PDF Download: UTILEV 1.3T-2.0T 3-Wheel Electric Counterbalanced Forklift Truck Service Manual

1.3T–2.0T

3-Wheel Electric Counterbalanced Forklift Truck

Service Manual

APRIL 2017

Part No. 76002086 (R4)

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized UTILEV® distributor. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow the instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

Part No. 76002086 (R4)

May 2013 (Ref. Date)

Foreword This manual covers the components, operation, and servicing of the 1.3T-2.0T 3 Wheel Electric forklift truck. To ensure safe operation of this truck, it is important to read and understand the contents of this manual.

Only qualified service personnel should perform maintenance on this truck.

Product specifications in this manual may vary from your actual truck due to periodic improvements in design. Please contact your sales agent if you have any questions or comments regarding this manual.

This electric three-wheel forklift truck has passed the requirements for, and is approved for operation in countries adhering to CE regulations.

Model

Drive Controller

Pump Controller

Rated Capacity(t)/ Load Center(mm)

UT13PTE

CURTIS 1234X2

CURTIS 1234

1.3 / 500

UT15PTE

CURTIS 1234X2

CURTIS 1234

1.5 / 500

UT16PTE

CURTIS 1234X2

CURTIS 1234

1.6 / 500

UT18PTE

CURTIS 1234X2

CURTIS 1234

1.8 / 500

UT20PTE

CURTIS 1234X2

CURTIS 1234

2.0 / 500

Contents Foreword 1. Drive System .............................................................................................................. 5 Gearbox.................................................................................................................... 5 Structure ................................................................................................................... 6 2. Steering System......................................................................................................... 8 Steering Device ........................................................................................................ 8 Steering Axle ............................................................................................................ 9 3. Braking System ........................................................................................................ 11 Brake Master Cylinder ............................................................................................. 11 Hand Brake ............................................................................................................ 12 4. Hydraulic System .................................................................................................... 13 Main Oil Pump ........................................................................................................ 13 Multi-Way Valve ...................................................................................................... 14 Pressure Adjustment of Main Safety Valve ............................................................. 15 Hydraulic Schematic Diagram ................................................................................ 16 5. Lifting System .......................................................................................................... 17 Mast........................................................................................................................ 18 Lift Cylinder ............................................................................................................ 19 Tilt Cylinder............................................................................................................. 20 6. Electrical System ..................................................................................................... 21 Controller ................................................................................................................ 21 Fault Code Tables................................................................................................... 23 Diagnostics And Troubleshooting ............................................................................ 28 Troubleshooting Tables........................................................................................... 29 Schematic Diagram (Australian Standard).............................................................. 38 Schematic Diagram (Standard) .............................................................................. 43

1. Drive System The drive system adopts a dual-motor front wheel drive, wherein the left and right drive wheels are driven independently by different motors, the rotation speed of the left and right motors is controlled by the rear wheel steering angle, and each motor is connected to the gearbox, brakes, solid tires, rims and other components.

The reduction gearbox is a double reduction system with a compact structure, comprising a first-stage cylindrical helical gear set and a second-stage planetary final drive.

The brakes are maintenance-free, wet disc brakes.

Failure Loud impact sound when travelling and changing direction

Gear Noise when Travelling

Possible Cause

Remedy

Excessive Gear Backlash

Adjust

Excessive Gear Wear

Replace

Gearbox Oil Level Too Low

Top Up Gear Oil

Excessive Gear Backlash

Adjust

Excessive Gear Wear

Replace

Gearbox Technical Parameters Item

Parameter

Weight (Without Oil)

31 kg

Oil Capacity

0.35 L

Oil Type

ATF DEXRON II Brake Fluid

DOT3

Operating Pressure

60-80 bar

Normal Pressure (Maximum Continuous)

80 bar

Maximum Pressure

100 bar

Hydraulic Cylinder Brake Fluid Volume (Under Normal Conditions) Hydraulic Cylinder Brake Fluid Volume (Under Maximum Wear Conditions)

1.71 cm3

Hand Brake Lever Pulling Force

100 N

Stroke

6 mm

Wear Limit Stroke

13 mm

Foot Brake

Hand Brake

5

3.71 cm3

Structure

Figure 1-1 6

The brake rocker arm has three holes – Air bleed plug: after adding brake fluid, loosen the bleed plug to expel any trapped air.

– Hand brake cable connection head: connection head has a wear limit of 13 mm. Replace connection head once this limit is exceeded.

– Brake wheel cylinder inlet port: replace in the event of brake wheel cylinder leakage.

7

2. Steering System The steering system consists of the steering device and the steering axle.

Steering Device The steering device consists of the steering wheel, upper shaft assembly, universal joint, lower shaft assembly, bearings, snap rings, shaft pump, priority valve, lever, hydraulic switch and other components. The steering wheel forward/backward tilt angle can be adjusted. See Figure 2-1.

1. STEERING WHEEL

3.UPPER SHAFT ASSY

8.UNIVERSAL JOINT

10.LOWER SHAFT ASSY

12.BEARING

13.SNAP RING

14.SHAFT

17. PUMP

18. PRIORITY VALVE

19.BOLT

22.LEVER-TILT

26.HYDRAULIC SWITCH

Figure 2-1 Steering Device (Major Components)

8

Steering Axle Italian-made steering axle with a compact structure, see Figure 2-2.

1.SCREW M6

2.BRACKET

3.NUT M6

4.SCREW M6

5.WASHER M6

6.NUT

7.GASKET

8.ADJUST NUT

9.O’RING

10.BEARING

11.SHAFT

12.SEAL RING

13.GUIDE SLEEVE

14.SEAL RING

15.CYLINDER BODY

16.SEAL RING

17.CYLINDER CAP

18.AXLE HOUSING

19.BEARING

20.SEAL RING

21.GEAR SHAFT

22.STEER AXLE SPINDLE

23.PIN

24.GASKET

25.SEAL RING

26.BEARING

27.HUB

28.BEARING

29.WASHER

30.COTTER PIN

31.NUT

32.HUB CAP

33.PLUG M10

Figure 2-2 Steering Axle The axle housing (18) is fixed to the rear of the vehicle frame. Forces acting on it from the ground are carried by the support bearings (10, 19). The adjusting nut (8) is used to adjust the preload of the bearings (10, 19). The cylinder body (15) is connected to the axle housing (18). The end sections of the shaft (11) acts like pistons; when hydraulic oil from the priority valve flows towards the cylinder body (15); it pushes the shaft (11) to the left or to the right. The shaft (11) engages with the gear shaft (21), which rotates the steer wheels left or right and turns the vehicle, with a maximum steering angle of 85° in both directions.

9

Precautions for Use:    



In the event of oil leakage from the cylinder body, check and replace the seal rings (12, 14, and 16). Also check the guide sleeve and cylinder body for damage.

Periodically check the bearings (10, 19) and their seal rings (9, 20), and replace promptly if damaged. Also change grease on a regular basis.

Periodically check the bearings (26, 28), and their seal ring (25), and replace promptly if damaged. Also change grease on a regular basis; Adjusting the preload of the steer wheels hub bearings: remove the counterweight and its cover panel, and then jack up the rear of the frame with an automotive jack so that the wheels are off the ground. Tighten nut (3) until the steer wheels hubs cannot be moved by hand, then rotate it 1/6 to 1/4 turn in the opposite direction.

