function is used to optimize motor and control performance, and this setting will be determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

Important: This function is used to optimize motor and control performance, and this setting will be determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

Function 27 - Minutes Register (Push CONT 12)

Function 25 - Monitor

This register is only intended for storage of the minutes value for proper operation of the hour meter and should not be adjusted.

(Push CONT 10) This function is not used. To ensure optimum operation of the control, this function must be left with zero stored in this register.

2-10

PROGRAMMING

Function 28 - Stored Status Code Count Pointer

Function 30 - Power Steering Hours (Hundreds and Thousands)

(Push CONT 13)

(Push CONT 15)

This register contains the location of the last stored status code recorded of the 16 stored status codes.

These stored status codes have caused a PMT controller shutdown and/or disruption of normal vehicle operation.

This register is only intended for storage of the hundreds and thousands values of the hours of operation of the power steering motor and should not be adjusted..

To determine which stored status code was the last one recorded, read the number stored in Function 28. Using the Memory Map, match the “stored status code pointer number” [the number shown in the HS (Handset) number column] on the memory map, with the number obtained from Function 28.

This will be the last stored status code recorded.

DASH DISPLAY MODES The following functions (functions 48 through 63) are mode settings that are activated from the Dash Display. No mode should be set to values lower than the preceding mode.

NOTE

The following functions have function numbers larger than the numbers on the Handset keyboard. To access these functions. Push the CONT key and the number shown in the following instructions at the same time. THE SEAT SWITCH MUST BE CLOSED AND KEY SWITCH OFF.

When scrolling through the stored status code register, the register always starts at status code 1 and scrolls to status code 16.

Function 29 - Power Steering Hours (Ones and Tens) Function 48 - Mode 1 Armature Controlled Acceleration

(Push CONT 14) This register is only intended for storage of the ones and tens values of the hours of operation of the power steering motor and should not be adjusted.

(Push CONT 1) This function allows for the adjustment of the rate of time it takes for the control to accelerate to 100% applied battery voltage to the motor on hard acceleration.

Range Set Resolution Example:

1.0 to 25.5 seconds 10 to 255 0.10 seconds per set unit Setting of 20 = 2.0 seconds

This C/A takes effect when the Mode 1 settings are called for by the Dash Display.

2-11

PROGRAMMING

Function 49 - Mode 1 Regen Current Limit

Function 52 - Mode 2 Armature Controlled Acceleration

(Push CONT 2)

(Push CONT 5)

This function allows for the adjustment of the maximum current seen by the motor during regenerative braking; the higher the current, the shorter the stopping distance.

Volts

Min

Max

Set

Same as Function 48.

This C/A takes effect when the Mode 2 settings are called for by the Dash Display.

Resolution Example Per unit value If set at 220

36/48 182A 591A 0 to 255 1.625

Function 53 - Mode 2 Regen Current Limit

344 amps

(Push CONT 6)

REGEN BRAKE IA = (VAL X 1.625) + 182 at 36/48 volts

Same as Function 49.

This REGEN CURRENT LIMIT takes effect when the Mode 1 settings are called for by the Dash Display.

This REGEN CURRENT LIMIT takes effect when the Mode 2 settings are called for by the Dash Display.

Function 50 - Mode 1 Auto Regen Current Limit

Function 54 - Mode 2 Auto Regen Current Limit (Push CONT 7)

(Push CONT 3)

Same as Function 50.

This function allows for the adjustment of the braking torque applied when the start or directional switch is opened, and the counter EMF is above the setting of Function 5. A higher current correlates to a shorter stopping distance.

This AUTO REGEN CURRENT LIMIT takes effect when the Mode 2 settings are called for by the Dash Display.

Current = (Value of Setting /4) x 6.5

Function 55 - Mode 2 Speed Limit

Note, if the result is less than 52 amps, the control will default to 52 amps.

(Push CONT 8)

This AUTO REGEN CURRENT LIMIT takes effect when the Mode 1 settings are called for by the Dash Display.

Same as Function 51.

Function 51 - Mode 1 Speed Limit

Function 56 - Mode 3 Armature Controlled Acceleration

This SPEED LIMIT 2 takes effect when the Mode 2 settings are called for by the Dash Display.

(Push CONT 4) This function allows for the adjustment of the motor speed limit (maximum battery volts to the motor.

Range Set Resolution Example:

(Push CONT 9) Same as Function 48.

100% to 0% battery volts 46 to 180 0.75% per set unit Setting of 80 = 75% of battery volts

This C/A takes effect when the Mode 3 settings are called for by the Dash Display.

SPEED LIMIT = 100% - ((VAL-46) x 0.75%) This speed limit takes effect when the Mode 1 settings are called for by the interactive Dash Display.

2-12

PROGRAMMING

Function 57 - Mode 3 Regen Current Limit

Function 62 - Mode 4 Auto Regen Current Limit

(Push CONT 10)

(Push CONT 15)

Same as Function 49.

Same as Function 50.

This REGEN CURRENT LIMIT takes effect when the Mode 3 settings are called for by the Dash Display.

This AUTO REGEN CURRENT LIMIT takes effect when the Mode 4 settings are called for by the Dash Display.

Function 58 - Mode 3 Auto Regen Current Limit

Function 63 - Mode 4 Speed Limit 2 (Push CONT ESC)

(Push CONT 11) Same as Function 50.

Same as Function 51.

This AUTO REGEN CURRENT LIMIT takes effect when the Mode 3 settings are called for by the Dash Display.

This speed limit takes effect when the Mode 4 settings are called for by the Dash Display.

Function 59 - Mode 3 Speed Limit 2 (Push CONT 12) Same as Function 51.

This speed limit takes effect when the Mode 3 settings are called for by the Dash Display.

Function 60 - Mode 4 Armature Controlled Acceleration (Push CONT 13) Same as Function 48.

This C/A takes effect when the Mode 4 settings are called for by the Dash Display.

Function 61 - Mode 4 Regen Current Limit (Push CONT 14) Same as Function 49.

This REGEN CURRENT LIMIT takes effect when the Mode 4 settings are called for by the Dash Display.

2-13

PROGRAMMING

The "maximum field current" setting is adjusted by Function 8. This function, along with the "armature current limit", Function 4, sets the maximum torque of the motor.

MAXIMUM

FIELD CURRENT

The " ratio " setting is adjusted by Function 26.

This function sets the ratio between armature and field current when operating, IMOTOR is above FWS and less than the full load transistion point. Setting is the value of field current changed for each 100 amps of armature current changed.

The " minimum field current " setting is adjusted

by Function 7. The function sets the top speed of the motor.

The " field weakening start " setting is adjusted by Function 24. This function sets the armature current at which minimum field current will be achieved.

ARMATURE CURRENT

The "full load transition point "

The "armature current limit " setting is adjusted by Function 4.

The function along with the "maximum field current", Function 8, sets the maximum torque of the motor.

2-14

MAXIMUM

ZERO

ZERO

PROGRAMMING

Setup Functions For Hydraulic Pump Control

Function 7 - Internal Resistance Compensation Rate (Push 7) This function allows for the adjustment of the rate of time it takes for the control to add the internal resistance compensation voltage that is applied to the motor. This function will add 0.375 volts to the motor at the rate of time adjusted until the total IR compensation voltage has been added.

Function 1 - Not Applicable This function is not applicable to this type of control and should not be adjusted.

Range Setting Resolution Example:

Function 2 - Internal Resistance Compensation Star (Push 2)

For example, if you had selected 2.08 volts from Function 16 to be added to the motor, it would take 0.18 seconds to add a total of 2.08 volts. (2.08/ 0.375)=0.032

This function allows for the adjustment of the current level at which the internal resistance compensation feature (Function 16) will take effect.

Range Setting Resolution Example:

0.0015 to 0.383 seconds 0 to 255 0.0015 seconds per set unit Setting of 20 = 0.032 seconds

0 to 1325 amps 52 to 255 6.5 amps per set unit Setting of 72 = (72-52) x 6.5 = 130 amps

Function 11 - Aux 1/Aux 2 Speed Limit (SL1) (Push 11) This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL1 limit switch input signal is received by the control card at pin P1-12. SL1 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit.

Function 3 - Controlled Acceleration (Push 3) This function allows for the adjustment of the rate of time it takes for the control to accelerate to 96% applied battery voltage to the motor on hard acceleration.

Range Setting Resolution Example:

Range Setting Resolution Example:

0.1 to 5.5 seconds 0 to 255 0.021 seconds per set unit Setting of 20 = 0.52 seconds C/A

0 volts to 96 volts 0 to 255 0.375 volts per set unit Setting of 50=18.75 volts

Function 12 - Lift 1 Speed Limit (SL2) Function 4 - Armature Current Limit

(Push 12)

(Push 4)

Same as Function 11 except using SL2 limit switch for input to control card at pin P1-19.

This function allows for the adjustment of the current limit of the control. The setting for this function should always remain at 255 for this family of controls to achieve maximum current limit.

Function 13 - Tilt Speed Limit (SL3) (Push 13) Same as Function 11 except using SL3 limit switch for input to control card at pin P1-20.

2-15

PROGRAMMING

Function 14 - Lift 2 Speed Limit (SL4)

Function 17 - Card Type Selection

(Push 14)

(Push CONT 2)

Same as Function 11 except using SL4 limit switch for input to control card at pin P1-21.

This function should be set in accordance with the control type in use in the vehicle:

Function 15 - Not Applicable This function is not applicable to this type of control and should not be adjusted.

Function

Setting

No BDI

Std C/L BDI Lockout High C/L BDI Lockout

54 to 62 63 to 71

36 to 44 45 to 53

BDI Lockout means that the BDI signal from the traction control must be present in order for the pump control to operate. This control will stop operation when the battery state of charge reaches 9%.

NOTE The following functions have function numbers larger than the numbers on the Handset keyboard. To access these functions, push the CONT key and the number shown in the following instructions at the same time. THE KEY SWITCH MUST BE ON.

Settings for these functions should be made in between the values shown.

WARNING This setting must be changed by authorized personnel only, following instructions supplied by MCFA Service Engineering. Card type selection must be made within the capabilities of the TRANSISTOR control panel used and the supporting electro-mechanical devices. Failure to comply with proper application standards could result in mis-operation or damage to the control and/or motors.

Function 16 - Speed/Torque Compensation (Push CONT 1) This function is used to stabilize pump speed at heavy loads. The voltage selected will be added to the motor at each 100 amp increment starting at the value set in Function 2. The voltage compensation selected will be added in increments of 0.375 volts until the entire voltage is added. For example, a setting of 2 will be added in 30 steps of 0.375 volts each whereas, a setting of 4 will be added in 15 steps of 0.375 volts each.

Function 18 - Overcurrent Setting (Push CONT 3)

SPEED / TORQUE COMPENSATION TABLE VOLTAGE VOLTAGE SETTING DROP SETTING DROP 2 11.44 17 1.34 3 7.60 18 1.27 4 5.72 19 1.20 5 4.57 20 1.14 6 3.81 21 1.09 7 3.27 22 1.04 8 2.86 23 0.99 9 2.54 24 0.95 10 2.28 25 0.91 11 2.08 26 0.88 12 1.90 27 0.85 13 1.76 28 0.82 14 1.63 29 0.79 15 1.52 30 0.76 16 1.43 31 0.74

This function allows for the adjustment of the amount of overcurrent that is allowed by the motor for a time of 0.001 second before shutting the pump control down. The current setting is determined by SETTING/4 x 6.5 + (800A).

Range Setting

2-16

800A to 1200A 0 to 255

PROGRAMMING

Function 28 - Fault Count Pointer

DASH DISPLAY MODES The Following functions (functions 48 through 63 are mode settings that are activated from the Dash Display.

(Push CONT 13) This register contains the location of the last stored status code recorded of the 16 stored status codes.

These stored status codes have caused a PMT controller shutdown and/or disruption of normal vehicle operation.

NOTE The following functions have function numbers larger than the numbers on the Handset keyboard. To access these functions, push the CONT key and the number shown in the following instructions at the same time. THE KEY SWITCH MUST BE OFF.

To determine which stored status code was the last one recorded, read the number stored in Function 28. Using the Memory Map, match the “stored status code pointer number” in the HS (Handset) number column) on the memory map, with the number obtained from Function 28. This will be the last stored status code recorded.

Function 48 - Mode 1 – Controlled Acceleration

NOTE

(Push CONT 1)

When scrolling the stored status code register, the register always starts at status code 1 and scrolls to status code 16.

This function allows for the adjustment of the rate of time it takes for the control to accelerate to 96% applied battery voltage to the motor on hard acceleration.

Range Setting Resolution Example:

0.1 to 22.0 seconds 0 to 255 0.084 seconds per set unit Setting of 20 = 1.8 seconds C/A

Function 49 - Mode 1 – Lift 1 Speed Limit (SL2) (Push CONT 2) This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL2 limit switch input signal is received by the control card. SL2 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit.

Range Setting Resolution Example:

2-17

0 volts to 96 volts 0 to 255 0.375 volts per set unit Setting of 50=18.75 volts

PROGRAMMING

Function 50 - Mode 1 – Tilt Speed Limit (SL3)

Function 55 - Mode 2 – Lift 2 Speed Limit (SL4)

(Push CONT 3)

(Push CONT 8)

This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL3 limit switch input signal is received by the control card. SL3 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit.

Range Setting Resolution Example:

Same as Function 51.

Function 56 - Mode 3 – Controlled Acceleration (Push CONT 9)

0 volts to 96 volts 0 to 255 0.375 volts per set unit Setting of 50=18.75 volts

Same as function 48.

Function 57 - Mode 3 – Lift 1 Speed Limit (SL2)

Function 51 - Mode 1 – Lift 2 Speed Limit (SL4)

(Push CONT 10) Same as Function 49.

(Push CONT 2) This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL4 limit switch input signal is received by the control card. SL4 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit.

Range Setting Resolution Example:

Function 58 - Mode 3 – Tilt Speed Limit (SL3) (Push CONT 11) Same as Function 50.

0 volts to 96 volts 0 to 255 0.375 volts per set unit Setting of 50=18.75 volts

Function 59 - Mode 3 – Lift 2 Speed Limit (SL4) (Push CONT 12) Same as Function 51.

Function 52 - Mode 2 – Controlled Acceleration

Function 60 - Mode 4 – Controlled Acceleration

(Push CONT 5) Same as function 48.

(Push CONT 13) Same as function 48.

Function 53 - Mode 2 – Lift 1 Speed Limit (SL2)

Function 61 - Mode 4 – Lift 1 Speed Limit (SL2)

(Push CONT 6) Same as Function 49.

(Push CONT 14) Same as Function 49.

Function 54 - Mode 2 – Tilt Speed Limit (SL3) (Push CONT 7) Same as Function 50.

2-18

PROGRAMMING

Function 62 - Mode 4 – Tilt Speed Limit 3 (SL3) (Push CONT 15) Same as Function 50.

Function 63 - Mode 4 – Lift 2 Speed Limit (SL4) (Push CONT ESC) Same as Function 51.

