Page 1 SB4082E00 Dec. 2002 Specifications Systems Operation Testing & Adjusting MicroController Control System Models : B20S-3, B25S-3, B30S-3 for Electric Lift Trucks...
Page 2 Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skill and tools to perform these functions properly.
Page 4: Table Of Contents
Index Speciﬁcations Operational Circuit Elements........17 Component Measurements........5 Battery Discharge Indicator (BDI) ......21 Console..............7 Central Vehicle Monitoring System.......17 Contactor ..............8 Chat (Wait) Mode ..........20 Control Panel (Layout) ..........9 Contactor..............20 Current Measurements ..........5 CVMS International Pictorial Symbols....19 Direction Switch ............
Page 5 Electrical System Adjustments....... 102 Accelerator Control Linkage ......102 Lift Sensor............103 Parking Brake Switch......... 102 Tilt and Auxiliary Switches Adjustment ....104 Valve Control Card Adjustment......103 LED Diagnosis for Drive controller ......47 Preparation Tests and Checks ......... 41 System Tests and Adjustments ........
Page 6: Component Measurements
Speciﬁcations Component Measurements Meter Meter Positive Meter Negative Component Desired Indication Scale (+) Test Lead (-) Test Lead CONTACTOR COILS (resistance Indication) Line, Bypass 90 to 110 ohms Directional, Regen 60 to 80 ohms H2 / HP Technical Speciﬁcations Motor Types : ....................DC Series Traction + DC Series Pump Power ratings : Traction .............................13.5kW Pump ............................11.0kW Supply Voltage : ..............................
Page 7: Mosfet Connections
MOSFET Connections 1. Gate 2. Drain 3. Source MOSFET Measurements SPECIFICATIONS Multimeter Setting (+) Test Lead (-) Test Lead Results Resistance Gate Source Over 20 Mohms Resistance Gate Drain Over 20 Mohms Resistance Drain Source Over 20 Mohms Resistance Drain Gate Over 20 Mohms Resistance...
Page 8: Console
Display Layout Console Instrument Panel (1) Tighten bolts that fasten the cover to a torque of ....... 1.5 to 2.5 N • m (13 to 22 lb • in) Direction Switch (1) Tighten screws that fasten the instrument panel to a torque of ........
Page 9: Contactor
Thermal Senders - Control Panel Thermal protection at......80 °C (176 °F ) Contactor Torque for nuts that hold contactor bridge assembly.........2.2 N • m (20 lb • in) Fuses Traction ..............675A Pump..............400A Key .................10A Horn ...............10A DC / DC Converter..........10A Light ...............10A Option light.............10A MicroController Control System...
Page 10: Control Panel (Layout)
Control Panel (Layout) (1) Use a backup wrench to hold bolts and tighten (4) Tighten screw that fasten the contactors to nuts the fasten bus bars and cables to a torque of backplate to a torque of ........4 to 6 N • m (36 to 54 lb • in) ........
Page 11: Glossary
Systems Operation Glossary NAME DESCRIPTION Accelerator A device that converts mechanical movement into a analog voltage pattern to the logics for variable drive motor speed. Activate Word used with a component or circuit. To change from the normal condition to the “activated” condition because of an application of force or electricity. Ammeter An electric meter used to measure current ﬂow in amperes.
Page 12 NAME DESCRIPTION Continuity Having the ability to allow current ﬂow. Control Circuits The wires and components carrying low current used to signal the logic unit, turn on main components, or support auxiliary circuits (indicated by narrow lines on a schmatic). Counter Electromotive An opposing voltage set up by a collapsing or increasing magnetic ﬁeld Force (CEMF)
Page 13 NAME DESCRIPTION Logics or Logic Unit The main printed circuit board containing a microprocessor and circuits to condition the voltage signals that go into or come out of the logics. It electronically monitors and controls the truck's functions. Magnetic Field The area around a magnet where magnetic forces can be detected.
Page 14 NAME DESCRIPTION Semiconductor Components such as, transistors, diodes, thyristors, etc. Having electrical characteristics between a conductor and an insulator. Series Wound Motor A motor in which the armature is connected in series with the ﬁeld windings. Short Circuit An electrical connection between two or more components that is not desired.
Page 15: Symbol Library
Symbol Library ARM. P10-10 Schematic Symbols (1) MOSFET (2) Shunt (3) Thermal Sender (4) Thermal Switch (5) Battery (6) Resistor (7) Diode (8) Normally Closed Contacts (9) Normally Open Contacts (10) Armature (11) Male Terminal of Connector(Pin) (12) Female Terminal of Connector(Socket) (13) Wire Connection (14) No Wire Connection (15) Contactor Coil (16) Field Windings (17) Capacitor (18) Fuse (19)Switch MicroController Control System System Operation...
Page 16: Location Of Control Panel Components
Location of Control Panel Components < DRIVE > MicroController Control Panel (1) Controller-drive (2) Logic card(Logics) (3) Line Contactor (4) Directional Contactor (5) Regen. Contactor (6) Bypass Contactor (7) Drive Fuse (8) Key Fuse < PUMP > MicroController Control Panel (1) Controller-pump (2) Logic card(Logics) (3) Pump Fuse MicroController Control System System Operation...