Adjusting the preload of the support bearings (10, 19): Remove counterweight and its cover panel, and then jack up the rear of the frame. Tighten nut (8) until the steering spindle cannot be moved by hand, then rotate nut (8) 1/6 to 1/4 turn in the opposite direction.

Problem

Steer wheels will not turn

Cause Analysis

Remedy

Pump damaged or faulty

Replace

Clogged or damaged priority valve Hose or connector damaged or pipe blocked Diverter valve pressure too low

Steering is hard

Air in the oil line

Bleed off air

Steering gear fails to centre, positioning spring broken or weak

Replace spring Check piston seal

Excessive leakage inside steering cylinder

Abnormal noise

Flush or replace Replace or flush Adjust pressure

Low oil tank level

Add oil

Damaged steering gear shaft rack

Replace

Damaged wheel bearing or support bearing

Replace

Inadequate lubrication

Add grease

Clogged suction pipe or oil filter

Flush or replace

Oil leak

Defective steering cylinder seal ring or damaged pipe or connector Damaged wheel hub bearing or support bearing or seal ring

Steering angles of left and right drive wheels (front wheels) do not match

Controller parameters incorrect

10

Replace Replace seal ring Adjust

3. Braking System The braking system includes operation of the hand brake and foot brake. The hand brake consists of a lever and cable; the foot brake consists of a brake pedal, brake master cylinder, lines and brakes, etc. The brakes are maintenance-free wet disc brakes.

Brake Master Cylinder The brake master cylinder consists of a valve seat, check valve and return spring, as well as a cup piston and auxiliary cup. The end part is secured using a snap washer and retaining wire, the outer part is protected by a rubber dust cover, and the master cylinder piston is actuated by the brake pedal via a pushrod. When the brake pedal is depressed, the pushrod pushes the piston forward and the brake fluid in the pump flows back to the reservoir via the return port until the main cup blocks the return port. Once the main cup pushes past the return port, the brake fluid in the front chamber of the master cylinder is compressed and opens the check valve, thereby flowing through the brake line to the wheel cylinders. This forces each wheel cylinder piston outward so that the brake shoe friction plate contacts the brake drum, thus causing the vehicle to decelerate or brake. At this point, the piston's rear chamber is replenished with brake fluid from the return and inlet ports. When the brake pedal is released, the pistons are forced back by the pressure of the return spring. At the same time, the brake shoe return spring forces the brake fluid in each brake wheel cylinder back through the check valve to the master cylinder (the front chamber of the piston). The piston returns to its original position and the brake fluid in the master cylinder flows back through the return port into the tank.

The pressure of the check valve is adjusted until it reaches a certain ratio of the residual pressure in the brake line and brake wheel cylinders, so as to correctly position the wheel cylinder cups to prevent oil leakage, as well as eliminate the possibility of air resistance during hard braking.

1. LOCK NUT

2. PUSHROD

3. DUST COVER

4. RETAINING RING

5. RETAINING WASHER

6. AUXILIARY CUP

7. PISTON

8. MAIN CUP

9. SPRING

10. CHECK VALVE

11. VALVE SEAT

12. PUMP HOUSING

Figure 3-1 Brake Master Cylinder

11

Hand Brake The hand brake device has a pull cable mechanism. Together with the foot brake it is connected to automatically assist brakes that act on the front wheels. Only use the hand brake when parking the forklift.

Fault

Insufficient braking force

Dragging brakes

Possible Cause

Corrective measure

Brake line leaks oil

Rectify and add oil

Air in the brake line

Bleed off air

Brake master cylinder not functioning properly

Rectify or replace

Clogged oil line

Flush

No free play at the brake pedal

Adjust

Damaged piston cup

Replace

Return spring weak or broken

Replace

Master cylinder return port clogged

Flush

Clogged line

Flush

12

4. Hydraulic System As high-pressure oil from the main oil pump flows through the priority valve, it is divided between two circuits. One circuit runs via the multi-way valve. High-pressure oil from this multi-way valve is routed to the lift cylinder or tilt cylinder. When the slide valves of both the lift and tilt cylinders are in the neutral position, no oil is supplied by the priority valve. When the lift slide valve is pulled, the high-pressure oil flows under the lift cylinder piston and pushes the piston rod upward. When the lift slide valve is pushed, the bottom of the lift cylinder piston is changed to the low pressure and relies on its own weight and the load weight to make the piston rod drop. At this point, oil flowing out of the lift cylinder and through the one-way speed limiting valve controls the lowering speed, and oil is not supplied by the priority valve. When the tilt slide valve is operated, high-pressure oil flows into a chamber of the tilt cylinder and the other side is changed to the low pressure, thereby causing the mast to tilt forward or backward. The other circuit runs via the steering gear, which is prioritised to ensure operation of the steering system.

Main Oil Pump Fault

Possible Cause

Corrective Measure

Oil pump not pumping out oil

Low oil tank level

Top up to specified oil level

Clogged suction pipe or filter

Flush oil circuit and oil tank. Change hydraulic oil if dirty

Worn bearing; damaged ring, O-ring

Replace defective parts

Misadjusted safety valve

Raise the pressure with a pressure gauge Tighten loose connectors on the suction side

Oil pump delivers oil at low pressure

Add hydraulic oil to the tank Air in the oil pump Check pump oil seals Wait for bubbles in oil tank to disappear before using pump Cavitation generated by kinked suction-side hose or clogged filter Air entering from loosened suction-side connectors

Oil pump noisy

Oil pump leaks oil

Cavitation caused by high viscosity of hydraulic oil

Adjust or replace hose and clean filter Re-tighten every connector Replace with new hydraulic oil of viscosity suitable for the oil pump operating speed Only work when oil temperature is normal

Air bubbles in hydraulic oil

Check cause of appropriate steps

Damaged pump oil seal, damaged O-ring or sliding surfaces of oil pump worn

Replace defective parts

13

bubbles,

then

take

Multi-Way Valve Fault

Safety valve pressure erratic or cannot be adjusted up

Lift motor is off, operating the forward/backward tilt lever tilts the mast forward

Mast erratic when tilted forward

Forks drop noticeably when lift lever is in neutral position

Possible Cause

Corrective Measure

Pressure adjusting screw loose

Readjust pressure and tighten screw

Pressure adjusting spring distorted or damaged

Replace

Safety valve spool worn or stuck

Replace or remove, clean and reassemble

Pump malfunctioning

Overhaul pump

Tilt locking valve worn or damaged

Replace the spool and tilt locking valve as an assembly

Broken tilt locking spring

Replace spring

Tilt valve stem O-ring damaged

Replace O-ring

Tilt relief valve malfunctioning

Replace tilt relief valve assembly

Excessive wear clearance between valve body and valve stem

Replace stem according to required clearance

Valve stem is not centred

Maintaining valve stem in neutral position

Cylinder seals defective

Overhaul cylinder

Overload valve worn or stuck with dirt

Replace or flush overload valve

Damaged or warped return spring

Replace spring

Dirt between valve body and stem

Flush

Control mechanism catching

Adjust

Fails to reset Reset parts (mis-aligned)

are

not

coaxial

Defective O-ring

Replace

Poor oil port connector seal

Check fastening and sealing of corresponding parts

Loose seal plate

Clean seal plate and retighten bolts

Safety valve lock nut/gasket and inter-gasket connection bolts loose

Fasten

Multi-way valve lever is interfering with the valve movement

Adjust

External leakage

Multi-way valve cannot move back and forth

Reassemble, maintaining coaxiality (center axial of parts)

14

Pressure Adjustment of Main Safety Valve The main safety valve pressure is pre-adjusted at the factory should not be readjusted by the user under normal conditions. The following example describes the adjustment method for a forklift truck with a rated load of 1600 kg: 1. Place a load rated at 125% of the forklift's lifting capacity (i.e. a load of 2000 kg) onto the forks in a stable manner.