2-19

PROGRAMMING

Setup Procedures Controller Setup

Before setting up any controller, the configuration of the truck must be determined. For the traction and pump controller setup, Two things must be determined; UL type (E or EE) and truck voltage. The UL type and truck voltage should be available on the build paperwork that comes with the truck. The traction and pump motor sizes are the same for the UL (E) and UL (EE) configurations and are shown in the following table.

Every controller has a basic number of settings that come with the controller. These basic settings are generic and will not allow the truck to operate properly. After the controller is installed into a truck, the settings must be changed to match the voltage of the truck and the UL configuration of the truck. All trucks have a traction controller and pump controller that must be setup.

SN PREFIX

MOTORS

VOLTAGE

TRACTION

PUMP

A2EC4

330 mm (13")

279 mm (11")

36/48V

A2EC5

330 mm (13")

279 mm (11")

36/48V

7 Ton 8 Ton 10 Ton 12 Ton

Once the configuration of the truck is known, the correct settings will need to be input into the traction and pump controller. Inputting the settings into the traction or pump controller will require a GE controller handset with the proper cable.

2-20

PROGRAMMING

Traction Controller Settings Chart For 7 Ton, 8 Ton, 10 Ton and 12 Ton SN Prefix: A2EC4 OR A2EC5 Traction Motor Diameter: 330 mm (13") SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12]

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

*Valve changes to zero after calibration.

2-21

36V 48V 9 9 60 60 20 20 255 255 15 15 255 255 67 67 255 255 100 100 170 170 35 35 0 0 113 113 18 18 36 48 130 130 135 135 149 149 255 255 255 255 70 70 183 183 50 50 160 160 0 0 2 2 0 0 0 0 Truck Hrs Do Not Adjust Truck Hrs Do Not Adjust 40 40 0 0 0 0 80 80 40 40 0 0 0 0 0 0 30 30 50 50 35 35 0 0 20 20 100 100 70 70 0 0

PROGRAMMING

Traction Controller Settings Chart For UL EE Closed Motor Option For 7 Ton, 8 Ton, 10 Ton and 12 Ton SN Prefix: A2EC4 OR A2EC5 Traction Motor Diameter: 330 mm (13") SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12]

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 29 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

*Valve changes to zero after calibration.

2-22

36V 48V 9–10 9–10 60 60 27 27 255 255 15 15 255 255 85 85 255 255 35 35 160 160 35 35 0 0 113 113 16 16 36 48 180 180 135 135 149 149 255 255 255 255 0 0 183 183 50 50 90 90 0 0 6 6 0 0 0 0 Truck Hrs Do Not Adjust Truck Hrs Do Not Adjust 54 54 0 0 0 0 80 80 54 54 70 70 0 0 0 0 40 40 35 35 0 0 0 0 27 27 35 35 0 0 0 0

PROGRAMMING

Pump Controller Settings Chart FOR 7 Ton, 8 Ton, 10 Ton AND 12 Ton SN PREFIX: A2EC4 OR A2EC5 PUMP MOTOR DIAMETER: 279 mm (11") SETTING DESCRIPTION N/A Internal Resistance Compensation Start Controlled Acceleration Armature Current Limit N/A N/A Internal Resistance Compensation Rate N/A N/A N/A Aux1/Aux2 Speed Limit (SL1) Lift 1 Speed Limit (SL2) Tilt Speed Limit (SL3) Lift 2 Speed Limit (SL4) N/A Speed Torque Compensation Card Type Selection (500A/600A) Over current setting (0.001 sec) N/A N/A N/A Truck Mode Set by Display minutes minutes seconds N/A Monitor N/A Stored Fault Count Pointer Pump Hourmeter Storage Register Pump Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Lift 1 Speed Limit (SL2) [#12] MODE 1 - Tilt Speed Limit (SL3) [#13] MODE 1 - Lift 2 Speed Limit (SL4) [#14] MODE 2 - Controlled Acceleration [#3] MODE 2 - Lift 1 Speed Limit (SL2) [#12] MODE 2 - Tilt Speed Limit (SL3) [#13] MODE 2 - Lift 2 Speed Limit (SL4) [#14] MODE 3 - Controlled Acceleration [#3] MODE 3 - Lift 1 Speed Limit (SL2) [#12] MODE 3 - Tilt Speed Limit (SL3) [#13] MODE 3 - Lift 2 Speed Limit (SL4) [#14] MODE 4 - Controlled Acceleration [#3] MODE 4 - Lift 1 Speed Limit (SL2) [#12] MODE 4 - Tilt Speed Limit (SL3) [#13] MODE 4 - Lift 2 Speed Limit (SL4) [#14]

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

2-23

UL (E) 36V/48V 0 67 20 255 255 255 99 255 255 255 51 20 80 255 255 21 67 255 255 255 255 183 0 0 0 0 255 0 0 0 40 20 50 255 40 20 50 255 20 20 75 255 20 20 75 255

UL (EE) 36/48V 0 67 20 255 255 255 99 255 255 255 51 20 80 255 255 21 67 255 255 255 255 183 0 0 0 0 255 0 0 0 40 20 50 255 20 20 50 255 20 20 75 255 20 20 75 255

PROGRAMMING

Memory Maps – Traction Control E2

Func No.

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 46 47 48 49 50 51

HS No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

(18)

(20)

(22)

(26)

Traction Control Function MPH Scaling Creep Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Braking Auto Calibration of Accelerator Pot Minimum Field Current Maximum Field Current Regen Current Limit Field Current for Regen Speed Limit 1 Top Speed Limit Maintenance & Truck Mgmt Speed Limit IR Compensation Battery Volts Select Stall Protection and % ON-Time Trip Card Type Select Steer Pump Time Delay Maintenance Code HM (Tens/Units) Maintenance Code HM (Thou/Hun) Auto Regen Braking Current Limit Mode Storage Regen Cancel Current FW Start Monitor Ratio Steer Pump Minutes Fault Count Pointer Steer Pump Hours (Tens/Ones) Steer Pump Hours (Thou/Hun) Traction Hours (Tens/Ones) Traction Hours (Thou/Hun) Stored Status Code #1 BDI 1 Hours (Tens/Ones) 1 Hours (Thou/Hun) 1 Stored Status Code #2 BDI 2 Hours (Tens/Ones) 2 Hours (Thou/Hun) 2 Stored Status Code #3 BDI 3 Hours (Tens/Ones) 3 Hours (Thou/Hun) 3 BDI 4 Hours (Tens/Ones) 4 Hours (Thou/Hun) 4 Stored Status Code #5 BDI 5 Hours (Tens/Ones) 5 2-24

Access By HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only

Restrictions None None None None None None Contact Service Engineering None None None None None None None None None None None None None None For DD on power up None Contact Service Engineering Temporary Storage Contact Service Engineering Temporary Storage None None None None None Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only

PROGRAMMING

Memory Maps – Traction Control E2

Func No.

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 90 91 92 94 95 96 97 98 99 100

52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 ; 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 91 92 93 95 96 67 98 99 100 101

HS No. (28)

(30)

(32)

(34)

(36)

(38)

(40)

.

(42)

(44)

(46)

(48)

48 49 50 51 52

Traction Control Function Hours (Thou/Hun) 5 Stored Status Code #6 BDI 6 Hours (Tens/Ones) 6 Hours (Thou/Hun) 6 Stored Status Code #7 BDI 7 Hours (Tens/Ones) 7 Hours (Thou/Hun) 7 Stored Status Code #8 BDI 8 Hours; (Tens/Ones) 8 Hours (Thou/Hun) 8 Stored Status Code #9 BDI 9 Hours (Tens/Ones) 9 Hours (Thou/Hun) 9 Stored Status Code #10 BDI 10 Hours (Tens/Ones) 10 Hours (Thou/Hun) 10 Stored Status Code #11 BDI 11 Hours (Tens/Ones) 11 Hours (Thou/Hun) 11 Stored Status Code #12 BDI 12 Hours (Tens/Ones) 12 Hours (Thou/Hun) 12 Stored Status Code #13 BDI 13 Hours (Tens/Ones) 13 Hours (Thou/Hun) 13 Stored Status Code # 14 BDI 14 Hours (Tens/Ones) 14 Hours (Thou/Hun) 14 Stored Status Code # 15 BDI 15 Hours (Tens/Ones) 15 Hours (Tens/Ones) 15 Hours (Thou/Hun) 15 Stored Status Code #16 Hours (Tens/Ones) 16 Hours (Thou/Hun) 16 Dash Display CA-1 Dash Display Regen C/L-1 Dash Display Auto Regen C/L-1 Dash Display Speed Limit 2 - 1 Dash Display CA-2 2-25

Access By PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only HS or PC HS or PC HS or PC HS or PC HS or PC

Restrictions Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only None None None None None

PROGRAMMING

Memory Maps – Traction Control E2

Func No.

101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127

102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128

HS No. 53 54 55 56 57 58 59 60 61 62 63

Traction Control Function Dash Display Regen C/L-2 Dash Display Auto Regen C/L-2 Dash Display Speed Limit 2 - 2 Dash Display CA-3 Dash Display Regen C/L -3 Dash Display Auto Regen C/L-3 Dash Display Speed Limit 2 - 3 Dash Display CA-4 Dash Display Regen C/L-4 Dash Display Auto Regen C/L-4 Dash Display Speed Limit 2 - 4 Secure HM (Tens/Ones) Steer Pump Secure HM (Thou/Hun) Steer Pump Secure Aux HM (Tens/Ones) Secure Aux HM (Thou/Hun) Reserved Reserved Reserved Reserved Truck Minutes Pump Minutes Pump Hours (Tens/Ones) Pump Hours (Thou/Hun) OEM Use OEM Use Accelerator Auto Calibration Slope Accelerator Auto Calibration Y-Intercept

2-26

Access By HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only

Restrictions None None None None None None None None None None None Read Only Read Only Read Only Read Only GE Future Use GE Future Use GE Future Use GE Future Use None None None None None None None None

PROGRAMMING

Accelerator Setup

13. Push the directional lever into forward and ‘A’ should now appear on the handset display.

The purpose of this setup procedure is to make the GE SX Traction controller learn the range of the accelerator potentiometer. If this procedure is not done after new settings are installed into the controller, the display will show a fault code -08. The default settings are designed to require the accelerator setup every time new settings are installed. Because of this, the accelerator setup should ALWAYS be done right after inputting the settings into the traction controller.

14. Put the directional lever back into neutral and -11 should now appear on the handset display.

15. Release the accelerator and the truck should operate normally.

If during this procedure a fault code -86 appears, there may be something wrong with the output of the accelerator or there was just a glitch in the setup.

Turn the key switch OFF then back ON to reset the procedure and try again. If the procedure is unsuccessful more than 3 times, then there may be something wrong with the output of the accelerator. The voltage output for the accelerator must not exceed 4.3V and the difference between the output voltage in the OFF position and the output voltage at full activation of the accelerator must be between 2.5V and 4.2V. If any of these criteria are not met, a fault code -86 will appear. One possible cause for this is the incorrect adjustment of the accelerator pedal stop bolt. The distance from the top of the threaded bolt to the flat surface of the floor plate should be 22 ± 2 mm X (26 ± 2 mm for foot direction control).

This setup should be done any time the accelerator or traction controller is replaced for the production trucks. This procedure can also be performed any time the accelerator appears to be out of adjustment.

This adjustment is possible only on traction software version M and higher.

1. Unplug the battery and blow the horn to discharge the capacitor.

2. Unplug the small black connector from the traction control and plug in the GE handset.

3. Make sure the battery is plugged in and the key switch is OFF.

If the accelerator range is set properly, function 6 will automatically change back to a value of 0. Because the value of function 6 is defaulted to 255 when a controller is initially set up, the accelerator must also be set up every time new settings are installed into the controller.

4. Turn on the Key and while holding down the CONT key on the handset, then release the CONT key after 8888 appears on the handset.

(The seat switch must be open) 5. Push 6 on the handset and change the value to 18 by pushing CONT, (the display will start flashing), turn the knob when you see the 18, push store to save setting.

6. Sit on the seat to close the seat switch.

7. Leave the handset plugged in.

8. Make sure the directional lever is in neutral position and the seat switch is closed, Press the ESC key on the handset.

9. If a -83 appears, one of the above conditions has not been met. You will need to start over. ‘AAAA’ should appear on the handset display.

10. With your foot off of the accelerator pedal, the start switch in the “ON” position, push the directional lever into forward and ‘AAA’ should now appear on the handset display.

11. Put the directional lever back into neutral and ‘AA’ should now appear on the handset display.

12. Depress the accelerator all the way down and hold it.

2-27

PROGRAMMING

Premium Display Speedometer Setup •

The premium display has the ability to show the speed of the truck. Since the gear ratio is different between a 1 ton truck and a 2–3 ton truck, the display must be set to show the right speed for the right size truck.

•

Plug the battery into the truck with the key switch OFF and make sure the display is blank.

•

Once the display is blank, press and hold down both gray buttons on the display for 15 seconds.

•

While holding down the buttons, the display will first show a blinking speed unit for 10 seconds, then it will show nothing for 5 seconds.

•

After 15 seconds a number will appear blinking on the right side of the display. At this time, release both buttons.

•

Now you are in the speed setup mode. The value of this setting can be changed from 1 to 12.

•

Set the value to 5.

•

To set the value, press and hold down the right button. The number will start counting up. Once the correct number is shown, release the right button.

•

To input this value, press and release the left button once. The number should stop blinking if it is set.

•

To exit this setup mode, press and release both buttons once.

•

If the number does not seem like it is being set, exit this setup mode and reenter to try again.

2-28

CHECKS AND REPAIRS 3 — CHECKS AND REPAIRS General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Contactor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Brush Wear Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Motor Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Thermal Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Why is Thermal Transfer important? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 What determines “Good” Thermal Transfer?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Insuring Proper Thermal Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Mounting Instructions for Motor Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Necessary Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 The Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Vehicle Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Application of Thermal Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Mounting the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Troubleshooting Tips (Motors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Successful Commutation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Sparking At Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Insulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Armature Winding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Unsatisfactory Brush Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 Table One - Primary Sources of Unsatisfactory Brush Performance. . . . . . . . . . . . . . . . . . . 3-11 Table Two - Indications Appearing at Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 Table Three - Indications Appearing at Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 Table Four - Indications Appearing at Commutator Surface . . . . . . . . . . . . . . . . . . . . . . . . .3-15 Commutator Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Notes

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CHECKS AND REPAIRS CHECKS AND REPAIRS

General Information

Traction fuse (750 Amperes)

Pump fuse (350 Amperes)

Traction Fuse (350 Ampere for 600 Amp control) (750 Ampere for 1000 Amp control) Traction and Pump Ampere rating is identified by the 11th, 12th and 13th digit of the GE part number

WARNING Some adjustments in this section must be done with the battery connected and power applied to the controller. When making these adjustments, make sure the drive wheels are raised from the floor. Some voltage measurements must be made with the SRO circuit complete. Make sure the drive wheels are raised from the surface before doing troubleshooting. If working alone, put a weight in the seat to close the seat switch. Position the voltmeter so that you can see it from the operator area. This will allow the controls to be operated while taking voltage measurements.

