Model 5200 High-Level Orderpicker

•JPC7-5 (Deadman 2 S23)

•JPC7-8 (24" limit switch S6)

•JPC7-11 (60" height switch S7)

•JPC12-15 (optional sidegate switch 2, S20)

•JPC1-1 (operator display)

8.+5 volts is present at JPC2-3 and JPC12-12 (steer encoder) on the Carriage Manager.

9.+5 volts is present at PT6-3 steer feedback encoder) on the Steer/Tractor Manager.

With the wire guidance option, the Guidance Manager receives:

1.Battery positive at JPS2-11 as B+ESTOP. This is also used by the power supply on the Guidance Manager (GM) to generate +12 volts that is used by the Guidance Manager microprocessor, internal circuitry, and the filter card. The +12 volts is also supplied to:

•Tractor sensor at JPW2-15

•Load sensor at JPW1-15

•Speed encoder at JPS1-19

2.Battery negative at JPS2-24.

3.Battery negative at JPS4-3 as DGND.

When the key switch is first turned ON, the microprocessors perform a SelfTest of certain inputs and outputs.

The Carriage Manager checks:

1.The +12 volt supply from the Steer/Tractor Manager.

2.Checks to make sure the steer tiller encoder is plugged in.

3.Checks the state of Deadman 1 and informs the STM.

4.Checks the voltages from the travel pot and lift pot and sends the voltages to the STM.

The Steer/Tractor Manager checks:

1.The +12 volt supply.

Section 8.Theory of Operation

Closing Deadman Switches

2.The voltages from the travel pot and lift pot and compares them to the learned neutral and out-of-range values.

3.The state of the P contactor at JPT12-3.

4.The state of the mast switches.

5.The state of the EPO switch at JPT10-3.

6.The state of the Deadman switches.

7.The state of the PC contactor at JPT12-3.

8.Battery Voltage for correct range at B+KEY.

9.Calculates BSOC using B+PC.

10.Requests feedback from the Guidance Manager on the results of its SelfTest.

11.Inputs from the TPA to verify its operation.

The Guidance Manager checks:

1.To make sure the filter card is plugged in.

If a problem is detected, the Steer/Tractor Manager prevents lift truck operation and tells the CM to display a corresponding fault code on the operator display.

Closing Deadman Switches

Stepping on the deadman pedal closes deadman switches S2 (Deadman 1) and S23 (Deadman 2). Both switches must be closed to travel, lift/lower and/or steer. If either switch opens while traveling, the travel command to the traction power amplifier stops and the brake is applied.

1.With S2 closed, a circuit is completed between JPC7-3 and JPC7-1 on the Carriage Manager.

2.With S23 closed, a circuit is completed between JPC7-6 and JPC7-4 on the Carriage Manager.

3.With the S2 (Deadman 1) circuit complete, the microprocessor on the CM detects that the switch is closed. The Carriage Manager communicates to the Steer/Tractor Manager via the transmit line that switch S2 is closed.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 8.Theory of Operation

Closing Deadman Switches

4.The Deadman 2 input from S23 is wired directly through the mast cable from the Carriage Manager (JPC8-5) to the Steer/Tractor Manager (JPT9-5). The CM does not look at the input or use it for anything.

5.The Deadman 1 message and Deadman 2 input are received by the Steer/Tractor Manager and monitored continually to make sure they both agree. If only one of the switches closes while the pedal is depressed the operator display indicates a fault. LEDs on the Steer/Tractor Manager for Deadman 1 (IL6-10) and Deadman 2 (IL2) are lit when the switches are closed.

6.After the Steer/Tractor Manager determines both Deadman switches agree, it turns on the PC contactor coil driver that is indicated by an LED (IL6-8). With this coil driver ON, a current path is completed between JPT12-21 and JPT12-20 energizing the PC contactor coil.

7.The PC contactor tips close and battery voltage is supplied to the following:

•TP1, TP2

•B+ side of the open pump (P) contactor tips, P-1

•MHA-1 on the steer power head

•Traction motor armature terminal A1

•B+ terminal of trac tion power amplifier

•M- terminal of traction power amplifier

•Traction motor armature terminal A2

•MDA2 sense at JPT11-7

•JPT12-1 as B+PC

•FU1 as B+PC and B+PCF

•JPT12-2 as PCSENSE

•JPT12-13 to pump contactor coil (X) terminal as B+PCF

•JPT12-13 to warning light as B+PCF

8.The Steer/Tractor Manager also turns on the brake coil driver that is indicated by an LED (IL6-4). With this coil driver ON, a current path is completed between JPT12-21 and JPT12-17 and the brake releases. If the Deadman switches are opened during travel, the brake is applied.

Model 5200 High-Level Orderpicker

9.After the lift truck has completed SelfTest and the deadman pedal is depressed, the STM looks at the input from the Home Reference Proximity Sensor. If the prox. is over metal, the STM turns the drive unit to the left. As soon as the prox. switch transitions from metal to no metal, the STM removes the steer command. If it is not over metal, the drive unit turns to the right. When the home prox. transitions from OFF to ON, the STM turns the drive unit back to the left until the switch transitions to no metal and removes the steer command. This position is considered center and the position register for the steer feedback encoder is set to a zero reference point. During the auto steer center function, the STM monitors the steer feedback encoder and the steer motor current to verify the drive unit is actually powered and moving in the correct direction. If the STM does not see current or encoder pulses, an error code displays. If the STM does not see a home reference proximity sensor transition, it turns the drive unit to the physical stop. Current limit is invoked and an error code is displayed.

10.The STM places the lift truck in a speed limit condition waiting to see inputs from the steer tiller.

Publication Number: 1043922B, Revised: 2 Sept 2015