2. Depress the service brake pedal fully, operate the lift lever. If the forks can be lifted within a height range of 0–300 mm, the main safety valve pressure is correct. Otherwise adjust according to step (3).

3. If the forks cannot lift the load off the ground, the pressure of the main safety valve needs to be increased. To do this, remove the front floor plate, slacken off the main safety valve lock nut, then turn the adjusting screw clockwise to increase the pressure of the main safety valve.

If the forks can be lifted above 300 mm, turn the adjusting screw anticlockwise to reduce the pressure of the main safety valve.

4. Depress the service brake pedal fully and make sure that the forks are able to lift within a height range of 0–300 mm. If this is not the case, adjust according to step (3) until the pressure meets the required lifting height range.

WARNING The load must be placed stably and securely; once the pressure has been adjusted, it should not be readjusted unnecessarily.

Tonnage Item Main Relief Valve Pressure (Working Pressure)

1.3T

1.5 T

1.6T

1.8T

2.0T

14 MPa

15.5 MPa

15.8 MPa

16.5 MPa

17.5 MPa

15

Hydraulic Schematic Diagram

16

5. Lifting System Fault Fork carriage and mast tilt without operator touching controls Fork carriage lift and tilt action stiff

Possible Cause

Remedy

Excessive wear on tilt cylinder seal rings.

Replace piston seal rings or cylinder

Multi-way valve control valve spring inoperative.

Piston seized to cylinder wall or piston rod bent.

Excessive cylinder fouling.

Fork carriage assembly improperly adjusted

Fork lifting movement not smooth

Insufficient clearance between rollers and mast channel.

Dirt stuck between moving parts.

Insufficient lubrication.

Forks lift unevenly Lifting rollers do not rotate

Inner mast skewed or fork bent.

Lifting chains not adjusted.

Grease has hardened or rollers are clogged with dirt.

Lifting rollers incorrectly adjusted.

Insufficient lubrication.

Fork carriage side rollers unevenly adjusted. With the mast tilted, side roller strikes mast channel when descending.

Excessive mast noise Buffer pad below outer mast does not work (container forklifts).

Wear on oil pump gear and pump body leading to excessive clearance.

Worn seal ring on lift cylinder piston causing internal leakage.

Multi-way valve, safety valve spring defective.

Worn multi-way valve lever and valve body causing excessive oil leakage.

Lifting weak or cannot lift

Multi-way valve body leaks oil.

Hydraulic line leaks oil.

Oil temperature too high, diluted hydraulic oil, insufficient flow.

Excessive load weight.

17

Replace Replace damaged parts Flush Adjust clearance between channel guide rail and side rollers Adjust roller clearance Clear foreign bodies Smear contact surfaces of guide rail with grease Repair or replace Adjust chains to same tension Clean and lubricate rollers Adjust Lubricate Adjust rollers and side adjusting shims Adjust gaskets and rubber buffer pad so that the piston rod in the cylinder only touches the bottom of the cylinder after the inner mast contacts the buffer pad.

Replace worn parts or pump Replace with new Y-ring Replace spring Replace After grinding, reassemble and sequentially tighten screws Compress coupling nut, check sealing gasket and coupling nut for damage Change non-compliant hydraulic oil or reduce amount of oil, check reason for high oil temperature Carry out lifting in accordance with regulations

Mast The basic mast has a lifting height of 3 m and consists of the inner mast, outer mast, chains, fork carriage, rollers and other components.

1. OUTER MAST

2. INNER MAST

3. CHAIN ASSEMBLY

4. RH LIFT CYLINDER

5. FORK CARRIAGE ASSEMBLY

6. FORK ASSEMBLY

7. TILT CYLINDER

8. LH LIFT CYLINDER

Figure 5-1 Mast 2 STG LFL Size and weight of basic mast (lifting height 3 m) MAST DIMENSIONS

MAST WEIGHT

1895 mmX1050 mmX287 mm

428 kg 18

Lift Cylinder

1. PISTON ROD

2. AF DUSTPROOF RING

3. B3 DUSTPROOF RING

4. O-RING

5. GUIDE SLEEVE

6. CYLINDER HOUSING

7. SNAP RING

8. PISTON

9. SUPPORT RING

10. GUARD RING

11. B7 SEAL RING

12. VALVE BUSHING

13. SNAP RING

14. GREASE FITTING(RH ONLY)

15. O-RING

16. PIN

Figure 5–2 Lift Cylinder

19

Tilt Cylinder

1. RING

2. SPHERICAL BEARING 3. GREASE FITTING 4. WASHER

5. NUT

6. BOLT

7. PISTON ROD

8. AM DUSTPROOF RING

9. GUIDE SLEEVE

10. GUIDE RING

11. B3 SEAL RING

12. BUSHING

13. WIRE RETAINING RING 14. O-RING

15. CYLINDER HOUSING

16. PISTON

17. O-RING

18. GUIDE RING

19. NUT

20. COTTER PIN

21. OK SEAL RING

22. O-RING

Figure 5–3 Tilt Cylinder

20

6. Electrical System Note: The hour meter counts while the key is “ON” and no one in the seat. Turn key to “OFF” when truck not in use.

Controller The MOS chopper series represents a state-of-the-art answer to the needs of the 21st century. To ensure that products remain on the market without running the risk of becoming technically obsolete, the MOS series offers the following features: – Advanced technology – Economical costs – Maximum safety – Maximum adaptability – Open to future technical innovations – Optimum level of protection Basic Design Theory – High-frequency MOS technology – Real-time control over the internal and external components that influence the vehicle's performance, with self-diagnosis of the checking circuits themselves – Stored Program Machine (SPC), where the hardware is completely separate from the functions to be configured. The program is parametric and can easily be modified by the end user – Various chopper configurations can be selected, without the need for hardware modifications – Future technology updates are made easy for the user – The communication protocol will continue to evolve, thereby offering increasing possibilities of interaction and expansion. For this reason, the series offers a standard dialogue mode with external systems, which allows interfacing with commercially available machines. A range of individually designed control software is also offered with various prices and features.

– The controller meets IP51 requirements, providing excellent protection against spray (water, acid) and the ingress of dust or small foreign particles. Access to the control logic is very simple and allows substitution or replacement.

Steer Wheels Angle Sensor – The dual-motor drive is equipped with a steered wheel angle sensor that transmits angle signals to the electronic controller, thereby helping the motors apply differential control.