3-1

CHECKS AND REPAIRS

Fuses

WARNING Make sure to disconnect the battery and separate the connector before disassembling any part of the controller. The capacitor stores electrical energy and can cause injury if a person discharges a capacitor through parts of the body.

AFTER the battery is disconnected, make sure to also discharge the capacitor by using a p/n 358280 Resistor across the positive and negative terminals on the control panel for a least 20 seconds.

The fuses are found on the SX control panel. The value of the power fuse for the traction controller is 350 amps for the 600 amp controller and 750 amps for the 1000 amp controller. The value of the power fuse for the hydraulic pump controller is 350 amps and the value for the hydraulic pump contactor is 500 amps. The value of the power fuse for the power steering motor is 100 amps. The condition of the fuses can be determined by looking at them or checking with an ohmmeter, or volt drop testing.

NOTE The electronic controller in these forklift trucks can not be seen from the operator area. Some checks and adjustments are difficult to do unless another person can operate the controls.

NOTE The bolts and screws connected to the electronic components are normally metric sizes. Make sure that the correct fastener for the part that has been disassembled is used.

3-2

CHECKS AND REPAIRS

Contactor Repair Contactor Line 1. CONTACTOR 2. WASHER, PLAIN 3. TIP, SPRING TOP 4. TIP, SPRING 5. TIP, SPRING SEAT 6. TIP, MOVABLE 7. CLAMP, BUS 8. SCREW 9. WASHER, LOCK 10. TIP, CARRIER 11. BUSHING, PLUNGER 12. TIP, STATIONARY 13. BASE, BUS 14. ARMATURE 15. SPRING, ARMATURE 16. FRAME 17. COIL 18. MAGNET 19. BASE ASSY 20. KIT, SERVICE TIP 21. NUT

Make a location identification for the wires and cables then disconnect from the contactor assembly.

Remove the mounting screws and remove the contactor assembly.

Contactor Contacts. The contacts in a contactor are made of special silver alloy. The contacts will look black and rough from normal operation. This condition does not cause problems with the operation of the forklift truck. Cleaning is not necessary.

DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS.

WARNING ALWAYS replace all of the contacts in a contactor at the same time. Replace the contacts in the contactors when the thickness of any area of a contact is less than 30% of the thickness of a new contact or if there is any transfer of contact material.

1

Typical Contactor Assembly

3-3

CHECKS AND REPAIRS

Contactor Repair

ter. A suppressor diode (and sometimes a resistor in series) is part of the coil. The diode will cause the ohmmeter to indicate a difference in resistance in one direction. Reverse the probes of the ohmmeter to the opposite terminals and measure the resistance. Use the highest resistance.

Coil. Check the coil with an ohmmeter for an open circuit or a short-circuit. Replace if damaged. The coils in the contactors for the hydraulic pump and 1A have an external suppressor. The coil and the suppressor can be checked separately with an ohmme-

COIL RESISTANCE TEST SPECIFICATIONS Line, Traction Line and Pump Line (36/48V)

59 ohms ± 10%

Power Steering (36/48V)

77 ohms ± 10%

Pump and 1A Bypass (36/48V)

33 ohms ±10%

Brush Wear Indicators

Motor Thermal Switches

The brush wear indicator will illuminate on the premium display only, when the motor brushes must be replaced. The sensor is located on the brush carrier and will come in contact with the brush holder when the brushes have passed a serviceable limit. When the brush wears within approximately 1.5 mm (0.060 in) of the brush lead, the connection between the brush and the sensor causes the indicator to illuminate on the premium display

The motor thermal switch will illuminate on both displays. The switch is located in the motor and the over temperature action light will illuminate when the motor overheats. The thermal switch cannot be replaced if it is damaged. The thermal switch can only be replaced by replacing the motor fields.

WARNING To prevent damage and injury if the forklift truck moves. Raise the drive wheels from the floor during these tests.

The operation of the brush wear indicators can be checked during periodic maintenance. The battery must be removed from the forklift truck for access to the motors.

Use a jumper cable so that the battery can be connected for operation of the motors. See FIGURE 1.

Disconnect the sensor wires from outside of the motor case. Touch the ends of the sensor wire together. The warning light will illuminate if the circuit is operating correctly.

Use a jumper cable so that the battery can be connected for operation of the motors. See FIGURE 1.

Disconnect the sensor wires from the outside of the motor case. Touch the ends of each sensor wire to the A1 terminal of the motor while it is in operation.

The warning light will illuminate on the display if the circuit is operating properly.

1.

RAISE DRIVE WHEELS

2.

REMOVE BATTERY

3.

INSTALL JUMPER

Connect the battery so that the motor can be operated. The battery must be removed for access to the motor. Use a jumper cable to connect the battery to the forklift truck. Raise the drive wheels. See “Before Servicing Forklift Truck” in the GENERAL INFORMATION Section.

FIGURE 1. Connect Battery to Operate Motor 3-4

CHECKS AND REPAIRS

Thermal Transfer

Insuring Proper Thermal Transfer

Why is Thermal Transfer important?

Mounting Instructions for Motor Controls

Solid-state electronic devices are often considered “lossless” as compared to their electro-mechanical counterparts. However, these devices are not entirely 100% efficient and losses exist in the form of generated heat which must be dissipated properly to insure long-term reliability and performance.

In the design of this family of motor controls, performance assumptions were made based on heat transfer between the control and the ambient environment. The vehicle mounting surface acts as a heat sink, which increases the effective surface area for heat dissipation. If this assumed heat transfer is not achieved during control installation and operation, the controllers will fall short of their anticipated performance. It should be noted that the condition of the mounting surface, and the quality of the resulting interface between the control and the vehicle, can significantly hinder heat transfer from the control. This why each control has a thin sheet of copper between the control and the frame of the truck. The presence of contaminants, or of air voids created by surface inconsistencies in either the vehicle or the control, degrade the control’s capacity for heat transfer. The control’s performance is de-rated proportionally as its own thermal sensors reduce its operation to protect it from damage due to excessive heating.

The Control incorporates solid-state devices throughout. It also incorporates heat sinking to provide proper dissipation of the generated heat through these heat sinks to the control base to be eventually dissipated in the vehicle control mounting structure (i.e. bulkhead).

The Control heat sinks are designed to provide relief from short-term thermal peak overloads, but longterm cooling is dependent on proper thermal transfer from the heat sink to the vehicle frame.

What determines “Good” Thermal Transfer?

The primary factor for insuring “good” thermal transfer is a good mechanical surface-to-surface interfacing for flat and threaded surface mating. The effectiveness of the thermal transfer is a function of the amount of actual surface contact there is between a heat “source” and a properly selected heat “sink”.

While most commercially prepared surfaces appear flat and smooth, good thermal transfer of the heat generated in solid-state devices requires the optimum in surface contact. The smallest amount of surface irregularity can be detrimental as it adds to the thermal resistivity between the two surfaces and limits thermal transfer.

Contained within the software of the controls are several diagnostic status codes related to controller thermal performance. Failure to follow these mounting recommendations increases the likelihood of encountering these status codes.

Careful surface preparation, including adequate application of thermal compound, as detailed in the following paragraphs, must be completed during the installation of the controls. There are many techniques for applying thermal compound, and one approach is outlined below that has shown to apply a consistent thickness of material.

“Good” thermal transfer is thus dependent on 3 factors: 1. Proper heat sinking.

2. Proper mechanical mating (mounting).

3. Optimum surface contact.

3-5

CHECKS AND REPAIRS

Necessary Tools

Vehicle Mounting Surface

Recommended use of the following components, or equivalent substitutions, during the control installation process:

The quality of the vehicle mounting surface is critical for the optimum heat transfer between the control and the ambient environment. Conduction through the base of the control is the control’s only means of heat rejection. While the controls are highly efficient, a few percent of the electrical energy will be converted into heat. As previously mentioned, if this energy is not dissipated through the base of the control, a thermal protector will reduce the performance of the control until the temperature stabilizes. For optimal heat transfer from control to vehicle, the flatness of the vehicle mounting surface should be equivalent to the flatness of the control surface (0.005" per linear inch). Use a straight edge or dial indicator to verify the mounting surface.

1. Thermal compound, (5P9837), maintained per the manufacturer’s recommendations and free of contaminants 2. 3/32" notched trowel, such as a adhesive spreader, model SE000049 3. Calibrated torque wrench (0 – 15 ft-lbs)

The Controls During the manufacture of the control, the surface flatness is maintained at 0.005" per linear inch (not to exceed 0.025" per 10.0 inches). The surface finish of the control has an Ra (average roughness) of 64 (microinches), or better. This finish is consistent with cold rolled or extruded aluminum.

The biggest hindrance to heat transfer is the presence of rust, scale, weld splatter or paint on the vehicle mounting surface. If any of these items are noted, prepare the surface per the following guidelines:

Care should always be taken in the handling and storage of controllers. The base of the control should be free from nicks, bumps, protrusions or any other foreign object that would prevent the control from sitting flush with the vehicle mounting surface. Examine the base of the control to verify that it is in good condition and free from damage or contamination.

1. Clean the mounting surface with a rotary wire brush until the metal surface is exposed.

2. Using 80–100 grit emery paper, sand the surface until the metal shines.

3. Flush the surface clean with an appropriate liquid de-greaser or parts cleaner.

3-6

CHECKS AND REPAIRS

Application of Thermal Compound

Mounting the Control

Due to the minute differences in the control mounting surface and the vehicle mounting surface, small pockets of air will be created. These air pockets will add to the overall thermal resistance of the interface.

To avoid these air pockets and improve thermal conductivity, thermal compound must be applied between the control base plate and the vehicle mounting surface. The function of this compound is to conform to surface discrepancies, filling gaps and optimizing the metal-to-metal contact of the control and the vehicle.

1. After control mounting surface is prepared with heat sink grease, place the copper heat conducting pad on heat sink grease and align holes as positioned.

2. After placing the copper pad, apply heat sink grease to the exposed side of the pad using the same method as before.

3. Prepare mounting surface of truck.

4. Place the control unit with desired orientation on mounting surface of truck with mounting holes aligned.

1. Prepare the two mounting surfaces (control and vehicle) as indicated above.

5. Move the control slightly in all directions to eliminate voids and enhance the distribution of the thermal compound.

2. Using a triangular notched trowel of 3/32" (.09" ± .01), apply the grease to the vehicle mounting surface.

6. Insert all of the mounting hardware (6 or 8 bolts, M6, necessary for the mounting of the respective control).

3. Use straight, non-crossing strokes of the trowel to apply the compound.

7. Tighten these bolts (as per sequence shown in diagrams below) to half of the nominal torque value (4 ft-lb).

4. Make multiple vertical passes until a uniform consistency is achieved.

8. Lastly, tighten the bolts to the nominal torque value (8 ft-lb), following the same sequence.

Calibrated torque wrench for hardware installation

Adhesive spreader model SE000049

Vehicle surface after proper grease application

3-7

CHECKS AND REPAIRS

Traction 8

5

2

Hydraulic 4

5

2

1

6

3

3

4

1

6

7

Proper sequence for use in tightening hardware during control mounting

Maintenance If it is necessary to remove the control, careful consideration must be given to removing the old thermal compound from the control and mounting surface, prior to replacement of the unit. Never re-use thermal compound. Use a putty knife or similar straight edge to carefully remove all thermal compound residue without damaging either mounting surface. Flush the surfaces with a liquid de-greaser or parts cleaner and allow them to dry, before re-applying the thermal compound and mounting the control. Take care not to contaminate the surfaces with hydraulic fluid or battery acid.

If the copper heat conducting pad between the control and the truck shows signs of corrosion that cannot be cleaned, then the copper pad must be replaced. otherwise, carefully remove the old thermal compound and reapply it before installing the new control.

3-8

CHECKS AND REPAIRS

Traction Control

1. Traction Control

5. Bolt, Lockwasher Assembly

2. Pad, TR Heats

6. Washer, Plain

3. Bolt, Washer Assembly

7. Bus Bar

4. Washer, Plain

8. Washer, Spring

3-9

CHECKS AND REPAIRS

Troubleshooting Tips (Motors)

Insulation System

Successful Commutation Requirements

•

Insulation resistance - 0.10 Mega-ohm (or greater)

•

Less than 0.10 Mega-ohm, investigate: -

Excessive dirt

Mechanically true commutator

-

Moisture

•

Brushes free to move in holders

-

Insulation break down

•

Copper-Oxide-Carbon film (as opposed to pure copper surface) noted by color variations

•

Good contact between commutator and brush

•

•

Commutator surface should be clean and smooth—light film will occur with use and should not be removed

•

Clean commutator—do not store commutator unless replacing brushes

For moisture, bake in an oven at 90° C (190°F) •

600V - 60HZ - 1 minute

•

Test older motors at 75% of above values

Armature Winding Problems •

NOTE Refer to the next following pages for charts on “Unsatisfactory Brush Performance” and illustrations of “Commutator Surfaces” which show the main patterns of film build-up on commutators, and indicate the type of brush/commutator interaction which give rise to each pattern.

