Electrical System – 5000

Troubleshooting

14.9 Troubleshooting

14.9.1 Error codes and troubleshooting

The table below describes the error codes that can be displayed with the status light or read on the hand unit. STATUS

ExplanationPossible cause

LED off-No voltage or error in the regulator.

Defective fuse, poor contact, not connected, error in the regulator.

LED on-Error in the regulator.Error in the regulator.

1,1¤ ¤CURRENT SHUNT FAULT Error in the built-in current shunt.

1,2¤ ¤¤HW FAILSAFECAN timeout in power amplifier.

1,3¤ ¤¤¤M- SHORTEDInternal M- short circuited to B-.

3,1¤¤¤ ¤CONT COIL/FLD SHORT Voltage too high for contactor feed or short-circuited field winding.

Error in the rotor current sensor in the motor monitor.

The motor monitor is reporting an unexpected data loss from the tiller arm head.

Problem with switch transistor in the rotor circuit inside the motor monitor.

Attempt to extract more current than the output device can manage.

Problem regulating the field current.

Internal monitoring error.

3,3¤¤¤ ¤¤¤FIELD OPENOpen field winding.Shunt field open, defective cable, defective motor monitor.

4,1¤¤¤¤ ¤LOW BATTERY VOLTAGE Low battery voltage.1. Battery voltage < 17 volt.

2. Battery poles affected by corrosion.

3. Loose battery or regulator connections. 4,2¤¤¤¤ ¤¤OVERVOLTAGEVoltage too high.1. Battery voltage > 33 volt.

4,3¤¤¤¤ ¤¤¤THERMAL CUTBACK Too high/too low temperature reduction.

14.9.2 Reset error

1. Temp. > 85oC or < -25oC

2. The truck is overloaded.

3. Incorrectly installed transistor regulator.

4. Operation under extreme conditions.

When you want to clear an error, first turn S17 to the “OFF” position and then “ON” again.

ErrorReset when

OVERVOLTAGEThe battery voltage is below 33 V. THERMAL CUTBACKThe temperature is within the permitted interval.

THROTTLE FAULT 1, 2The fault has been dealt with.

LOW BATTERY VOLTAGE When the battery voltage exceeds 16 V.

14.9.3

Safety

The regulator is a heavy current component. When it is used on a battery-powered vehicle, all necessary safety measures must be taken. This means, among other things, that the driver must have suitable training, use goggles, avoid loose clothing, take off watches and jewellery and only use insulated tools. It may also be necessary to take other measures.

WARNING !

Risk of short circuiting Remove watches, jewellery and always use insulated tools only.

Electrical System – 5000

Technical specifications – Curtis 1243

T-codeValid

14.10 Technical specifications – Curtis 1243

ValueUnitExplanation

Operating voltage24Volt

Top voltage limit33Volt

Bottom voltage limit16VoltMinimum operating voltage

Electrical insulation against cold chassis 500V ACMinimum

PWM frequency16kHz

Maximum current in rotor winding*150Amperefor 2 minutes

100Amperefor 1 hour

Maximum current in field winding20Amperefor 2 minutes

20for 1 hour

Contactor voltage24VoltThe same as for the battery

Contactor current2AmpereMax (valid limit for 2.5 ampere)

KSI input voltage, min.16,8Volt

KSI input current50mA

* Under special test conditions.

15- Hydraulic/Pneumatic – 6000

15.1 General

To avoid functional problems with the lowering valve (Y41), such as unintentional lowering of forks, the valve must be cleaned and the function checked before replacing the valve.

15.2 Hydraulic chart and list of symbols

7PM18, 7PM20

15.2.1 List of Symbols

Pos NoDescriptionFunctionRemarks

1Lift cylinderLifting the forks

2Preasure relief valve

3Flow control valve

4Non-return valve

5Filter

M3MotorPump motor

PPump

TTank1,2 litre (B20 0,5 litre)

Y41ValveLowering valve for the forks

Hydraulic/Pneumatic – 6000 Adjustments 7PM18

15.3 Adjustments 7PM18

15.3.1 Adjusting the pressure limit valve

The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The truck should be capable of lifting a load of between 1850-1900 kg.

1.Locking nut. Use special tool, see drawing in chapter “Tools”.

2.Adjuster screw, pressure limit. Adjusting clockwise results in increased pressure. Adjusting anticlockwise results in decreased pressure.

3.Pressure limit valve. Use special tool, see drawing in chapter “Tools”.

•Loosen the locking nut (1) using a special tool (see drawing 3.2). Place a load of 1800 kg on the forks and check that the truck can lift it.

•If the truck lifts 1800 kg, place a further 100 kg on the forks. Check whether the truck can lift the load.

•If the truck lifts 1900 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load.

15.3.2 Tools

•Use a 22 mm standard socket and turn it down to the values shown below in drawing A, when you wish to loosen or tighten the pressure limit valve.

•Use a 10 mm standard socket and turn it down to the values shown below in drawing B, when you wish to loosen or tighten the locking nuts.

Hydraulic/Pneumatic – 6000 Adjustments 7PM20

15.4 Adjustments 7PM20

15.4.1 Adjusting the pressure limit valve

The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The truck should be capable of lifting a load of between 2050-2100 kg.

1.Locking nut.

2.Adjuster screw, pressure limit. Adjusting clockwise results in increased pressure. Adjusting anticlockwise results in decreased pressure.

•Loosen the locking nut (1) using a 13 mm spanner.

•Place a load of 2000 kg on the forks and check that the truck can lift it.

•If the truck lifts 2000 kg, place a further 100 kg on the forks. Check whether the truck can lift the load.

•If the truck lifts 2100 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load.

15.5 Hydraulic chart and list of symbols

15.5.1 List of Symbols

1Lift cylindersLifting the forks2 pieces

2PowertrakcylinderIncrease the pulling quality when loaded 3Preasure relief valve 4Flow control valve valve for the forks

Hydraulic/Pneumatic – 6000

Adjusting the pressure limit valve

15.6 Adjusting the pressure limit valve

The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The truck should be capable of lifting a load of between 2050-2100 kg.

1.Locking nut.

2.Adjuster screw, pressure limit. Adjusting clockwise results in increased pressure. Adjusting anticlockwise results in decreased pressure.

•Loosen the locking nut (1) using a 13 mm spanner.

•Place a load of 2000 kg on the forks and check that the truck can lift it.

•If the truck lifts 2000 kg, place a further 100 kg on the forks. Check whether the truck can lift the load.

•If the truck lifts 2100 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load.