– The SET STEER MIN and SET STEER MAX functions can be used to obtain the minimum and maximum voltages of the steering potentiometer range.

Safety and Protection Features – Battery polarity protection: the circuits must be constantly tested to avoid damage to the power unit. It is necessary to fit a main contactor controlled by the logic unit to protect against reverse battery polarity.

– Circuit connection protection: all inputs are protected against connection errors. The contactor driver can withstand a load of 2 A and has overload protection – Thermal protection: when the controller temperature exceeds 85°C, the thermal protection function is triggered, which reduces the maximum current in proportion to the thermal increase.

The temperature can never exceed 95°C. – Battery over discharge protection: when the battery charge is low, the maximum current is reduced in proportion to the battery's charge.

– External protection: the chopper effectively prevents ingress of dust, liquid and other foreign bodies to a degree of protection meeting IP51 – Starting sequence protection: a precise sequence of operations is necessary before the vehicle will start. The key switch must be closed before vehicle will start.

21

Safety And Protection Features (cont’d) – Other protection: if any of the following situations occurs, the main contactor will not close.

- Power unit is not functioning - Logic unit is not functioning properly - The output voltage of the accelerator does not fall below the minimum voltage value stored, with 1 V added - Running micro switch in closed position Operating Characteristics – Speed control – Optimal sensitivity at low travel speeds – Speed can be reduced in both forward and reverse directions. Level can be set using handheld unit – Regenerative Braking based on deceleration ramps – Three different braking modes: Release Braking, Inversion Braking and Deceleration Braking – Speed control during descent: the motor speed follows the accelerator. The chopper automatically brakes if the motor speed exceeds the accelerator set point. This provides optimum performance on a gradient – Starts on a ramp without roll back, even without an electric brake – Programmable anti-roll back function: when the key switch is closed, if the motor is rotating, the chopper detects the speed and automatically brakes, keeping the motor at a very low speed during descent on a gradient. This is a very useful safety feature and is not driver-dependent – Indication of faults via LEDs – Modification of parameters via instrument or handheld unit – Internal hour meter displayed on instrument – Memory of the last 10 electrical control alarms – Test function for checking main parameters – Internal contactor coil absorption circuit – High motor and battery performance due to high-frequency switching – Presence of an auxiliary microprocessor for safety monitoring of the CPU that controls the motor Controller Maintenance There are no user serviceable parts in the controller. No attempt should be made to open, repair or otherwise modify the controller. Doing so may damage the controller and will void the warranty. It is recommended that the controller and connections be kept clean and dry.

Cleaning Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical control problems created by dirt, grime and chemicals.

Use the following cleaning procedure: – Disconnect the power plug.

– Discharge the capacitors in the controller by connecting a load (such as a contactor coil or horn) across the controller’s B+ and B- terminals.

– Remove any dirt or corrosion from the power and signal connector areas. The controller should be wiped clean with a moist rag.

– Dry it before reconnecting the battery.

22

Fault Code Tables The red and yellow LEDs on the controller housing have different display modes to indicate the type of fault condition, as shown in the following table:

Curtis 1234 Controller Fault Code Table Display

Status

Neither LED illuminated

Controller is not powered on because of dead battery or line failure

Yellow LED flashing

Controller is operating normally

Yellow and red LEDs both on solid

Controller software update in progress

Yellow and red LEDs both flashing

Controller has detected a fault

Left/Right Traction Controller Fault Code Table Instrument DisplayDisplay Codes

Handheld Display Fault Codes

Possible Cause

1.2

Controller Overcurrent

1. External short of phase U. V or W motor connections.

2. Motor parameters are mistuned.

3. Controller defective.

1.3

Current Sensor Fault

1. Leakage to vehicle frame from phase U. V or W (short in motor stator) 2. Controller defective.

1.4

Pre-Charge Failed

1. External load on capacitor bank (B+ terminal) that prevents the capacitor bank from charging.

2. See 1313-4401 menu Monitor » Battery: Capacitor Voltage

1.5

Controller Severe Under Temperature

1. Controller is operating in an extreme environment (Below -40°C).

2. See 1313-4401 menu Monitor » Controller: Temperature.

Controller Severe Over Temperature

1. Controller is operating in an extreme environment (Above 95°C).

2. Excessive load on vehicle.

3. Improper mounting of controller.

4. See 1313-4401 menu Monitor » Controller: Temperature.

Severe Under Voltage

1. Battery Menu parameters are misadjusted.

2. Vehicle seriously overloaded.

3. Battery resistance too high.

4. Battery disconnected while driving.

5. See 1313-4401 menu Monitor » Battery: Capacitor Voltage.

6. Blown B+ fuse or main contactor did not close

1.6

1.7

23

Left/Right Traction Controller Fault Code Table Instrument DisplayDisplay Codes

Handheld Display Fault Codes

Possible Cause

1.8

Severe Overvoltage

1. Battery Menu parameters are misadjusted.

2. Battery resistance too high for given regen current.

3. Battery disconnected while regen braking.

4. See 1313-4401 menu Monitor » Battery: Capacitor Voltage.

2.1

Controller Under Temperature Cutback

1. Controller is performance-limited at this temperature (below -25°C).

2. Controller is operating in an extreme environment.

3. See 1313-4401 menu Monitor » Controller: Temperature.

Controller Over Temperature Cutback

1. Controller is performance-limited at this temperature (above 85°C).

2. Controller is operating in an extreme environment.

3. Excessive load on vehicle.

4. Improper mounting of controller.

5. See 1313-4401 menu Monitor » Controller: Temperature.

2.2

2.3

Under Voltage Cutback

2.4

Overvoltage Cutback

1. Normal operation. Fault shows that the batteries need recharging.

Controller is performance-limited at this voltage.

2. Controller battery parameters are misadjusted.

3. Check for non-controller system drain on battery.

4. Battery resistance too high.

5. Battery disconnected while driving.

6. See 1313-4401 menu Monitor » Battery: Capacitor Voltage.

7. Blown B+ fuse or main contactor did not close 1. Normal operation. Fault shows that regen braking currents elevated the battery voltage during regen braking.

Controller is performance-limited at this voltage.

2. Battery parameters are misadjusted.

3. Battery resistance too high for given regen current.

4. Battery disconnected while regen braking.

5. See 1313-4401 menu Monitor » Battery: Capacitor Voltage.

2.5

+5V Supply Failure

1. External load impedance on the +5 V supply (pin 26) is too low.

2. See 1313-4401 menu Monitor » Outputs: 5 Volts and Ext Supply Current.

2.6

Digital Out 6 Overcurrent

1. External load impedance on Digital Output 6 driver (Pin 19) is too low.

2.7

Digital Out 7 Overcurrent

1. External load impedance on Digital Output 7 driver (Pin 20) is too low.

24

Left/Right Traction Controller Fault Code Table Instrument DisplayDisplay Codes

Handheld Display Fault Codes

Possible Cause

Motor Temp Hot Cutback

1. Motor temperature is at or above the programmed Temperature Hot setting (above 145°C). And the requested current is being cut back.