•

•

Sparking At Brushes •

Commutator in poor condition

•

Eccentric or rough commutator

•

Excessive vibration

•

Broken or sluggish spring

•

Brushes to short

•

Machine overloaded

•

Short circuit in armature

3-10

Open Circuit -

Thin red sparks encircling commutator

-

Blackens or flattens commutator bars, especially at edges

Short Circuit -

Blue spark in vicinity of brush holder

-

Commutator bars oxidize or burn

Grounded -

High current draw

-

Rapid brush wear

CHECKS AND REPAIRS

Unsatisfactory Brush Performance Table One - Primary Sources of Unsatisfactory Brush Performance

Preparation and Care of Motor

Mechanical Fault in Motor

Electric Fault in Motor

Load or Service Condition

Disturbing External Condition

• • • • •

Poor operation of commutator surface

• • • • • • •

Brushes tight in holders

• • • • •

Open or high resistance connection at commutator

• • • • • • • • • •

Overload

• • • • • • • • •

Loose or damaged motor mounting

3-11

High mica Side mica Need for periodic cleaning Clogged ventilating ducts

Brushes too loose in holders Brush holders loose at mounting Loose pole pieces Loose or worn bearings Dynamic imbalance Variable angular velocity

Connection at series terminal Short circuit in field or armature winding Ground in field or armature winding Reversed polarity on main pole

Dynamic braking Low average current density in brushes Contaminated atmosphere “Contact positions” Oil on commutator or oil mist in air Abrasive dust in air Humidity too high Humidity too low Silicone contamination

External source of vibration External short circuit Contact drop of brushes too high Contact drop of brushes too low Lack of film-forming properties in brush Lack of polishing action in brush Brushes too abrasive Lack of carrying capacity

CHECKS AND REPAIRS

Unsatisfactory Brush Performance Table Two - Indications Appearing at Brushes INDICATION Sparking

IMMEDIATE CAUSES

PRIMARY FAULTS

Commutator surface condition

• • • • • • • • • •

Poor operation of commutator surface High mica Side mica Low average current density in brushes Contaminated atmosphere Contact positions Oil on commutator or oil mist in air Humidity too low Lack of film-forming properties in brush Lack of polishing action in brush

Mechanical fault in motor

• • • • • • • •

Clogged ventilating ducts Brushes tight in holders Brushes too loose at mounting Loose pole pieces Loose or worn bearings Dynamic unbalance Incorrect spring tension Poor operation of commutator surface

Electrical fault in motor

• Open or high resistance connection at commutator • Short circuit in field or armature winding • Ground in field or armature winding • Reversed polarity on main pole

Bad load condition

• Overload • Rapid change of load

Vibration

• Loose or damaged motor mountings • External source of vibration

Chattering of brushes

• See Chattering or Noisy Brushes

Wrong brush grade for

• Lack of film-forming properties in brush application

• Silicone contamination

Other Etched or Burned Bands on Brush Face

Embedded copper

Rapid Brush Wear

Commutator surface condition

• See specific surface fault in evidence • Silicone contamination

Severe sparking

• See Sparking

• See Copper in Brush Face

3-12

CHECKS AND REPAIRS

Unsatisfactory Brush Performance Table Two - Indications Appearing at Brushes (Continued) INDICATION Rapid Brush Wear (continued)

Copper in Brush Face

Chattering or Noisy Brushes

IMMEDIATE CAUSES

PRIMARY FAULTS

Imperfect contact w/ commutator

• • • • • •

Wrong brush grade f/application

• Lack of film-forming properties in brush

Commutator surface condition

• High mica • Side mica

Bad service condition

• • • •

Wrong brush grade f/application

• Lack of film-forming properties in brush • Brushes too abrasive

Commutator surface condition

• Raised Commutator Bars

Looseness in motor

• Brushes too loose in holders • Brushes holders loose at mounting • Incorrect spring tension

High friction

• • • •

Wrong brush grade f/application

• Lack of film-forming properties in brush

3-13

Incorrect spring tension Brushes tight in holders Brushes too loose in holders Brushes holders loose at mounting Loose or damaged motor mountings External source of vibration

Oil on commutator or oil mist in air Abrasive dust in air Humidity too high Humidity too low

Clogged ventilating ducts Contact poisons Humidity too low External source of vibration

CHECKS AND REPAIRS

Unsatisfactory Brush Performance Table Three - Indications Appearing at Heating INDICATION Heating in Windings (Field or Armature)

IMMEDIATE CAUSES

PRIMARY FAULTS

Severe load condition

• Overload • External short circuit • Stalled motor

Unbalanced magnetic field

• Loose or worn bearings • Short circuit in field or armature winding

Lack of ventilation Heating at Commutator

Heating at Brushes

Severe load condition

• Overload

Severe sparking

• Contact positions • See Sparking

High friction

• • • •

Poor commutator surface

• See specific surface fault in evidence

Depreciation

• Clogged ventilating ducts

High contact resistance

• Contact drop of brushes too high

Severe load condition

• Overload

Faulty motor adjustment

• Incorrect spring tension

Severe sparking

• See Sparking

Raw streaks on commutator

• See Streaking or Threading of Surface

Embedded copper

• See Copper in Brush Face

Wrong brush grade f/application

• • • •

3-14

Incorrect spring tension Contact poisons Humidity too low Lack of film-forming properties in brush

Contact drop of brushes too low Lack of film-forming properties in brush Brushes too abrasive Lack of carrying capacity

CHECKS AND REPAIRS

Unsatisfactory Brush Performance Table Four - Indications Appearing at Commutator Surface INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Commutator surface condition

• See specific surface fault in evidence

Looseness in motor

• Brushes too loose in holders • Brushes holders loose at mounting

Vibration

• External source of vibration

Chattering

• See Chattering or Noisy Brushes

Sluggish brush movement

• Brushes tight in holders • High mica • Side mica

High Commutator Bar

Sparking

• Stalled motor

Low Commutator Bar

Sparking

• High mica • Open or high resistance connection at commuta-

Brush Chipping or Breakage

tor

• Stalled motor Sparking

• • • • • •

Low average current density in brushes Contaminated atmosphere Contact positions Oil on commutator or oil mist in air Humidity too low Lack of film-forming properties in brush

Copper or foreign material in brush face

• • • • • •

High mica Side mica Oil on commutator or oil mist in air Abrasive dust in air Humidity too high Brushes too abrasive

Bar Etching or Burning

Sparking

• High mica • Side mica

Bar Marking at Pole Pitch Spacing

Sparking

• Open or high resistance connection at commuta-

Bar Marking at Slot Pitch Spacing

Sparking

• Lack of polishing action in brush • Lack of film-forming properties in brush

Flat Spot

Sparking

• Open or high resistance connection at commuta-

Streaking or Threading of Surface

tor

tor

• Stalled motor 3-15

CHECKS AND REPAIRS

Unsatisfactory Brush Performance Table Four - Indications Appearing at Commutator Surface (Continued) INDICATION Discoloration of Surface

Raw Copper Surface

Rapid Commutator Wear with Blackened Surface

Rapid Commutator Wear with Bright Surface

Copper Dragging

IMMEDIATE CAUSES

PRIMARY FAULTS

High temperature

• See Heating at Commutator

Atmospheric condition

• Contaminated atmosphere • Oil in commutator or oil mist in air

Wrong brush grade for application

• Lack of polishing action in brush • Lack of film-forming properties in brush

Embedded copper

• See Copper in Brush Face

Bad service condition

• Contact positions • Abrasive dust in air • Humidity too low

Wrong brush grade for application

• Lack of film-forming properties in brush • Brushes too abrasive

Burning

• • • •

Severe sparking

• See Sparking

Foreign material in brush face

• • • •

Wrong brush grade for application

• Brushes too abrasive • Lack of film-forming properties

Brush Vibration

• External source of vibration • Lack of film-forming properties in brush

3-16

High mica Side mica Incorrect spring tension Brushes tight in holders

Contact positions Abrasive dust in air Humidity too low Brushes too abrasive

CHECKS AND REPAIRS

Commutator Surfaces GOOD CONDITION

UNSATISFACTORY CONDITION

LIGHT FILM

UNEVEN FILM

Uniform coloring indicates satisfactory operation of machine and brushes. Film color is largely an effect of thickness, therefore provided the film is uniform it is perfectly acceptable.

Patchy colors of varying densities and shape. Due to unclean operating conditions or incorrect physical condition of commutator.

SATISFACTORY CONDITION

UNSATISFACTORY CONDITION

LIGHT AND DARK PATTERN

FILM WITH DARK AREAS

This is not a good condition but in our experience it is known that machines having this commutator pattern have operated with satisfactory results for long periods of time. This condition can appear in alternating bars as shown or every 3rd or 4th bar, etc. This is related to the winding design of the armature. Difficulty caused from split windings crossing in the same slot.

These areas can be isolated or regular. Commutator out of round. This can be caused by vibration or mechanical deficiencies in equipment operation, bearings, couplings, etc.

UNSATISFACTORY CONDITION

UNSATISFACTORY CONDITION

STREAKY FILM WITH NO COMMUTATOR WEAR

EXAMPLE OF POOR COMMUTATOR MACHINING

Frequently due to under-loaded operation, machine grossly over-brushed or brush grade incorrect for particular machine application. Atmosphere and environmental conditions can contribute.

Bars are low on entry and leaving edges giving rise to the brushes riding on the middle of the bars.

3-17

CHECKS AND REPAIRS

UNSATISFACTORY CONDITION

UNSATISFACTORY CONDITION

EXAMPLE OF POOR COMMUTATOR MACHINING

BRUSH CONTACT MARK Storage of machines, for lengthy periods, with brushes in position.

This can also result from operation of machine in prolonged stall conditions.

Bars are low in the middle giving rise to the brushes riding on entry and leaving bar edges.

This and the previous illustration indicate the need for better maintenance.

UNSATISFACTORY CONDITION

UNSATISFACTORY CONDITION

STREAKY FILM WITH COMMUTATOR WEAR

BAR EDGE BURNING CAUSE HIGH MICA

This is a further development of the third example, previous page. Brush grade, machine applications and working environment all suspect. Earlier corrective action should have been taken.

Illustration shows high mica in every slot. Same effect can occur on one bar only. Similar conditions can be caused by a high or low bar.

UNSATISFACTORY CONDITION

UNSATISFACTORY CONDITION

DOUBLE POLE PITCH

SMALL BRIGHT SPOTS

Darkening of commutator in sequences two pole pitches apart is due to armature fault, defective coil, riser bars or equalizer connections.

Related to over-loaded machines and low brush pressure. Due to sparking under brush which gives rise to spots being of a random distribution. If not corrected, will result in scored commutator.

3-18

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM 4 — SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM SX Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Instructions for Removal of SX Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Table One - Failures That Cause Reduced or No Motor Torque . . . . . . . . . . . . . . . . . . . . . . .4-2 Table Two - Mis-operation of Other Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 Table Three - Mis-operation of Other Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Notes

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SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

SX Control F1

F2

P2

Neg

GE Name Plate and Part Number

Positive P1

A2

These troubleshooting instructions are intended as a method to check all outside devices and eliminate them as the source of the problem in order to conclude that the SX Control is faulty.

NOTE The settings for the controller must be set after installation. See Controller Setup in the Handset section for the proper procedure.

Instructions for Removal of SX Control 1. Disconnect Battery, Discharge Cap, Raise drive wheels.

2. Unplug main and Y plugs by pressing down on tab and pulling straight out on connector. Never use wires to pull out connector.

3. Remove power fuse and all Bus or cable connections from control.

4-1

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM The primary method of diagnosing SX Control System faults is to use the diagnostic features of the display and handset. These, along with the preceding fault code tables, aid in the resolution of the majority of faults encountered.

secondary guide to aid in the identification of the fault.

1st Check is for shorts to frame. Voltage on frame may cause many problems and codes.

2nd Checks are always loose/dirty connections at controller and harness connections.

If a problem is readily identified through the built-in diagnostics feature, use the following tables as a

Table One - Failures That Cause Reduced or No Motor Torque NOTE Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

1a. Line Contactor does not pick up. No control voltage from positive to negative.

• Check power and control fuses.

• Check battery for low specific gravity and connections for looseness or broken connector.

1b. Line Contactor does not pick up with control voltage positive to negative.

• Check PTC (Positive Temperature Coefficient) for • • •

•

• • •

4-2

heating. If hot to touch, check for proper battery polarity to control panel.

Plug in the battery with the key switch OFF. Voltage on should be battery volts at P1-1.

Close key switch and check volts at P1-2; voltage should be battery volts. If not check control fuse FU2.

With key switch and seat switch closed, check for battery volts at P1-6. If zero, check control fuse, wiring or faulty key switch. If low check for volt drop across circuit from battery pos to P1-6.

With key switch and seat switch closed, check for battery volts at P1-2. If zero, check control wire #10 between key switch and seat switch and control card or fault seat switch. If low check for volt drop across circuit to P1-2.

Check for positive at line contact coil. P10-2 connection. If not battery volts check line coil for open or possible loose connections.

Static Return to Off Fault.

If monitoring system warning light on display (!) comes on, once the key switch and seat switch are closed: • Check for fault in directional control switch.

• Check for fault in wiring to directional control switch.

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Table One - Failures That Cause Reduced or No Motor Torque (Continued) NOTE Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

1c. Line contact closes, truck doesn't move.

• Check power fuse at positive on control. Should be • •

• • •

• • • •

•

4-3

battery volts. If not, check power fuse by volt drop check across fuse.

Check for over temperature condition on traction motor or traction control.

Check voltage at A1 and A2, should be battery volts. If not, check motor cables and volts at A1 and A2 to locate open circuit. Check motor brushes for sticking.

Check F1 to F2 for open field circuit (loose connections).

Check for voltage on F1 and F2, it should increase and decrease by pressing accelerator and releasing.

Check voltage at P1-7. Should be 0.5 volts with accelerator at creep speed, increasing to 3.5 volts or more as the accelerator is pressed down to top speed. If P1-7 remains at about 0.5 or less volts, check start switch and accelerator potentiometer.

Check circuit from accelerator start switch and potentiometer to traction control for open wires.

Check motor A1 to A2 for open circuit in motor armature.

Check motor F1 to F2 for open circuit in motor fields.

Check for direction switch inputs to control at P1-5 and P1-6 for forward and reverse. If voltage not present, check circuit to accelerator. Positive at P7A and check for circuit through switch at P7-B and P7-C. Replace the SX Traction control.

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Table One - Failures That Cause Reduced or No Motor Torque (Continued) NOTE Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

1d. Line contactor closes, display powers up.

Power steering contactor does not close.

• Check for direction switch positive to control at P1-4 and P1-5. If not present check direction switch and voltage to switch.

• With direction switch input voltage to P1-4 or P1-5.

Check for positive voltage to power steering coil at P10-3 wire 21. If voltage is not present check coil for open by resistance check. If Low voltage check for volt drop across wire 10 from key switch and across key switch.

• If battery voltage is correct at P10-3 and all other voltage are correct to traction control. The power steering driver in the control has failed and SX controller must be replaced.

4-4

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Table Two - Mis-operation of Other Features NOTE Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

1a. 1A Bypass contact does not close.

• Check accelerator voltage to control at P1-7. Volt-

WARNING

•

Do Not use jumper wire on coil driver with motor in static condition or severe damage may occur to motor armature. However, controller protects against this action and should produce a code.

• • • • •

4-5

age should start at below 0.5v and increase to above 3.5 volts as accelerator is depressed.

Voltage from accelerator must go above 3.5V at P17 to achieve 1A By Pass operation.

Check Battery position voltage at 1A bypass coil to PID driver terminal 3 wire 30.

Check for Battery Neg at PID driver terminal 2.

Check for signal voltage from control at P1-11 to PID driver terminal 1. Voltage should be less than 12.

If voltage is 12 or higher at P1-11 or PID driver terminal 1 then check for open PID driver.

If voltage is 2 or less and terminal 2 and 3 do not complete the circuit the PID driver may be shorted or open and should be replaced.

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Table Three - Mis-operation of Other Features NOTE Conduct all testing with drive wheels raised off the floor.

• Check for short to negative on wire 45 from coil to

1a. 1A Bypass contactor close with key.

driver terminal 3.

• Check for signal voltage at P1-11 if present.

Replace SX controller.

1b. Power Steering contact closes with key switch.

• Check for voltage short to battery neg on wire 21 between P10-3 and P1-18.

• Check Negative voltage at P10-3. If present replace SX controller.

4-6

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Table Three - Mis-operation of Other Features (continued) NOTE Conduct all testing with drive wheels raised off the floor.

3a. 1A Bypass contactor will not close at stall.

• Check voltage.

• Check Bypass contactor and driver and wiring.

• Replace SX Controller.

3b. 1A will not open until start switch is opened.

• Check voltage at P1-7. Should be near 0.5 volts, or below when accelerator is released. If not, check accelerator output.

3c. Stiff Regen (severe reversal).

• • • •

3d. Very soft reversal during regen braking mode.

• Check for proper adjustment of regen.

• Check controller type setting.

• Replace SX Controller.

Check Regen adjustment setting on Controller.

Check controller type setting.

Check traction motor brushes.

Check traction motor commotator for raised bars or out of round.