2. Motor Temperature Control Menu parameters are mistuned.

3. See 1313-4401 menus Monitor » Motor: Temperature and Monitor » Inputs: Analog 2 4. If not using a thermistor. Temp Compensation and Temp Cutback should be programmed to OFF

2.9

Motor Temp Sensor Fault

1. Motor thermistor is not connected properly.

2. If not using a thermistor. Temp Compensation and Temp Cutback should be programmed to OFF 3. See 1313-4401 menus Monitor » Motor: Temperature and Monitor » Inputs: Analog 2

3.1

Coil 1 Driver Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3.1

Main Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3.2

Coil2 Driver Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3.2

EM Brake Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3.3

Coil3 Driver Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring

3.4

Coil4 Driver Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring

3.5

PD Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring

3.6

Encoder Fault

1. Motor encoder failure.

2. Bad crimps or faulty wiring.

3. See 1313-4401 menu Monitor » Motor: Motor RPM

3.7

Motor Open

1. Motor U. V. W line is open.

2. Bad crimps or faulty wiring.

2.8

25

Left/Right Traction Controller Fault Code Table Instrument DisplayDisplay Codes

Handheld Display Fault Codes

Possible Cause

Main Contactor Welded

1. Main contactor tips are welded closed.

2. Motor phase U is disconnected or open.

3. An alternate voltage path (such as an external pre-charge resistor) is providing a current to the capacitor bank (B+ terminal).

3.9

Main Contactor Did Not Close

1. Main contactor did not close.

2. Main contactor tips are oxidized.

3. External load on capacitor bank (B+ terminal) that prevents capacitor bank from charging.

4. Blown B+ fuse.

4.1

Throttle Wiper High

1. Throttle pot wiper voltage too high.

2. See 1313-4401 menu Monitor » Inputs: Throttle Pot

4.2

Throttle Wiper Low

1. Throttle pot wiper voltage too low.

2. See 1313-4401 menu Monitor » Inputs: Throttle Pot

4.3

Brake Wiper High

1. Brake pot wiper voltage too high.

2. See 1313-4401 menu Monitor » Inputs: Brake Pot

4.4

Brake Wiper Low

1. Brake pot wiper voltage too low.

2. See 1313-4401 menu Monitor » Inputs: Brake Pot

4.5

Pot Low Overcurrent

1. Combined pot resistance connected to Pot Low is too low.

2. See 1313-4401 menu Monitor » Outputs: Pot Low

EEPROM Failure

1. Failure to write to EEPROM memory.

This can be caused by EEPROM memory writes initiated

by VCL. By the CAN bus. By adjusting parameters with the 1313-4401. Or by loading new software into the controller.

4.7

HPD/Sequencing Fault

1. Key switch. Interlock. Direction. And throttle inputs applied in incorrect sequence.

2 Faulty wiring. Crimps or transfer switches at key switch.

Interlock. Direction or throttle inputs.

3. See 1313-4401 menu Monitor » Inputs.

4.7

Emer Rev HPD

1. Emergency Reverse operation has concluded. But the throttle. Forward and reverse inputs. And interlock has not been returned to neutral.

Parameter Change Fault

1. This is a safety fault caused by a change in certain 1313-4401 parameter settings so that the vehicle will not operate until key switch input is cycled.

For example, if a user changes the Throttle Type this fault will appear and require cycling the key switch input before the vehicle can operate.

VCL Runtime Error

1. VCL code encountered a runtime error.

2. See 1313-4401 menu Monitor » Controller VCL Error Module and VCL Error. This error can then be compared with the runtime VCL module ID and error code definitions found in the specific OS system information file.

3.8

4.6

4.9

6.8

26

Left/Right Traction Controller Fault Code Table Instrument DisplayDisplay Codes

Handheld Display Fault Codes

Possible Cause

6.9

External Supply Out of Range

1. External load on the 5 V and 12 V supplies draws either too much or too little current.

2. Fault Checking Menu parameters Ext Supply Max and Ext Supply Min are mistuned.

3. See 1313-4401 menu Monitor » Outputs: Ext Supply Current.

7.1

OS General

1. Internal controller fault.

7.2

PDO Timeout

1. Time between CAN PDO messages received exceeded the PDO Timeout Period.

Stall Detect

1. Stalled motor.

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4.Problems with power supply for the motor encoder.

5. See 1313-4401 menu Monitor » Motor: Motor RPM.

7.3

7.4

?

Look for a fault on the other Traction Controller

8.7

Motor Characterization Fault

1. Motor characterization failed during the characterization process.

8.8

Encoder Characterization Fault

1. Encoder characterization failed during the motor characterization process.

2. Motor encoder pulse rate is not a standard value (32. 48.

64. 80 ppr)

8.9

Motor Type Fault

1. The Motor_Type parameter value is out of range.

9.2

EM Brake Failed to Set

1. Vehicle movement sensed after the EM Brake has been commanded to set 2. EM Brake will not hold the motor from rotating.

9.3

Limited Operating Strategy (LOS)

1. Limited Operating Strategy (LOS) control mode has been activated as a result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code 73).

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. Vehicle is stalled.

9.4

Emer Rev Timeout

1. Emergency Reverse was activated and concluded because the EMR timeout timer has expired; 2. The emergency reverse input is stuck On

27

Diagnostics and Troubleshooting The 1234 controller detects a wide variety of faults or error conditions. Faults can be detected by the operating system or by the VCL code. This section describes the faults detected by the operating system.

Faults detected by VCL code (faults 51–67 in Table 5-See Table 5 below) cannot be defined here as they will vary from application to application. Refer to the appropriate OEM documentation for information on these faults.

DIAGNOSTICS Diagnostics information can be obtained in either of two ways: (1) by reading the display on a 1313-4401 programmer or (2) by observing the fault codes issued by the Status LEDs. See Table 4 for a summary of LED display formats.

The 1313-4401 Programmer will display all faults that are currently set as well as a history of the faults that have been set since the history log was last cleared. The 1313-4401 displays the faults by name.

The pair of LEDs built into the controller (one red, one yellow) produce flash codes displaying all the currently set faults in a repeating cycle. Each code consists of two digits. The red LED flashes once to indicate that the first digit of the code will follow; the yellow LED then flashes the appropriate number of times for the first digit.

The red LED flashes twice to indicate that the second digit of the code will follow; the yellow LED flashes the appropriate number of times for the second digit.

Example: Battery Under Voltage (Code 23) In the Fault menu of the 1313-4401 programmer, the words UNDER VOLTAGE CUTBACK will be displayed; the real-time battery voltage is displayed in the Monitor menu (“Key switch Voltage”).

The Controller’s Two Leds Will Display This Repeating Pattern RED

YELLOW

RED

YELLOW

✱

✲✲

✱✱

✲✲✲

(first digit)

(2)

(second digit)

(3)

The numerical codes used by the yellow LED are listed in the Troubleshooting Chart (Table 5), which also lists possible fault causes and describes the conditions that set and clear each fault?

SUMMARY OF LED DISPLAY FORMATS The two LEDs have four different display modes, indicating the type of information they are providing.

TYPES OF LED DISPLAY (Table 4) DISPLAY

STATUS

Neither LED illuminated

Controller is not powered on, has a dead battery, or is severely damaged.

Yellow LED flashing

Controller is operating normally.

Yellow & Red LEDs Both on Solid

Controller is in flash program mode.

Red LED on Solid

Watchdog failure. Cycle KSI to restart.

Red LED & Yellow LED flashing alternately

Controller has detected a fault. 2-Digit Code flashed by yellow LED identifies the specific fault; one or two flashes by red LED indicate whether first or second code digit will follow.

TROUBLESHOOTING The troubleshooting chart, Table 5, provides the following information on all the controller faults:  Fault Code  Fault Name as displayed on the programmer’s LCD  The Effect of the Fault  Possible Causes of the Fault  Fault Set Conditions  Fault Clear Conditions Whenever a fault is encountered and no wiring or vehicle fault can be found, shut off KSI and turn it back on to see if the fault clears. If not, shut off KSI and remove the 35-pin connector. Check the connector for corrosion or damage, clean it if necessary, and re-insert it.

28

Troubleshooting Tables TROUBLESHOOTING CHART (Table 5) CODE

PROGRAMMER LCD DISPLAY EFFECT OF FAULT

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

14

Pre-charge Failed Shutdown Main Contactor Shutdown Motor Shutdown EM Brake

1. External short of phase U, V, or W motor connections.

2. Motor parameters are mistuned.

3. Controller defective.

1. Leakage to vehicle frame from phase U, V, or W (short in motor stator).

2. Controller defective.

1. External load on capacitor bank (B+ connection stud) that prevents the capacitor bank from charging.

2. See 1313-4401 menu Monitor » Battery: Capacitor Voltage.

Set: Phase current exceeded the current measurement limit.

Clear: Cycle KSI. Set: Controller current sensors have invalid offset reading.

Clear: Cycle KSI. Set: Pre-charge failed to charge the capacitor bank to the KSI voltage.

Clear: Cycle Interlock input or use VCL function Pre-charge().

15

Controller Severe Under Temperature 1. Controller is operating in an Shutdown Main Contactor extreme environment.

Shutdown Motor 2. See 1313-4401 menu Monitor » Shutdown EM Brake Controller: Temperature.

Shutdown Throttle, Full Brake

Set: Heat sink temperature below -40°C. Clear: Bring heat sink temperature above -40°C, and cycle interlock or KSI.

16

Controller Severe Over Temp Shutdown Main Contactor Shutdown Motor Shutdown EM Brake Shutdown Throttle, Full Brake

1. Controller is operating in an extreme environment.

2. Excessive load on vehicle.

3. Improper mounting of controller.

4. See 1313-4401 menu Monitor » Controller: Temperature.

Set: Heat sink temperature above +95°C. Clear: Bring heat sink temperature below +95°C, and cycle interlock or KSI.

Severe Under Voltage Reduced Drive Torque

1. Battery Menu parameters are misadjusted.

2. Non-controller system drain on battery.

3. Battery resistance too high.

4. Battery disconnected while driving.

5. See 1313-4401 menu Monitor » Battery: Capacitor Voltage.

6. Blown B+ fuse or main contactor did not close.

Set: Capacitor bank voltage dropped below the Severe Battery Under voltage limit (see page 49) with FET bridge enabled.

Clear: Bring capacitor voltage above Severe Battery Under voltage limit.

1. Battery Menu parameters are misadjusted.

Severe Overvoltage 2. Battery resistance too high for Shutdown Main Contactor given regen current.

Shutdown Motor 3. Battery disconnected while regen Shutdown EM Brake braking.

Shutdown Throttle, Full Brake 4. See 1313-4401 menu Monitor » Battery: Capacitor Voltage.

Set: Capacitor bank voltage exceeded the Severe Battery Overvoltage limit (see page 49) with FET bridge enabled.

Clear: Bring capacitor voltage below Severe Battery Overvoltage limit and then cycle KSI.

12

13

17

18

Controller Overcurrent Shutdown Main Contactor Shutdown Motor Shutdown EM Brake Current Sensor Fault Shutdown Main Contactor Shutdown Motor Shutdown EM Brake

29

TROUBLESHOOTING CHART (Table 5) CODE

PROGRAMMER LCD DISPLAY EFFECT OF FAULT

21

Controller Under Temperature Cutback None, unless a fault action is programmed in VCL.

22

1. Controller is performance-limited at this temperature.

2. Controller is operating in an Controller Over Temp Cutback extreme environment.

Reduced Drive and Brake 3. Excessive load on vehicle.

Torque 4. Improper mounting of controller.

5. See 1313-4401 menu Monitor » Controller: Temperature.

Set: Heat sink temperature exceeded 85°C. Clear: Bring heat sink temperature below 85°C.

23

Under Voltage Cutback Reduced Drive Torque

1. Normal operation. Fault shows that the batteries need recharging. Controller is performance limited at this voltage.

2. Battery parameters are misadjusted.

3. Non-controller system drain on battery.

4. Battery resistance too high.

5. Battery disconnected while driving.

6. See 1313-4401 menu Monitor Battery: Capacitor Voltage.

7. Blown B+ fuse or main contactor did not close.

Set: Capacitor bank voltage dropped below the “Battery Under Voltage” limit (see p. 49) with the FET bridge enabled.

Clear: Bring capacitor voltage above the under voltage limit.

24

Over Voltage Cutback Reduced Brake Torque

1. Normal operation. Fault shows that regen braking currents elevated the battery voltage during regen braking. Controller is performance limited at this voltage.

2. Battery parameters are misadjusted.

3. Battery resistance too high for given regen current.

4. Battery disconnected while regen braking.

5. See 1313-4401 menu Monitor » Battery: Capacitor Voltage.

Set: Capacitor bank voltage exceeded the Battery Overvoltage limit (see page 49) with the FET bridge enabled.

Clear: Bring capacitor voltage below the Overvoltage limit.

25

+5V Supply Failure None, unless a fault action is programmed in VCL

1. External load impedance on the +5V supply (pin 26) is too low.

2. See 1313-4401 menu Monitor » outputs: 5 Volts and Ext Supply Current.

Set: +5V supply (pin 26) outside the +5V±10% range.

Clear: Bring voltage within range.

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

1. Controller is performance-limited at this temperature.

2. Controller is operating in an extreme environment.

3. See 1313-4401 menu Monitor » Controller: Temperature.

Set: Heat sink temperature dropped below 25°C. Clear: Bring heat sink temperature above -25°C.

30

TROUBLESHOOTING CHART (Table 5) CODE

PROGRAMMER LCD DISPLAY EFFECT OF FAULT

POSSIBLE CAUSE

26

Digital Out 6 Overcurrent Digital Output 6 driver will not turn on

1. External load impedance on Digital Output 6 driver (pin 19) is too low.

27

Digital Out 7 Overcurrent Digital Output 7 driver will not turn on

1. External load impedance on Digital Output 7 driver (pin 20) is too low.

28

Motor Temp Hot Cutback Reduced Drive Torque

29

Motor Temp Sensor Fault Max Speed reduced (LOS, Limited Operating Strategy) and motor temperature cutback is disabled

31

Coil 1 Driver Open/Short Shutdown Driver 1

31

Main Open/Short Shutdown Driver 1 Shutdown Motor Shutdown EM Brake

32

Coil 2 Driver Open/Short Shutdown Driver 2

SET/CLEAR CONDITIONS

Set: Digital Output 6 (pin 19) current exceeded 15 mA. Clear: Remedy the overcurrent cause and use the VCL function Set_DigOut() to turn the driver on again.