• Replace SX Controller.

4-7

Notes __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________

ELECTRICAL 5 — ELECTRICAL Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Connections to Main Traction Plug P1 with Controller Hydraulics. . . . . . . . . . . . . . . . . . . . . .5-5 Connections to Main Traction Plug P5 with Controller Hydraulics. . . . . . . . . . . . . . . . . . . . . .5-6 Connections to Main Plug (23 Pin) and P2 or P4 Plug (12 Pin) . . . . . . . . . . . . . . . . . . . . . . .5-7 Pump Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Shorted or Open Field or Armature FET Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Armature FET Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Field FET Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Notes

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ELECTRICAL

Voltage Checks Connections to Main Traction Plug P1 with Controller Hydraulics Pin 1 2 3 4 5 6 7

Wire 2 10 15 6 8 7 29

COLOR Blue Yellow Yellow / Black Green Green / White Red White

8

28

Clear

9

56

Black

10

17

Black / White

11

9

Black / Blue

12

38

White / Blue

13

19

Brown

17

20

Black /Red

18

21

Black / Green

14 15 16

19 20 21

10 K

Yellow

22 23

PUMP INPUT/OUTPUT Battery volts from battery Battery volts from key Accelerator Start Switch Forward Switch Reverse Switch Seat Switch Accelerator Input Voltage Signal Accelerator Negative Accelerator Pot + 5 Volt Supply BDI Interrupt for Lift Lockout Blank Foot Brake SW Seat Belt SW Blank Blank Blank LINE CONTACTOR DRIVER AND SUPPRESSION STEER PUMP CTR DRIVER AND SUPPRESSION Blank Blank HOURMETER INPUT FOR PUMP CONTACTOR Blank Blank

NORMAL B+ 0 0 0 0 0 .3 – .8 V

ACTIVE B+ B+ B+ B+ B+ B+ 3.4 – 4.2 v

0

B-

Checked to Battery +

4–5V

4.2 V

Battery Plugged in

.5 V

12 V 0V

Seat switch closed Low Battery (Lift Lockout)

B+

0-1 V

Line Contactor Closed

B+

0-1 V

Steer Contactor Closed

0V

B+

Key on

Pins 1 & 2 Normal Voltage is Battery plugged in Key and Seat Switch open.

Pins 3 – 8 Normal Voltage is Battery plugged in Key Closed and Seat Switch open.

Pins 9 – 23 Normal Voltage is Battery plugged in Key and Seat Switch Closed.

1

2 9

16

3 10

17

4 11

18

5 12

19

6 13

20

6 14

21

8

Input Pins 1–8

23

Outputs & Signal Voltage Pins 9–23

15 22

WIRE HARNESS VIEW- MAIN PLUG

5-5

TEST PROCEDURE Plug in Battery Key on Push Accelerator Move F/R to Forward Move F/R to Reverse Close Seat Switch Push Accelerator to floor

ELECTRICAL

Connections to Main Traction Plug P5 with Controller Hydraulics Pin

Wire

COLOR

PUMP INPUT/OUTPUT

NORMAL

ACTIVE

TEST PROCEDURE

1

2A

Blue

Battery volts from battery

B+

B+

Plug in battery

2

10A

Yellow

Battery volts from key

0 volts

B+

Key switch on

3

-

-

Blank

4

-

-

Blank

5

85

Blue/White

BWI Traction Motor

0 volts

Brushes worn

6

86

Yellow/White

BWI Traction Motor

0 volts

Brushes worn

7

-

-

Blank

8

87

Violet/White

BWI Pump

0 volts

Brushes worn

9

88

Green/White

BWI Pump

0 volts

Brushes worn

10

17

Black/White

Hyd. Enable signal

12 volts

0 volts

Low Battery (lift cutout) Seat switch closed

11

82

Red/White

Pump Temperature

5 volts

0 volts

Over Temp light on

12

52

Yellow/Blue

Pump Aux 1 & 2 Switch

5 volts

0 volts

Handle pulled (switch closed)

13

24

Green/Yellow

To Plug 2 – 8

5 volts

14

23

Green/Black

To Plug 2 – 9

5 Volts

15

-

-

Blank

16

80

Brown/White

Traction Temperature

5 Volts

0 Volts

Over temp light on

17

18

Black/Red

To Plug 10 – 6

18

-

-

Blank

19

53

Yellow/Black

Hyd lift Switch # 2

5 Volts

0 Volts

Pull lift lever full (High speed lift)

20

51

Yellow/Green

Tilt Switch

5 Volts

0 Volts

Push tilt lever

21

54

Yellow/Red

Hyd lift Switch #1

5 Volts

0 Volts

Pull lift lever back (Low speed lift)

22

-

-

Blank

23

-

-

Blank

1

2 9

16

3 10

17

4 11

18

5 12

19

6 13

20

6 14

21

8 15

22

23

WIRE HARNESS VIEW- MAIN PLUG

5-6

ELECTRICAL

Connections to Main Plug (23 Pin) and P2 or P4 Plug (12 Pin) PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

TRACTION INPUT/OUTPUT (P1) Battery volts from battery Battery volts from key Battery volts from start switch Battery volts from forward switch Battery volts from reverse switch Battery volts from seat switch Accelerator input voltage signal Accelerator negative Accelerator pot +5 volts supply BDI interrupt for lift lockout 1A Driver signal Brake switch current limit set by function 11 Seat belt switch Not used Not used Not used Line contactor driver and suppression Steer pump control driver and suppression 1 Not used Not used Hourmeter input for pump contactor Not used Not used

1

2

3

4

5

PUMP INPUT/OUTPUT (P5) Battery volts from battery Battery volts from key Status code 93 input Status code 93 input Status code 94 input Status code 94 input Potentiometer input voltage signal Status code 95 input Status code 95 input Pump Enable signal 12v DC Status code 91 input Speed limit #1 input TMM brush wear indicator output TMM over temperature output Status code 92 input Status code 90 input Line contactor driver A contactor driver Speed limit #2 input Speed limit #3 input Speed limit #4 input Not used Not used

1

6

2 9

7

8

9

10

11

4 11

5 12

6 13

6 14

8 15

12 16

WIRE HARNESS VIEW P2 or P4

Pin 1 2 3 4 5 6 7 8 9 10 11 12

3 10

17

18

19

20

21

22

23

WIRE HARNESS VIEW- MAIN PLUG

Traction P2 “Y” Plug Input/Output Not used Not used Not used Negative +5 volt supply Not used Not used Value Function Not used Serial Receive Serial Transmit

Pump “P4” Plug Input/Output Not used Not used Not used Negative +5 volt supply Not used Not used Not used Not used Not used Serial Receive Serial Transmit

5-7

ELECTRICAL

Pump Driver FUNCTION: Controls the power supply to the contactor coil according to the control signal input.

TERMINAL #

TRUCK HARNESS WIRE #

1

2

3

4

NA

13

18

WIRE #

52

13

50-1

DESCRIPTION

CONDITION

VOLTAGE ON TERMINAL

Not Activated

0V

Activated

5V

Always

0V

Contactor Not Activated

BV

Contactor Activated

0 - 0.5V

Control Signal Input

Battery Negative

Contactor Coil Input

N/A

Not Used

BV = Battery Volt

5-8

ELECTRICAL

Shorted or Open Field or Armature FET Test

is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller.

5. Attach the BLACK lead to POS and attach the RED lead to F1.

Description

6. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If a field FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller.

If a problem is suspected with the SX controller, the following test procedure will assist you in diagnosing field and armature transistor (FET) failures in the SX controllers. This test may be used for both the traction and pump controllers.

7. Attach the RED lead to F2.

NOTE

8. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If a field FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller.

You must use a digital meter set to the DIODE TEST FUNCTION to perform these tests.

Armature FET Test 1. Remove all cables and wire harnesses from the SX controller.

2. Verify the digital meter is set to the diode test function.

3. Attach the RED lead to the NEG terminal and attach the BLACK lead to the A2 terminal.

4. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If an armature FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller.

5. Attach the RED lead to the A2 terminal and attach the BLACK lead to the POS terminal.

6. A properly function SX controller will have a reading between 0.3 and 0.6 volts. If an armature FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller.

Field FET Test 1. Attach the RED lead to NEG and attach the BLACK lead to F1.

2. A properly function SX controller will have a reading between 0.3 and 0.6 volts. If a field FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller.

3. Attach the BLACK lead to F2.

4. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If a field FET 5-9

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DIAGNOSTIC STATUS CODES 6 — DIAGNOSTIC STATUS CODES Basic Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Display Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Status Codes - Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 TRACTION STATUS CODE -NONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 TRACTION STATUS CODE -01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 TRACTION STATUS CODE -02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 TRACTION STATUS CODE -03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 TRACTION STATUS CODE -05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 TRACTION STATUS CODE -06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 TRACTION STATUS CODE -07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 TRACTION STATUS CODE -08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 TRACTION STATUS CODE -09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 TRACTION STATUS CODE -11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 TRACTION STATUS CODE -15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 TRACTION STATUS CODE -16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 TRACTION STATUS CODE -21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 TRACTION STATUS CODE -23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 TRACTION STATUS CODE -24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 TRACTION STATUS CODE -27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 TRACTION STATUS CODE -28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 TRACTION STATUS CODE -41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 TRACTION STATUS CODE -42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 TRACTION STATUS CODE -43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 TRACTION STATUS CODE -44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 TRACTION STATUS CODE -45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 TRACTION STATUS CODE -46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15 TRACTION STATUS CODE -47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15 TRACTION STATUS CODE -49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 TRACTION STATUS CODE -51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 TRACTION STATUS CODE -57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 TRACTION STATUS CODE -64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 TRACTION STATUS CODE -65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18 TRACTION STATUS CODE -66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18 TRACTION STATUS CODE -67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19 TRACTION STATUS CODE -69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19 TRACTION STATUS CODE -76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 TRACTION STATUS CODE -77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 TRACTION STATUS CODE -82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 TRACTION STATUS CODE -83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 TRACTION STATUS CODE -85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 TRACTION STATUS CODE -86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 TRACTION STATUS CODE -89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23 TRACTION STATUS CODE -90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23 TRACTION STATUS CODE -91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24 TRACTION STATUS CODE -94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24 TRACTION STATUS CODE -95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25 TRACTION STATUS CODE -99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

DIAGNOSTIC STATUS CODES TRACTION STATUS CODE -117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26 HYDRAULIC STATUS CODE -127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26 HYDRAULIC STATUS CODE -128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27 HYDRAULIC STATUS CODE -141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27 HYDRAULIC STATUS CODE -142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 HYDRAULIC STATUS CODE -143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 HYDRAULIC STATUS CODE -144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29 HYDRAULIC STATUS CODE -145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29 HYDRAULIC STATUS CODE -146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 HYDRAULIC STATUS CODE -150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 HYDRAULIC STATUS CODE -151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 HYDRAULIC STATUS CODE -157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 HYDRAULIC STATUS CODE -180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 HYDRAULIC STATUS CODE -181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 HYDRAULIC STATUS CODE -185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 HYDRAULIC STATUS CODE -189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

DIAGNOSTIC STATUS CODES

Basic Checks

Always check each function and write down the reading.

The biggest mistake technicians can make is to assume they know the problem before starting to work on a truck. Unfortunately while making our life easier self-diagnostics also make us more susceptible to this type of mistake. Never start to fix a truck based solely on the number on the dash or handset display. Always follow the basic troubleshooting steps.

If the programming fails to match the specifications reprogram the controller and check the truck operation before going any further. If repairs are required turn the key switch off, then push the CONT and ESC keys at the same time to enter the History Folder.

DIAGNOSTIC STATUS CODES

•

Talk to the operator.

•

Confirm their description of the problem with an operational check.

•

Visually inspect cables, connectors, contactor tips, etc.

•

Perform basic battery cables to frame resistance tests. You should have at least 20,000 ohms.

•

Check for any voltage on the frame.

•

Check the battery condition.

These codes should only be zeroed out after the truck is repaired and running properly.

Utilize the Status Codes in the following pages to find the component or area to check for a fault. Status Codes can be the result of a defective controller, but all voltage checks and testing should be performed before replacing.

Display Codes NOTE Shorts to frame may cause false codes.

Now we are ready to allow the self-diagnostics to give us a starting point to repair the truck. Turn the key switch on and check when the display goes through its boot up sequence to be sure all of the LEDs or LCD segments are functional. At this time note the status (fault) code (if any) and then turn the key switch off so you can note the hours on the meter.

•

•

CCCC –

C– –C –

Disconnect the battery and discharge the capacitor with the 150–25 watt resistor between the Pos & Neg terminals on controller.

Remove the P2 plug which connects the dash display to the card and insert the handset plug connector.

•

Plug in the battery.

•

While holding the CONT button down on the handset turn on the key switch to enter the programming mode.

•

When you get the 8888 on the handset push down on the key pad #1 button to double check the Status Code stored in the memory which should be the same as the dash display (if it showed one).

•

Before proceeding check the card’s programming.

PC

–

DC

–

“=”

–

No activity detected on communication line from display to controller.

Check for shorts to frame by volts.

Activity detected on communication line to control, but does not make sense.

Pump controller information data cannot be read. Open in P4.

Drive controller information data cannot be read. Open in P2.

Fault Code Data from controller is outside of range

Please see Display Section for proper setup of speed sensor.