Set: Digital Output 7 (pin 20) current exceeded 15 mA. Clear: Remedy the overcurrent cause and use the VCL function Set_DigOut() to turn the driver on again.

1. Motor temperature is at or above the programmed Temperature Hot setting, and the requested current is being cut back.

2. Motor Temperature Control Menu Set: Motor temperature is parameters are mistuned. at or above the 3. See 1313-4401 menus Monitor » Temperature Hot Motor: Temperature and Monitor parameter setting. » Inputs: Analog2.

Clear: Bring the motor 4. If the application doesn’t use a temperature within range. motor thermistor, Temp Compensation and Temp Cutback should be programmed Off. 1. Motor thermistor is not connected properly.

2. If the application doesn’t use a Set: Motor thermistor input motor thermistor, Temp (pin 8) is at the voltage rail Compensation and Temp (0 or 10V).

Cutback should be programmed Clear: Bring the motor Off. thermistor input voltage 3. See 1313-4401 menus Monitor » within range.

Motor: Temperature and Monitor » Inputs: Analog2.

Set: Driver 1 (pin 6) is 1. Open or short on driver load. either open or shorted.

2. Dirty connector pins.

Clear: Correct open or 3. Bad crimps or faulty wiring. short, and cycle driver.

Set: Main contactor driver 1. Open or short on driver load. (pin 6) is either open or 2. Dirty connector pins. shorted.

3. Bad crimps or faulty wiring.

Clear: Correct open or short, and cycle driver.

Set: Driver 2 (pin 5) is 1. Open or short on driver load. either open or shorted.

2. Dirty connector pins.

Clear: Correct open or 3. Bad crimps or faulty wiring. short, and cycle driver.

31

TROUBLESHOOTING CHART (Table 5) CODE

PROGRAMMER LCD DISPLAY EFFECT OF FAULT

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

32

EM Brake Open/Short Shutdown Driver 2 Shutdown Throttle, Full Brake

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

Set: Electromagnetic brake driver (pin 5) is either open or shorted.

Clear: Correct open or short, and cycle driver.

33

Coil 3 Driver Open/Short Shutdown Driver 3

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

Set: Driver 3 (pin 4) is either open or shorted.

Clear: Correct open or short, and cycle driver.

34

Coil 4 Driver Open/Short Shutdown Driver 4

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

Set: Driver 4 (pin 3) is either open or shorted.

Clear: Correct open or short, and cycle driver.

35

PD Open/Short Shutdown PD

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

Set: Proportional driver (pin 2) is either open or shorted.

Clear: Correct open or short, and cycle driver.

36

1. Motor encoder failure.

Encoder Fault 2. Bad crimps or faulty wiring.

Control Mode changed to LOS 3. See 1313-4401 menu (Limited Operating Strategy) Monitor » Motor: Motor RPM.

Set: Motor encoder phase failure detected.

Clear: Cycle KSI.

37

Motor Open Shutdown Main Contactor Shutdown Motor Shutdown EM Brake

1. Motor phase is open.

2. Bad crimps or faulty wiring.

3. Bad crimps or faulty wiring.

Set: Motor phase U, V, or W detected open.

Clear: Cycle KSI.

Main Contactor Welded Shutdown Main Contactor Shutdown Motor Shutdown EM Brake

1. Main contactor tips are welded closed.

2. Motor phase U is disconnected or open.

3. An alternate voltage path (such as an external pre-charge resistor) is providing a current to the capacitor bank (B+ connection stud).

Set: Just prior to the main contactor closing, the capacitor bank voltage (B+ connection stud) was loaded for a short time and the voltage did not discharge.

Clear: Cycle KSI.

Main Contactor Did Not Close Shutdown Main Contactor Shutdown Motor Shutdown EM Brake

1. Main contactor did not close.

2. Main contactor tips are oxidized, burned, or not making good contact.

3. External load on capacitor bank (B+ connection stud) that prevents capacitor bank from charging.

4. Blown B+ fuse.

Set: With the main contactor commanded closed, the capacitor bank voltage (B+ connection stud) did not charge to B+.

Clear: Cycle KSI.

38

39

32

TROUBLESHOOTING CHART (Table 5) CODE

41

42

43

44

45

PROGRAMMER LCD DISPLAY EFFECT OF FAULT

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

1. Throttle pot wiper voltage too high.

2. See 1313-4401 menu Monitor » Inputs: Throttle Pot.

Set: Throttle pot wiper (pin 16) voltage is higher than the high fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring throttle pot wiper voltage below the fault threshold.

1. Throttle pot wiper voltage too low.

2. See 1313-4401 menu Monitor » Inputs: Throttle Pot.

Set: Throttle pot wiper (pin 16) voltage is lower than the low fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring throttle pot wiper voltage above the fault threshold.

1. Brake pot wiper voltage too high.

2. See 1313-4401 menu Monitor » Inputs: Brake Pot.

Set: Brake pot wiper (pin 17) voltage is higher than the high fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring brake pot wiper voltage below the fault threshold.

Brake Wiper Low Full Brake

1. Brake pot wiper voltage too low.

2. See 1313-4401 menu Monitor » Inputs: Brake Pot.

Set: Brake pot wiper (pin 17) voltage is lower than the low fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring brake pot wiper voltage above the fault threshold.

Pot Low Overcurrent Shutdown Throttle, Full Brake

1. Combined pot resistance connected to pot low is too low.

2. See 1313-4401 menu Monitor » Outputs: Pot Low.

Set: Pot low (pin 18) current exceeds 10mA. Clear: Clear pot low overcurrent condition and cycle KSI.

Throttle Wiper High Shutdown Throttle

Throttle Wiper Low Shutdown Throttle

Brake Wiper High Full Brake

33

TROUBLESHOOTING CHART (Table 5) CODE

46

47

47

49

51–67

PROGRAMMER LCD DISPLAY EFFECT OF FAULT

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

EEPROM Failure Shutdown Main Contactor Shutdown Motor Shutdown EM Brake Shutdown Throttle Shutdown Interlock Shutdown Driver 1 Shutdown Driver 2 Shutdown Driver 3 Shutdown Driver 4 Shutdown PD, Full Brake

1. Failure to write to EEPROM memory. This can be caused by EEPROM memory writes initiated by VCL, by the CAN bus, by adjusting parameters with the 1313-4401, or by loading new software into the controller.

Set: Controller operating system tried to write to EEPROM memory and failed.

Clear: Download the correct software (OS) and matching parameter default settings into the controller and cycle KSI.

HPD/Sequencing Fault Shutdown Throttle

1. KSI, interlock, direction, and throttle inputs applied in incorrect sequence.

2. Faulty wiring, crimps, or switches at KSI, interlock, direction, or throttle inputs.

3. See 1313-4401 menu Monitor » Inputs.

Set: HPD (High Pedal Disable) or sequencing fault caused by incorrect sequence of KSI, interlock, direction, and throttle inputs.