6-1

DIAGNOSTIC STATUS CODES

Status Codes - Table of Contents STATUS CODE Blank

DESCRIPTION

PAGE

Segments do not illuminate on the Dash Display and/or the Handset

6-4

-01

No seat switch input (no voltage to P1-6)

6-4

-02

Forward directional switch is closed on initial power up

6-5

-03

Reverse directional switch is closed on initial power up

6-5

-05

Start switch or brake switch fails to close

6-6

-06

Accelerator depressed with no direction selected

6-6

-07

Accelerator input voltage too high

6-7

-08

Accelerator input speed too high on power up after initial key switch closure

6-7

-09

Both the forward and reverse directional switches are closed at the same time

6-8

-11

Start switch closed on power up after initial key switch closure

6-8

-15

Battery voltage is too low or control card is mis-adjusted

6-9

-16

Battery voltage is too high or control card is mis-adjusted

6-9

-21

Accelerator voltage is too high

6-10

-23

Motor field current is too high on start up in the reverse direction

6-10

-24

Motor field current is too high on start up in the forward direction

6-11

-27

Control’s internal power supply is less than 10 volts DC

6-11

-28

Motor field current is too high during the run mode

6-12

-41

Shorted thermal protector (TP) or armature transistor over temperature

6-12

-42

Motor armature offset voltage is too high

6-13

-43

Motor armature offset voltage is too low

6-13

-44

Armature transistor did not turn off properly

6-14

-45

Armature transistor did not turn on properly

6-14

-46

Look Ahead test for A2 volts less than 12% of battery volts

6-15

-47

Motor armature is open

6-15

-49

Motor field current is too low during the run mode

6-16

-51

Capacitor volts are low before the line contactor closes

6-16

-57

Controller “motor current sensor” input too low during running

6-17

-64

The line driver input (P2-17) is less than 12% of battery volts

6-17

-65

The line coil is too high during the run mode

6-18

-66

The field current exceeds the current limit on the field transistor

6-18

-67

The armature current exceeds the armature transistor limit

6-19

-69

The power steering coil current is too high during the run mode

6-19

-76

Capacitor (1C) voltage too high

6-20

-77

Motor current is detected during regenerative braking

6-20

6-2

DIAGNOSTIC STATUS CODES STATUS CODE

DESCRIPTION

PAGE

-82

If the armature motor current is greater than a preset value for longer than 3.5 seconds, the armature motoring current will be turned off

6-21

-83

A switch position is incorrect during the accelerator potentiometer auto calibration routine

6-21

-85

Motor armature current is too high

6-22

-86

Accelerator pot values obtained during the auto calibration routine were not valid

6-22

-89

Hydraulic lever is activated before the pump is enabled when key switch is initially enabled

6-23

-90

Traction motor temperature has exceeded maximum temperature limit

6-23

-91

Pump motor temperature has exceeded maximum temperature limit

6-24

-94

Traction motor brush wear indicator had detected a worn brush

6-24

-95

Pump motor brush wear indicator has detected worn brush

6-25

-99

Maintenance alert and speed limit

6-25

-117

“Card Type” selection is invalid

6-26

-127

Control logic card power supply is less than 10 VDC

6-26

-128

Armature current is too high during the lift mode

6-27

-141

Shorted thermal protector (TP1) or transistor is over temperature

6-27

-142

Pump Controller “motor current sensor” input is missing

6-28

-143

Pump Controller “motor current sensor” input is too low

6-28

-144

Power Transistor (Q1) did not turn off properly

6-29

-145

Power Transistor (Q1) did not turn o properly

6-29

-146

“Look Ahead” test for pump motor circuit volts less than 12% of the battery volts

6-30

-150

Capacitor volts are low after the line contactor closes

6-30

-151

Capacitor volts are low before the line contactor closes (Internal card function during precharge)

6-31

-157

Controller “motor current sensor” input voltage polarity check

6-31

-180

Voltage at capacitor (1C) is less than 14 volts

6-32

-181

Battery voltage is less than 14 volts

6-32

-185

High current at start of motor operation or during low motor voltage

6-33

-189

Input switch closed before pump enable signal is received

6-33

6-3

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Segments do not illuminate on the Dash No input voltage to the Logic Card or the display unit.

-NONE Display and/or the Handset.

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Display screen on Dash Display and/or Handset is blank.

POSSIBLE CAUSE Positive or negative control voltage is not present.

Circuits valid • Insure that the key switch is closed and voltage is present between P1-1 & battery negafor tive. Also check for voltage between P1-2 and Traction control negative.

Controller Open circuit between control card AND the Dash Display or Handset.

•

Check for an open circuit or loose connection going from the control and the Dash Display or Handset.

Defective Dash Display or Handset.

•

Replace Dash Display or Handset.

DESCRIPTION OF STATUS

TRACTION STATUS CODE

No seat switch input (no voltage to P1-6).

-01

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM Control will not operate.

POSSIBLE CAUSE Mis-adjusted or defective seat or operator presence switch.

Circuits valid • Check to see that the seat switch closes properly. for Open circuit between battery positive and P1-6.

Traction • Check for loose connections or broken wires: Controller

- Between the seat switch and P1-6.

- Between the key switch and the battery positive side of the seat switch.

- Between the seat switch and P1-2.

•

CAUSE OF STATUS INDICATION This status code will be displayed when P1-6 is less than 50% battery volts.

On vehicles without a seat/operator presence switch, check for a loose connection or broken wire from P1-2 and/or P1-6.

6-4

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Forward directional switch is closed on This status code will be displayed when P1-4 is greater initial power up. than 60% of battery voltage at initial key switch on.

-02

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate because of Static Return to Off (SRO) lock out.

POSSIBLE CAUSE Forward directional switch is closed on initial start up (i.e., closure of battery, key switch or seat/ operator presence switch).

Circuits valid for • Return directional switch lever to neutral and Traction then return lever to forward position.

Controller Forward directional switch is welded closed or mis-adjusted to be held closed.

•

Replace or adjust directional switch to insure that it opens when the directional switch is returned to neutral.

Defective control.

•

Replace the controller unit.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Reverse directional switch is closed on This status code will be displayed when P1-5 is greater initial power up. than 60% of battery voltage at initial key switch on.

-03

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM Control will not operate because of Static Return to Off (SRO) lock out.

POSSIBLE CAUSE Reverse directional switch is closed on initial start up (i.e., closure of battery, key switch or seat/ operator presence switch).

Circuits valid for • Return directional switch lever to neutral and Traction then return lever to reverse position.

Controller Reverse directional switch is welded closed or mis-adjusted to be held closed.

•

Replace or adjust directional switch to insure that it opens when the directional switch is returned to neutral.

Defective control.

•

Replace the controller unit.

6-5

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE Start switch or brake switch fails to close.

-05

CORRECTIVE ACTIONS MEMORY RECALL

NO

CAUSE OF STATUS INDICATION This status code will be displayed when P1-7 is calling for greater than 40% speed and P1-3 is less than 60% of battery volts.

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate.

POSSIBLE CAUSE Defective start switch circuit.

•

Circuits valid • for Traction Controller

Check start switch to insure closure with accelerator pedal released.

Check for open circuit or loose connection in wiring from key switch to start switch and from P1-3 to start switch.

Defective accelerator switch.

•

Check accelerator switch potentiometer for proper operation and ohmic value.

TRACTION DESCRIPTION OF STATUS STATUS CODE Accelerator depressed with no direction selected.

-06

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM Control will not operate.

POSSIBLE CAUSE Accelerator pedal is depressed before closing forward or reverse directional switch.

Circuits valid • Status code will disappear when directional switch is closed or when accelerator pedal is for released.

Traction Defective directional switch.

Controller • Check forward or reverse switch to insure closure when direction is selected.

Open circuit between directional switch(es) and battery positive or between directional switch(es) and P1-4 or P1-5.

•

CAUSE OF STATUS INDICATION This status code will be displayed when P1-4 & P1-5 are less than 60% of battery volts, and P1-7 is calling for greater than 40% speed.

Check all control wires and connections shown in Troubleshooting Diagram.

6-6

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE Accelerator input voltage too high.

-07 CORRECTIVE ACTIONS MEMORY RECALL

NO

CAUSE OF STATUS INDICATION This status code will be displayed when the accelerator input voltage at P1-7 is 0.7 volts less than the zero speed auto calibration value for the accelerator.

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate when accelerator pedal is depressed or status code -07 is displayed then disappears when the vehicle starts to accelerate.

Circuits valid for Open circuit between battery negative and P1-7 in Traction accelerator input circuit.

Controller • Check for broken wires or loose connections or POSSIBLE CAUSE Accelerator input mis-adjusted or defective.

P9-1 P1-7 P1-8 56

29

P9-4

28 P9-1

open potentiometer / voltage supply.

ACC. POT

Short circuit from battery positive to wiring in accelerator input circuit.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator input speed too high on This status code will be displayed when the accelerapower up after initial key switch closure. tor input voltage at P1-7 is calling for greater than 20% -08 speed, and any of the following connections are opened and closed: battery or key switch.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM

Control will not operate.

POSSIBLE CAUSE Accelerator input mis-adjusted or defective.

•

Circuits valid for Traction • Controller

Input voltage at P1-7 should be more than 20% speed. Adjust or replace accelerator unit to insure that the voltage at P1-7 is calling for less than 20% before depressing pedal.

Repeat the auto calibration routine outlined in Accelerator Controller Set-up Procedures of this manual.

•

P1-7 or the accelerator pot negative have an open circuit.

•

Defective Control.

NOTE Make sure the park brake is released when performing the accelerator setup procedure or the accelerator will never set properly and the forklift truck will generate this code.

6-7

P9-1 P1-7 P1-8 56 P9-4

29

28 P9-1

ACC. POT

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Both the forward and reverse directional This status code will be displayed when P1-4 and P1-5 switches are closed at the same time. are greater than 60% of battery volts at the same time.

-09

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate.

POSSIBLE CAUSE Forward or reverse directional switch welded closed or mis-adjusted to be held closed.

Circuits valid • Replace or adjust directional switches to insure that they open when directional switch for is returned to neutral.

Traction Short circuit between battery positive and P1-4 Controller and/or P1-5.

•

Disconnect wires from P1-4 and P1-5 and check wire for short circuit to positive side of directional switch.

Defective card.

•

Disconnect wires and measure voltage at P1-4 and P1-5. Voltage should be less than 60% of battery volts.

TRACTION DESCRIPTION OF STATUS STATUS CODE Start switch closed on power up after initial key switch closure.

-11

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM Control will not operate.

POSSIBLE CAUSE Start switch input mis-adjusted or defective.

Circuits valid for Traction Controller

•

Input voltage at P1-3 should be less than 60% of battery volts at key switch closing. Adjust or replace accelerator unit to insure that the voltage at P1-3 is less than 60% of battery volts before closing the start switch.

Short circuit between battery positive and P1-3 in start switch input circuit.

•

Disconnect wire from P1-3. Check for short circuit from wire to battery positive.

Defective card.

•

CAUSE OF STATUS INDICATION This status code will be displayed when P3 is greater than 60% of battery voltage when the key switch is closed.

Disconnect wire from P1-3. Measure voltage from P1-3 to negative. Voltage should be zero, if not, replace card.

6-8

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is too low or control card This status code will be displayed when the battery is mis-adjusted. volts are less than 1.95 volts per cell at initial key -15 switch on. See table below.

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate.

12

POSSIBLE CAUSE Discharged battery.

•

12-1

NOMINAL BATTERY VOLTAGE

MINIMUM LIMIT VOLTS AT 1.95 VDC PER CELL

24

23.4

36

35.1

2

48

46.8

P1-1

72 80

70.2 78.0

Check battery for proper open circuit voltage as shown in “Trouble Shooting Diagram, charge battery, if required.

Circuits valid for Defective battery.

Traction • Check each battery cell for proper voltage Controller

+

(greater than 1.95 volts at cell). Replace or repair battery.

Incorrect control card adjustment.

•

FU1 15A

-

Check function 15 for proper adjustment for battery being used. See Handset instruction sheet for details. Adjust to proper settings.

NEG

Traction Control N Terminal

Check “minimum” battery volts at P1-1 and NEG.

TRACTION DESCRIPTION OF STATUS STATUS CODE Battery voltage is too high or control card is mis-adjusted.

-16

CAUSE OF STATUS INDICATION This status code will be displayed when the battery volts are greater than 2.40 volts per cell at initial key switch on. See table below.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM Control will not operate.

5

POSSIBLE CAUSE Incorrect control card adjustment.

•

FU1 15A

Check function 15 for proper adjustment for

Circuits valid battery being used. See Handset instructions for details. Adjust to proper setting. for Battery over-charged or incorrect battery used.

Traction • Check battery for proper open circuit voltage Controller per table in trouble-shooting diagram. If voltage excessive, check battery charger for proper output voltage.

Check “maximum” battery volts at P1-1 and NEG.

+

P1-1

NEG

Traction Control N Terminal

6-9

NOMINAL BATTERY VOLTAGE

MINIMUM LIMIT VOLTS AT 2.4 VDC PER CELL

24

28.8

36

43.2

48

57.6

72 80

86.4 100.8

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE Accelerator voltage is too high.

-21

CAUSE OF STATUS INDICATION This status code will be displayed when the voltage at P1-7 is greater than 4.5 volts.

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Controller will not operate.

POSSIBLE CAUSE

•

Circuits valid • for • Traction Controller

Verify wire connection between accelerator pot to P1-8.

P9-1 P1-7 P1-8

Verify wire connection between P1-7 to accelerator pot.

56

Verify that the accelerator pot is adjusted properly.

P9-4

29

28 P9-1

ACC. POT

TRACTION DESCRIPTION OF STATUS STATUS CODE Motor field current is too high on start up in the reverse direction.

-23

CAUSE OF STATUS INDICATION This status code will be displayed when the current draw in the motor field is too high at start up in the reverse direction.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM Control will not operate.

POSSIBLE CAUSE Defective control.

Circuits valid for Traction Controller

•

Replace controller unit.

6-10

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE Motor field current is too high on start up in the forward direction.

-24

CAUSE OF STATUS INDICATION This status code will be displayed when the current draw in the motor field is too high at start up in the forward direction.

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Control does not operate.

POSSIBLE CAUSE Defective control.

Circuits valid for Traction Controller

•

Replace controller unit.

TRACTION DESCRIPTION OF STATUS STATUS CODE Control’s internal power supply is less than 10 Volts DC. -27

CAUSE OF STATUS INDICATION This status code will be displayed when the control’s power supply is less than 10 volts.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

SYMPTOM Line contactor opens and closes, then can only be closed by opening and closing the key switch.

FU2

KEY SWITCH 12

POSSIBLE CAUSE

Circuits valid Discharged Battery.

• Check battery to insure proper state of charge. for Voltage may be dropping below 10 Volts DC Traction under load.

Controller Loose connection at P1-1.

•

Insure that the wire connection at P1-1 is tight.

P1-1 should be at battery voltage.

Defective control.

•

Replace controller unit.

6-11

FU1 10 2

+

P1-1 P1-2 NEG

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is too high during the This status code will be displayed when the current in run mode. the motor field is sustained above a preset limit for lon-28 ger than 70 seconds.

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate.

THE PRESENCE OF THIS STATUS CODE IS NOT NECESSARILY INDICATIVE OF A CONTROL POSSIBLE CAUSE Continued operation of vehicle in high motor cur- ISSUE. IF FUNCTION 7 IS NOT MIS-ADJUSTED, rent condition.

THE STATUS CODE INDICATES AN APPLICATION • Operate vehicle at lower motor current condi- ISSUE WHERE A MOTOR IS BEING STALLED, tion for 70 seconds.

ETC. DISPLAY OF THIS STATUS CODE SHOULD Function 7 is mis-adjusted to allow higher than NOT TRIGGER THE RETURN OF A CONTROL normal motor filed current.

FOR REPAIR OR REPLACEMENT.

Circuits valid for Traction Controller •

Adjust function per OEM instructions.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Shorted thermal protector (TP) or arma- This status code will be displayed when the voltage at ture transistor over temperature. the thermal protector is too low.

-41

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

Circuits valid for Traction Controller

SYMPTOM Reduced or no power to traction motor in transistor range.

THE PRESENCE OF THIS STATUS CODE IS NOT NECESSARILY INDICATIVE OF A CONTROL ISSUE. IF FUNCTION 7 IS NOT MIS-ADJUSTED, POSSIBLE CAUSE Control is in thermal cut-back.

THE STATUS CODE INDICATES AN APPLICATION • Allow control to cool, status code should disap- ISSUE WHERE A MOTOR IS BEING STALLED, pear.

ETC. DISPLAY OF THIS STATUS CODE SHOULD Defective control.

NOT TRIGGER THE RETURN OF A CONTROL • Replace controller unit.

FOR REPAIR OR REPLACEMENT.