Clear: Reapply inputs in correct sequence.

Emer Rev HPD Shutdown Throttle Shutdown EM Brake

1. Emergency Reverse operation has concluded, but the throttle, forward and reverse inputs, and interlock have not been returned to neutral.

Set: At the conclusion of Emergency Reverse, the fault was set because various inputs were not returned to neutral.

Clear: If EMR_Interlock = On, clear the interlock, throttle, and direction inputs.

If EMR_Interlock = Off, clear the throttle and direction inputs.

Parameter Change Fault Shutdown Main Contactor Shutdown Motor Shutdown EM Brake

1. This is a safety fault caused by a change in certain 1313-4401 parameter settings so that the vehicle will not operate until KSI is cycled.

For example, if a user changes the Throttle Type this fault will appear and require cycling KSI before the vehicle can operate.

Set: Adjustment of a parameter setting that requires cycling of KSI. Clear: Cycle KSI.

OEM Faults (See OEM documentation.

See next page, fault code 61)

1. These faults can be defined by the OEM and are implemented in the application-specific VCL code. See OEM documentation.

Set: See OEM documentation.

Clear: See OEM documentation.

34

TROUBLESHOOTING CHART (Table 5) CODE

PROGRAMMER LCD DISPLAY EFFECT OF FAULT

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

Wrong Controller Model: Changed Controller Model to 1234/6/8

1.In Operation Menu: Advanced Settings 2.Enter User Password 3.Enter OEM Password 4.On display, place arrow to Select Controller 5. Enter 1234/6/8 6. Turn off Key & restart, fault should disappear.

1. VCL code encountered a runtime VCL error.

2. See 1313-4401 menu Monitor » Controller: VCL Error Module and VCL Error. This error can then be compared to the runtime VCL module ID and error code definitions found in the specific OS system information file.

Set: Runtime VCL code error condition.

Clear: Edit VCL application software to fix this error condition; flash the new compiled software and matching parameter defaults; cycle KSI.

69

1. External load on the 5V and 12V supplies draws either too much or too little current.

External Supply Out of Range 2. Fault Checking Menu None, unless a fault action is parameters. Ext Supply Max and programmed in VCL. Ext Supply Min are mistuned.

3. See 1313-4401 menu Monitor » Outputs: Ext Supply Current.

Set: The external supply current (combined current used by the 5V supply [pin 26] and 12V supply [pin 25]) is either greater than the upper current threshold or lower than the lower current threshold. The two thresholds are defined by the Ext Supply Max and Ext Supply Min parameter settings (page 45).

Clear: Bring the external supply current within range.

71

OS General Shutdown Main Contactor Shutdown Motor Shutdown EM Brake Shutdown Throttle Shutdown Interlock Shutdown Driver 1 Shutdown Driver 2 Shutdown Driver 3 Shutdown Driver 4 Shutdown PD, Full Brake

Set: Internal controller fault detected.

Clear: Cycle KSI.

72

PDO Timeout 1. Time between CAN PDO Shutdown Interlock; CAN NMT messages received exceeded State set to Pre-operational the PDO Timeout Period.

61

OEM Fault: TRACTION HYD

68

VCL Runtime Error Shutdown Main Contactor Shutdown Motor Shutdown EM Brake Shutdown Throttle Shutdown Interlock Shutdown Driver 1 Shutdown Driver 2 Shutdown Driver 3 Shutdown Driver4 Shutdown PD, Full Brake

!,! !,!

1. Internal controller fault.

35

Set: Time between CAN PDO messages received exceeded the PDO Timeout Period.

Clear: Cycle KSI.

TROUBLESHOOTING CHART (Table 5) CODE

PROGRAMMER LCD DISPLAY EFFECT OF FAULT

POSSIBLE CAUSE

73

1. Stalled motor.

2. Motor encoder failure.

Stall Detect 3. Bad crimps or faulty wiring.

Control Mode changed to LOS 4. Problems with power supply for (Limited Operating Strategy) the motor encoder.

5. See 1313-4401 menu Monitor » Motor: Motor RPM.

87

Motor Characterization Fault Shutdown Main Contactor Shutdown Throttle Shutdown EM Brake Shutdown Motor

1. Motor characterization failed during the motor characterization process.

88

Encoder Characterization Fault Shutdown Main Contactor Shutdown Throttle Shutdown EM Brake Shutdown Motor Encoder_Steps set to value =31

1. Encoder characterization failed during the motor characterization process.

2. Motor encoder pulse rate is not a standard value (32, 48, 64, 80 ppr).

89

Motor Type Fault Shutdown Main Contactor Shutdown Throttle Shutdown EM Brake Shutdown Motor

1. The Motor_Type parameter value is out of range.

EM Brake Failed to Set Enter Position Hold

1. Vehicle movement sensed after the EM Brake has been commanded to set.

2. EM Brake will not hold the motor from rotating.

92

36

SET/CLEAR CONDITIONS

Set: No motor encoder movement detected.

Clear: Either cycle KSI, or detect valid motor encoder signals while operating in LOS mode and return Throttle Command = 0 and Motor RPM = 0.

Set: Motor characterization failed during the motor characterization process.

Clear: Cycle KSI. Set: During the motor characterization process, encoder pulses were detected but the Encoder_Steps were not detected as 32, 48, 64, or 80 ppr.

Clear: Manually set Encoder_Steps to the correct value for the motor encoder and cycle KSI. Set: Motor_Type parameter is set to an illegal value.

Clear: Set Motor_Type to correct value and cycle KSI. Set: After the EM Brake was commanded to set and time has elapsed to allow the brake to fully engage, vehicle movement has been sensed.

Clear: Activate the throttle.

TROUBLESHOOTING CHART (Table 5) CODE

93

94

PROGRAMMER LCD DISPLAY EFFECT OF FAULT

Limited Operating Strategy (LOS) Enter LOS control mode

Emer Rev Timeout Shutdown Throttle Shutdown EM Brake

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

1. Limited Operating Strategy (LOS) control mode has been activated, as a result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code 73).

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. Vehicle is stalled.

Set: Encoder Fault (Code 36) or Stall Detect Fault (Code 73) was activated, and Brake or Interlock has been applied to activate LOS control mode, allowing limited motor control.

Clear: Cycle KSI, or if the LOS mode was activated by the Stall Fault, clear LOS by ensuring encoder senses proper operation, Motor RPM = 0, and Throttle Command = 0.

1. Emergency Reverse was activated and concluded because the EMR Timeout timer has expired.

2. The emergency reverse input is stuck On.

Set: Emergency Reverse was activated and ran until the EMR Timeout timer expired.

Clear: Turn the emergency reverse input Off.

37

Schematic Diagram (Australian Standard)

38

39

40

41

42

Schematic Diagram (Standard)

43

44

45

46

47

Maintenance Record Date

Operation

48

Maintenance personnel

UTILEV TECHNICAL PUBLICATIONS “UTILEV is a registered trademark. THE UTILITY LIFT TRUCK and UTILITY YOU CAN TRUST are trademarks in the United States and certain other jurisdictions.

PART NUMBER 76002086

06/2017

49

(04/2017)