NOTE Thermal protector located in control is not serviceable.

6-12

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE Motor armature offset voltage is too high.

-42

CAUSE OF STATUS INDICATION This status code will be displayed when the voltage at the current sensor input is greater than 2.6 volts with no current flowing in the motor circuit.

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate.

POSSIBLE CAUSE Defective control.

Circuits valid for Traction Controller

•

Replace controller unit.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor armature offset voltage is too low. This status code will be displayed when the voltage at the current sensor input is less than 2.4 volts with no -43 current flowing in the motor circuit.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM Control will not operate.

POSSIBLE CAUSE Defective control.

Circuits valid for Traction Controller

•

Replace controller unit.

6-13

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature transistor did not turn off prop- This status code will be displayed when, during control erly. operation, the armature transistor fails to turn off. This -44 will result in a PMT condition.

SYMPTOM Line contactor opens and then can only be closed by opening and closing the key switch.

L

12-1

START SW.

FU1

24

Replace controller unit.

12 2

20

10 7

P1-17

P1-6 P1-2

P1-1

LINE

FORWARD SW.

10

POSSIBLE CAUSE Defective control.

Circuits valid • for Traction Controller

KEY SWITCH

FU2

SEAT SW.

YES

TROUBLESHOOTING DIAGRAM

15

6

REVERSE SW.

CORRECTIVE ACTIONS MEMORY RECALL

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

FU4

CAUSE OF STATUS INDICATION

TROUBLESHOOTING DIAGRAM

FU1

L

Replace controller unit.

START SW.

10

24 12 2

LINE

20

10 7

P1-17

P1-6 P1-2

P1-1

15

6

FU4

F1

POWER CONNECTIONS

NEG

6-14

A1 A2

F2

ARMATURE

POS

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

+

-

REVERSE SW.

12-2

SEAT SW.

Circuits valid for Traction Controller

KEY SWITCH

FU2

POSSIBLE CAUSE Defective control.

FORWARD SW.

SYMPTOM Truck will not operate.

•

F2

FIELD

YES

A2

ACC POT

This status code will be displayed when, during control operation, the armature transistor fails to turn on properly. This will result in a PMT condition.

CORRECTIVE ACTIONS MEMORY RECALL

F1

POWER CONNECTIONS

NEG

TRACTION DESCRIPTION OF STATUS STATUS CODE Armature transistor did not turn on properly.

-45

A1

FIELD

POS

-

ARMATURE

+

ACC POT

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE “Look Ahead” test for A2 volts less than This status code will be displayed when the voltage at 12% of battery volts.

A2 is less than 12% of battery volts.

-46

SYMPTOM Line contactor will open.

KEY SWITCH

FU2

Circuits valid Check for welded 1A contactor (if used). for Defective control.

Traction • Replace controller unit.

Controller

L

12-1

START SW.

FU1

24

12 2

LINE

20

10 7

P1-17

P1-6 P1-2

P1-1

FORWARD SW.

10

POSSIBLE CAUSE Check for short circuit from the motor armature to the frame of the vehicle.

SEAT SW.

YES

TROUBLESHOOTING DIAGRAM

15

6

REVERSE SW.

CORRECTIVE ACTIONS MEMORY RECALL

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

FU4

A1

STATUS

TROUBLESHOOTING DIAGRAM FU3

P1 LINE

Open motor armatures.

P17 P2 P6

P3 P4 P5 P8 P7 P9

FU1

NEG

6-15

A1

F1

A2

F2

ARMATURE

POS

POWER CONNECTIONS

FIELD

+

-

REVERSE SW.

L

Circuits valid for POSSIBLE CAUSE Traction Defective control or connection.

Controller • Replace controller unit.

START SW.

FU5

FORWARD SW.

KEY SWITCH SEAT SW.

SYMPTOM Control will not operate. The status code is cleared when the armature current goes above 26 amps, or the control goes through neutral, or the percent on-time goes below 17%. The code is only stored once in every twenty hours of occurrence.

•

F2

CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS YES

A2

ACC POT

This status code will be displayed when the on-time is >13% and the current in the motor armature is >-26 amps and <26 amps for four seconds.

-47

MEMORY RECALL

F1

POWER CONNECTIONS

NEG

TRACTION DESCRIPTION OF STATUS CODE Motor armature is open.

FIELD

POS

-

ARMATURE

+

ACC POT

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is too low during the This status code will be displayed when the current run mode. draw in the motor field is too low during the run mode.

-49

10 FU1

L

12-1

Replace controller unit.

24

Open motor field winding.

for Traction Controller

START SW.

• Circuits valid •

KEY SWITCH

FU2

POSSIBLE CAUSE Defective control or connection.

12 2

20

10 7

P1-17

P1-6 P1-2

P1-1

LINE

15

6

REVERSE SW.

SYMPTOM Control will not operate.

SEAT SW.

YES

TROUBLESHOOTING DIAGRAM

FORWARD SW.

CORRECTIVE ACTIONS MEMORY RECALL

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

FU4

CAUSE OF STATUS INDICATION

TROUBLESHOOTING DIAGRAM

Check for conductivity across open 1A contactor.

12 2

Insure that there is no device connected to load side of line contactor.

LINE

20

10 7

P1-17

P1-6 P1-2

P1-1

15

6

REVERSE SW.

24

Check PTC for open circuit on line contactor.

Defective control.

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

FU4

+

Replace controller unit.

-

POS

A1

F1

POWER CONNECTIONS

NEG

A2

F2

ARMATURE

•

L

12-1

Wiring error.

•

SEAT SW.

FU1

Welded 1A contactor (if used)

START SW.

10

POSSIBLE CAUSE

Traction Controller

KEY SWITCH

FU2

FORWARD SW.

SYMPTOM Line contactor does not close when capacitor does not pre-charge.

• Circuits valid • for •

F2

FIELD

NO

A2

ACC POT

This status code will be displayed during “key on” when the capacitor volts is less than 85% of battery volts at initial key switch on.

CORRECTIVE ACTIONS MEMORY RECALL

F1

POWER CONNECTIONS

NEG

TRACTION DESCRIPTION OF STATUS STATUS CODE Capacitor volts are low before the line contactor closes.

-51

A1

FIELD

POS

-

ARMATURE

+

ACC POT

1A CTR 740 Amp control only

6-16

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE Controller “motor current sensor” input too low during running.

-57

CAUSE OF STATUS INDICATION This status code will be displayed when the voltage input from the current sensor is too low during running.

SYMPTOM Control will not operate.

KEY SWITCH

FU2

10

Line contactor power tips did not close.

FU1

L

12-1

24

Volt drop across contactor tips.

Circuits valid Defective control. for • Replace controller unit.

Traction Controller

SEAT SW.

• •

START SW.

POSSIBLE CAUSE

12 2

20

10 7

P1-17

P1-6 P1-2

P1-1

LINE

15

6

REVERSE SW.

YES

TROUBLESHOOTING DIAGRAM

FORWARD SW.

CORRECTIVE ACTIONS MEMORY RECALL

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

FU4

A1

FIELD

POS

-

F1

POWER CONNECTIONS

NEG

A2

ARMATURE

+

F2

ACC POT

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The line driver input (P2-17) is less than This status code will be displayed when the control 12% of battery volts. detects that the line driver input (P2-17) is less than -64 12% battery volts when the key switch is turned on.

TROUBLESHOOTING DIAGRAM

SEAT SW.

L

12-1

24

Shorted line Driver transistor in control.

12

Possible open circuit in line contactor coil.

2

20

10 7

P1-17

P1-6 P1-2

15

6

8

Defective control.

•

Replace controller unit.

LINE

P1-1

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

FU4

+

-

POS

F1

POWER CONNECTIONS

NEG

6-17

A1 A2

F2

ARMATURE

Traction Controller

FU1

Open wire connection to Pin P1-17.

START SW.

10

POSSIBLE CAUSE

• Circuits valid • for •

KEY SWITCH

FU2

REVERSE SW.

SYMPTOM Control does not operate. Line contactor does not close.

FIELD

NO

FORWARD SW.

CORRECTIVE ACTIONS MEMORY RECALL

ACC POT

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE The line coil is too high during the run mode.

-65

CAUSE OF STATUS INDICATION This status code will be displayed when the current limit in the line coil driver is exceeded during the run mode. The line contactor will drop out and the key switch will have to be recycled to reset the control.

SYMPTOM Control does not operate.

KEY SWITCH

FU2

10

Shorted line contactor coil.

FU1

24

12 2

Defective control.

•

L

12-1

Short between wires connected to line coil.

If line coil resistance is correct: (59 for 36-48) (161 for 80V)

SEAT SW.

Circuits valid for Traction Controller

• •

START SW.

POSSIBLE CAUSE

10 7

P1-17

P1-6 P1-2

P1-1

LINE

Replace controller unit.

20

15

6

REVERSE SW.

YES

TROUBLESHOOTING DIAGRAM

FORWARD SW.

CORRECTIVE ACTIONS MEMORY RECALL

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

FU4

A1

F2

CAUSE OF STATUS INDICATION

TROUBLESHOOTING DIAGRAM KEY SWITCH

FU2

10

•

FU1

F1 or F2 terminals shorted to battery positive (B+).

24

12 2

F1 or F2 Terminals shorted to battery negative (B-).

LINE

Defective control.

•

L

12-1

Open FU4 fuse.

20

10 7

P1-17

P1-6 P1-2

P1-1

15

6

FU4

-

POS

Electrostatic Discharge

6-18

F1

POWER CONNECTIONS

NEG

EDS

A1 A2

F2

ARMATURE

+

(The controller looks for a high change in current over time to identify a short circuit in the field or cables.)

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

Replace controller unit.

FIELD

for Traction Controller

Shorted field F1 to F2.

SEAT SW.

• • Circuits valid •

START SW.

POSSIBLE CAUSE

REVERSE SW.

SYMPTOM Control will not operate. Line contactor opens.

FORWARD SW.

YES

A2

ACC POT

This status code will be displayed when the field transistor exceeds its specific current limit. The line contactor will drop out and the key switch will have to be recycled to restart the control.

CORRECTIVE ACTIONS MEMORY RECALL

F1

POWER CONNECTIONS

NEG

TRACTION DESCRIPTION OF STATUS STATUS CODE The field current exceeds the current limit on the field transistor.

-66

FIELD

POS

-

ARMATURE

+

ACC POT

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE The armature current exceeds the armature transistor limit.

-67

CAUSE OF STATUS INDICATION This status code will be displayed when the armature transistor exceeds its specific current limit. The control is reset by recycling the key switch.

SYMPTOM Control will not operate.

KEY SWITCH

FU2

10

Circuits valid for • Traction Controller

Shorted motor armature A1 to A2.

FU1

SEAT SW.

• •

L

12-1

24

Power cables may be shorted to each other (measure at control terminals).

START SW.

POSSIBLE CAUSE

12

A1 to A2 terminals may be shorted to battery positive or negative.

2

LINE

20

10 7

P1-17

P1-6 P1-2

P1-1

15

6

REVERSE SW.

YES

TROUBLESHOOTING DIAGRAM

FORWARD SW.

CORRECTIVE ACTIONS MEMORY RECALL

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

FU4

POS NEG

TRACTION DESCRIPTION OF STATUS STATUS CODE The power steering coil current is too high during the run mode.

-69

YES

F2

TROUBLESHOOTING DIAGRAM

POSSIBLE CAUSE Shorted power steering control coil.

Short between wires connecting to the power

Circuits valid steering coil. for • Open FU4 fuse.

Traction If the power steering coil resistance is correct Controller (59 for 36-48 volt) (161 for 80 volt) then:

•

A2

ACC POT

CAUSE OF STATUS INDICATION

SYMPTOM Control will not operate.

• •

F1

This status code will be displayed when the current in the power steering driver circuit exceeds current limit during the run mode. The control is reset by recycling the key switch.

CORRECTIVE ACTIONS MEMORY RECALL

A1

POWER CONNECTIONS

ARMATURE

-

FIELD

+

Defective control. Replace control unit.

6-19

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE Capacitor (1C) voltage too high.

-76

CAUSE OF STATUS INDICATION This status code will be displayed when the voltage on the capacitor goes above limit voltage* during the regenerative braking cycle.

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLESHOOTING DIAGRAM

SYMPTOM Line contactor opens and closes, then opens and can only close by opening and closing the key switch.

POSSIBLE CAUSE

Circuits valid • for • Traction Controller • •

Unplugging the battery connector during regenerative braking.

Line contactor bouncing open during regen.

Main power fuse opening during regen.

Intermittent battery plug connection.

* Limit Voltage: Limit Batt 50V 36V 70V 48V 96V 72/80V

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor current is detected during regen- This status code will be displayed when the current in erative braking. the power steering driver circuit exceeds current limit -77 during the run mode. The control is reset by recycling the key switch.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

SYMPTOM Truck will not operate.

POSSIBLE CAUSE Defective control.

Circuits valid for Traction Controller

•

Replace controller unit.

6-20

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE If the armature motor current is greater than a preset value for longer than 3.5 -82 sec the armature motoring current will be turned off.

CAUSE OF STATUS INDICATION This status code will be displayed when the armature motor current exceeds a preset value for 3.5 sec and the accelerator pedal is calling for maximum performance.

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLESHOOTING DIAGRAM

SYMPTOM The Control will not operate, and can only be reset by cycling the key switch.

*CODE WARNING*

THE PRESENCE OF THIS STATUS CODE IS NOT • Continued operation of vehicle in high motor NECESSARILY INDICATIVE OF A CONTROL ISSUE. IF FUNCTION 16 IS NOT MIS-ADJUSTED, current condition.

THE STATUS CODE INDICATES AN APPLICATION • Operating control at stall motor current for ISSUE WHERE A MOTOR IS BEING STALLED, more than 3.5 seconds.

• Function 16 is incorrectly adjusted for control% ETC. DISPLAY OF THIS STATUS CODE SHOULD NOT TRIGGER THE RETURN OF A CONTROL on time.

Adjust function.

FOR REPAIR OR REPLACEMENT. POSSIBLE CAUSE

Circuits valid for Traction Controller

• •

Function 16 is adjusted a level of 130 for all controls except the 9" 15K–18KL which is set to 120 and the EE’s are all set at 160.

*Continued occurrence of this code could lead to damage to motor assembly.

Possible mechanical resistance to motor rotation.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE A switch position is incorrect during the This status code will be displayed when the seat accelerator potentiometer auto calibra- switch is open, or the any of the forward, reverse or -83 tion routine. start switches are closed at the beginning of the accelerator potentiometer auto calibration routine.

TROUBLESHOOTING DIAGRAM

SEAT SW.

FU1

L

12-1

START SW.

10

POSSIBLE CAUSE Defective control.

24

Seat switch is open.

12

Confirm switch wiring, or replace switch, if required.

2

•

Any of the forward, reverse or start switches are closed.

•

Confirm switch wiring, or replace switch, if required.

LINE

20

10 7

P1-17

P1-6 P1-2

P1-1

15

6

FU4

+

-

POS

F1

POWER CONNECTIONS

NEG

6-21

A1 A2

F2

8

P1-3 P1-4 P1-5 P1-8 P1-7 P1-9

ARMATURE

Circuits valid • • for Traction Controller

KEY SWITCH

FU2

REVERSE SW.

SYMPTOM The auto calibration routine outlined in Section 8 of this manual will not start.

FIELD

NO

FORWARD SW.

CORRECTIVE ACTIONS MEMORY RECALL

ACC POT

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor armature current is too high, and This status code will be displayed when the motor the control trip time is less than 1 milli- armature current is >1600 amps in 1A mode, or >1325 -85 second. The key must be cycled off and amps in control run mode. on to reset the control.

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate. The key switch must be cycled off and on to clear the status code.

POSSIBLE CAUSE Defective control.

Circuits valid • Replace controller unit. for Shorted motor armature.

Traction • Verify that no shorts are present in the motor Controller armature.

NO GRAPHIC FOR THIS STATUS CODE

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator pot values obtained during Refer to Section 8 of this manual for possible causes the auto calibration routine were not of this status code.

-86 valid.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM The auto calibration routine outlined in Section 8 of this manual will not start.

POSSIBLE CAUSE Defective control.

Circuits valid • • for Traction Controller

P9-1 P1-7 P1-8

Seat switch is open.

56

Confirm switch wiring, or replace switch, if required.

P9-4

•

Any of the forward, reverse or start switches are closed.

•

Confirm switch wiring, or replace switch, if required.

29

28 P9-1

ACC. POT

6-22

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Hydraulic lever is activated before the This status code will be displayed when the voltage at pump is enabled when key switch is ini- P14 is greater than 3 volts at pump enable (10ms).

-89 tially activated.

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM The truck will not run or the pump will not operate.

POSSIBLE CAUSE Shorted or welded hydraulic switch.

Circuits valid • • for • Traction Controller

Verify connections to hydraulic switches.

Check for shorted switch.

Battery voltage has dripped to lift lockout conditions.

TRACTION DESCRIPTION OF STATUS STATUS CODE Traction motor temperature has exceeded maximum temperature limit.

-90 (with pump controller hyd.

CAUSE OF STATUS INDICATION This status code will be displayed when the voltage at the respective terminal of the TMM is at zero volts.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

Circuits valid for Traction Motor Temperature (Pump Controller)

SYMPTOM Status code flashes “on and off”. Action light flashes.

POSSIBLE CAUSE User defined status code is displayed by switch closure to battery negative.

•

Defective temp switch (shorted). Traction motor.

• • •

Defective pump card.

Wire 80 shorted to battery NEG. Battery Neg @ pump control P5-16.

6-23

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Pump motor temperature has exceeded This status code will be displayed when the voltage at maximum temperature limit. (with pump the respective terminal of the TMM is at zero volts.

-91 controller hyd.)

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLESHOOTING DIAGRAM

SYMPTOM Status Code flashes “on and off”.

POSSIBLE CAUSE User defined status code is displayed by switch closure to battery negative.

Circuits valid for Hydraulic Pump Temperature (Pump Controller)

• • • •

Defective temp switch (shorted). Pump motor.

Defective pump card.

Wire 82 shorted to battery NEG. Battery Neg at P5-11.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Traction motor brush wear indicator had This status code will be displayed when the voltage at detected worn brush. the respective terminal of the Pump Logic Card is at -94 zero volts.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

SYMPTOM Status Code flashes “on and off”.

POSSIBLE CAUSE User defined status code is displayed by motor brush sensor closure to battery positive.

Circuits valid for Traction Motor Brush Wear (Pump Controller)

• •

Worn brushes.

•

Defective input switch (shorted) check for proper adjustment of the BWI T-bar on brush holder.

• •

Wire 85 or 86 shorted to positive.

P5-5 or P5-6 is shorted to positive on pump control card.

Defective pump control card.

6-24

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE Pump motor brush wear indicator has detected worn brush.

-95

CAUSE OF STATUS INDICATION This status code will be displayed when the voltage at the respective terminal of the Pump Logic Card is at battery volts.

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLESHOOTING DIAGRAM

SYMPTOM Status Code flashes “on and off”.

POSSIBLE CAUSE User defined status code is displayed by motor brush sensor closure to battery positive.

Circuits valid for Pump Motor Brush Wear Indicator (Pump Controller)

• • •

Worn brushes.

• •

Wire 87 or 88 shorted to positive.

P5-8 or 5-9 is shorted to positive.

Defective input switch (shorted) check for proper adjustment of the BWI T-bar on brush holder.

Defective pump control card.

TRACTION DESCRIPTION OF STATUS STATUS CODE Maintenance alert and speed limit.

-99

CAUSE OF STATUS INDICATION This status code will be displayed when the “normal” hour meter exceeds the “maintenance alert hours” setting for the vehicle.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

Circuits valid for Traction Controller

SYMPTOM Status code is displayed for 4 seconds when the key switch is first turned on, and/or the vehicle may run at a reduced speed.

CUSTOMER SELECTED SETTING WITH THE HANDSET User defined status code is displayed when the normal hour meter reading exceeds the programmed “maintenance alert hours” setting selected by the user.

•

Maintenance Code Hour Meter, Functions 19 and 20, are programmed with the Handset and command the display of status code -99.

•

If desired, Maintenance Code Speed Limit, Function 13, can be programmed with the Handset.

User should perform the desired maintenance function. Re-set maintenance alert hour meter after maintenance is performed.

6-25

NO DIAGRAM USER SHOULD PERFORM THE DESIRED MAINTENANCE FUNCTION

DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS STATUS CODE Card Type” selection is invalid.

-117

CAUSE OF STATUS INDICATION This status code will be displayed when the card type selection value is set to an invalid number.

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate.

POSSIBLE CAUSE Invalid card type selection.

Circuits valid for Pump Controller

•

Review function 17 in the Handset Instruction sheets. Adjust and set card type value as instructed by Service Manual.

HYDRAULIC DESCRIPTION OF STATUS STATUS CODE Control logic card power supply is less than 10 VDC. -127

NO GRAPHIC FOR THIS STATUS CODE

CAUSE OF STATUS INDICATION This status code will be displayed when the logic card power supply is less than 10 volts.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

SYMPTOM Control will not operate.

POSSIBLE CAUSE Discharged battery.

•

Check battery to insure proper state of charge.

•

Check for Volt drop across wire 12 and wire 2.

Circuits valid • Check control fuse FU 11. for Loose connection at P1-1.

Pump • Insure that the wire connection at P1-1 is tight.

Controller • Insure that wire connection at P5-1 is tight.

Defective logic card.

•

Replace control.

6-26

DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature current is too high during the This status code will be displayed when the current in lift mode. the armature circuit is sustained above 400A for 70 -128 sec.

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLESHOOTING DIAGRAM

SYMPTOM Control will not operate.

POSSIBLE CAUSE Continued operation of vehicle in high motor current condition.

Circuits valid • for • Pump Controller

Operate vehicle at lower motor current condition for 70 seconds.

NO GRAPHIC FOR THIS STATUS CODE

Check hydraulic pressure adjustment.

HYDRAULIC DESCRIPTION OF STATUS STATUS CODE Pump control is over Temperature.

-141

CAUSE OF STATUS INDICATION This status code is displayed when the voltage at the thermal protector is less than 3.8 volts.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

SYMPTOM Reduced or no power to pump motor in control range.

POSSIBLE CAUSE Control is in thermal cut-back.

Circuits valid • for • Pump Controller • •

Allow control to cool, status code should disappear.

Check wire 23, P5-14 and P2-9.

Check hydraulic pressure adjustment.

Check thermal compound under controller.

NOTE Pump control thermal protection is located inside of pump control and is not serviceable.

6-27

DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Pump Controller “motor current sensor” This status code is displayed when the voltage at the input is missing. current sensor is greater than 1.6 volts with no current -142 flowing in the motor circuit.

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM No power to pump motor in control range.

POSSIBLE CAUSE Control is defective.

Circuits valid for Pump Controller

•

Replace controller unit.

NOTE Pump motor current sensor is located inside of pump control and testing is not possible.

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Pump Controller “motor current sensor” This status code is displayed when the voltage at the input is too low. current sensor is less than 0.6 volts with no current -143 flowing in the motor circuit.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

NO

SYMPTOM No power to pump motor in control range.

POSSIBLE CAUSE Control is defective.

Circuits valid for Pump Controller

•

Replace controller unit.

NOTE Pump motor current sensor is located inside of pump control and testing is not possible.

NOTE Pump control thermal protection is located inside of pump control and is not serviceable.

6-28

DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS STATUS CODE Power Transistor (Q1) did not turn off properly.

-144

CAUSE OF STATUS INDICATION This status code is displayed when, during pump control operation, the transistor fails to turn off.

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLESHOOTING DIAGRAM

SYMPTOM Control may run continuously.

POSSIBLE CAUSE Control is defective.

•

Circuits valid • for • Pump Controller

Check switch adjustment.

Check for shorts to Neg on wires 51,52,53,54.

Replace controller.

HYDRAULIC DESCRIPTION OF STATUS STATUS CODE Power Transistor (Q1) did not turn on properly.

-145

CAUSE OF STATUS INDICATION This status code is displayed when, during pump control operation, the transistor fails to turn on.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

SYMPTOM Control may run continuously.

POSSIBLE CAUSE Control is defective.

•

Circuits valid • for • Pump Controller

Replace controller unit.

Check for proper negative voltage at N terminal on control.

Check for shorts to Neg on wires 51, 52, 53, 54.

•

Check for proper positive voltage to control at P5-1, 19–20, 21 and 12.

• •

Check for proper positive voltage at P5-1.

Check for proper Neg voltage at N terminal on control.

6-29

DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE “Look Ahead” test for Pump motor cir- This status code will be displayed when the voltage in cuit volts less than 12% of battery volts. the pump motor is less than 12% of battery volts.

-146

CORRECTIVE ACTIONS SYMPTOM Pump contactor will operate.

FU6

P

POSSIBLE CAUSE

•

Check for short circuit from the motor armature to the frame of the vehicle.

Circuits valid • Check for open circuit from A1 to A2 on control for through motor.

Pump Control is defective.

Controller • Insure that the wire connection at P1-1 is tight.

•

A1

A1

Replace controller.

A1 P PUMP CONTROL POWER CONNECTION A2 N

A2

ARMATURE

YES

TROUBLESHOOTING DIAGRAM

FIELD

MEMORY RECALL

*

*

A2 N

HYDRAULIC DESCRIPTION OF STATUS STATUS CODE Capacitor volts are low after the line contactor closes.

-150

CAUSE OF STATUS INDICATION This status code will be displayed when the capacitor voltage is less than 85% of the battery voltage in the run mode.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS SYMPTOM Pump control will not operate.

325 amps

POSSIBLE CAUSE Defective line contactor.

• Circuits valid • for •

Pump Controller

FU6

P

Check for open line contactor power tips.

Check for volt drop across line contactor.

Check for loose or open connections in cables from battery positive to control positive circuit.

A1 A1 P PUMP CONTROL POWER CONNECTION A2 N

Defective power fuse.

•

A1

Check power fuse for open circuit.

No battery voltage at P5-1.

• •

A2

A2

Check for battery voltage at POS and P5-1.

Check for loose connection at P5-1.

6-30

N

ARMATURE

YES

FIELD

MEMORY RECALL

*

*

DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Capacitor volts are low before the line This status code will be displayed when the voltage at contactor closes. (Internal card function A2 is less than 12% of battery volts.

-151 during pre-charge.)

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Pump control will not operate.

POSSIBLE CAUSE

NOTE

Circuits valid Repeated “charging/discharging” the capacitors during troubleshooting will cause status code 51. for Also “do not” connect any loads to the load side of Pump the line contactor.

Controller • Check battery voltage.

• • •

Check for open PTC resistor.

•

Replace controller unit.

Check for battery voltage at P5-1.

Check for proper cable connections to controller.

Defective control.

NOTE PTC resistor is located across the line contactor that is serviceable. There is also a PTC resistor that is in the controller and it is not serviceable.

HYDRAULIC DESCRIPTION OF STATUS STATUS CODE “Controller motor current sensor” input voltage polarity check.

-157

CAUSE OF STATUS INDICATION This status code will be displayed when the voltage input to motor current sensor is of the wrong polarity.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

SYMPTOM Pump control will not operate.

POSSIBLE CAUSE Control is defective.

Circuits valid for Pump Controller

•

Replace controller unit.

6-31

DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Voltage at capacitor (1C) is less than 14 This status code will be displayed when the voltage at volts.

P1 is less than 14 volts. This occurs typically in the run -180 mode of operation.

CORRECTIVE ACTIONS MEMORY RECALL

NO

TROUBLESHOOTING DIAGRAM

SYMPTOM Pump Control will not operate.

POSSIBLE CAUSE (Line contactor controlled by traction control).

Line contactor opened up during run.

Circuits valid • for • Pump Controller • •

Check connection from P5-17 to Line coil (-) for loose connection.

Check connection from battery (+) to Line coil (+) for loose connection.

Check for failed power fuse at pump control.

Check for dirty contactor tips.

HYDRAULIC DESCRIPTION OF STATUS STATUS CODE Battery voltage is less than 14 volts.

-181

CAUSE OF STATUS INDICATION This status code will be displayed when the battery voltage measured at P1 is less than 14 volts.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

SYMPTOM Pump control will not operate.

POSSIBLE CAUSE

•

Circuits valid • for • Pump Controller

Check connection from control fuse to pump P1 for loose connections.

Check for low battery volts under load.

Check for volt drop between pos. and P5-1.

6-32

DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE High current at start of motor operation Current higher than function 18 setting for more than or during low motor voltage.

0.001 seconds.

-185

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLESHOOTING DIAGRAM

SYMPTOM Pump Control will not operate.

POSSIBLE CAUSE

•

Circuits valid • for • Pump Controller •

•

•

High overcurrent (above setting in Function 18).

Shorted motor armature.

NO GRAPHIC FOR THIS STATUS CODE

Defective control.

NOTE This code is controlled by Function 18 which is adjustable from 800 A (0) to 1200 A (255).

High current is determined by the formula: (Fun 18 value/4) x 6.5 + (800 A). The current must be high for approximately 0.0001 seconds. Example: Fun 18 = 250/4 = 6.25 x 6.5 = 406 A + (800 A) = 1206 A. If the control is operating with full voltage applied to the motor and the motor shorts, Code 185 may or may not occur to shut down the controller.

An improved controller with a software revision to MP3B was implemented to allow the armature over current fault setting to be adjusted via function #18. P/N 97G22-20010 Controller

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Input switch closed before pump enable This status code will be displayed when pin 12,19,20 signal is received. or 21 is pulled to negative before pin 10 is greater than -189 5.0 volts.

TROUBLESHOOTING DIAGRAM

CORRECTIVE ACTIONS MEMORY RECALL

YES

SYMPTOM Pump Control will not operate.

POSSIBLE CAUSE

•

Circuits valid • for • Pump • Controller

Hydraulic handle pulled before pump enable signal given.

Shorted hydraulic switch.

Check Hydraulic switch adjustment.

Defective control.

6-33