Page 17: General Information
General Information The speed of the hydraulic pump motor is controlled by voltage and switch inputs to and outputs from the logics. Outputs pulses the hydraulic pump MOSFET The MicroControl Panel is the control center and the The MOSFET pulse to control the speed of the Logic Unit (logics) is the decision making part of the hydraulic pump motor.
Page 18: Operational Circuit Elements
Operational Circuit Elements On Board “Run Time” Diagnostics (Fault Detection) Central Vehicle Monitoring System “Run Time” diagnostics use letters and numbers on The Central Vehicle Monitoring System (CVMS) is the seven segment LCD portion of the CVMS, located on the steering console. International Pictorial Symbols and LCD to signal It is a self contained, solidstate instrument panel both improper operating sequences and truck...
Page 19 Display = “Ec” Pump Controller Over Temperature Display = “F0” Overcurrent in Drive System The pump logic monitors the temperature of the pump The logics monitors the drive motor current via the controller. If the controller overheat(85°C), the logic shunt and compares the amount of current measured will slow lifting speeds and “Ec”...
Page 20: Cvms International Pictorial Symbols
Display = “FA” Regen Contactor Failure(Closed) Central Vehicle Monitoring System (CVMS) International Pictorial Symbols If the Regen contactor is not opened in running, “FA” will appear on the LCD, and all contactors will not be operated. Park Brake Symbol Display = “Fb” Battery Mismatch If the battery voltage is lower than 40 volts or higer than 60 volts, the logic will deactivate the Regen contactor and an “Fb”...
Page 21: Chat (Wait) Mode
Chat(Wait) Mode Drive Motor Overtemperature Symbol If the seat switch is closed, key turned to ON and the direction lever is left in neutral with no other operator requests, the line contactor will deactivate after approximately six seconds. The LCD will display “PP”.
Page 22: Battery Discharge Indicator (Bdi)
Battery Discharge Indicator(BDI) The logics monitors the battery voltage during truck BAR SYMBOLS BATTERY TERMINAL operation and shows the level of battery charge on DISPLAY VOLTAGE the LCD. If the battery voltage is below 40.0V or ABOVE 49.1V above 60.0V, this is a battery mismatch or 48.4V ~ 49.1V misconnection.
Page 23: Accessory Circuits
Accessory Circuits Horn Circuit The 12 volt output of the converter is protected The horn will operate when the battery is connected against short circuits and overloading by an and the horn button is pushed. Current ﬂows from internal 15 amp current limit circuit. A fuse on the battery positive through horn fuse, horn switch and converter protects it from reverse connection of the horn, back to battery negative.
Page 24: Description Of Connectors
Description of Connectors DRIVE CONTROLLER FUNCTION DESCRIPTION NORMAL VOLT DA-1 -LED ALARM LED NEGATIVE DA-2 +LED ALARM LED POSITIVE DB-1 PCLRXD SERIAL RECEPTION POSITIVE HIGH/LOW DB-2 NCLRXD SERIAL RECEPTION NEGATIVE HIGH/LOW DB-3 PCLTXD SERIAL TRANSMISSION POSITIVE HIGH/LOW DB-4 NCLTXD SERIAL TRANSMISSION NEGATIVE HIGH/LOW DB-5 GND CONSOLE SUPPLY NEGATIVE...
Page 25 PUMP CONTROLLER FUNCTION DESCRIPTION NORMAL VOLT PA-1 LOAD OF DISPLAY OUTPUT FOR INSTRUMENT(LOAD) HIGH/LOW PA-2 PB-1 PCLRXD SERIAL RECEPTION POSITIVE HIGH/LOW PB-2 NCLRXD SERIAL RECEPTION NEGATIVE HIGH/LOW PB-3 PCLTXD SERIAL TRANSMISSION POSITIVE HIGH/LOW PB-4 NCLTXD SERIAL TRANSMISSION NEGATIVE HIGH/LOW PB-5 GND CONSOLE SUPPLY OR INSTRUMENT NEGATIVE PB-6 +12V CONSOLE SUPPLY OR INSTRUMENT POSITIVE...
Page 26: Actuation Circuit
Actuation Circuit Actuation Circuit NOTE : The circuit diagrams have shaded lines for closed, current ﬂows from battery positive through illustration of current ﬂow in each circuit. the key fuse, key switch, wire #5 to the logic connector Other circuits can be activated at the same DD-1, and through the line contactor coil to battery time, but each one is shown separately to negative, then the line contactor will be closed.
Page 27: Hydraulic Pump Circuit
through 5 shield wires(RD, WH, GN, YL, BK). Hydraulic Pump Circuit The logics will start to perform a set of “Run Time” Only one hydraulic pump motor (series winding) is diagnostic checks. The letter “EE” will ﬂash on the used for all power steering, lift, tilt and auxiliary CVMS display indicating the key is ON with no hydraulic functions.
Page 28: Lift Circuit
Control Circuit Lift Circuit If the steering wheel is turned, hydraulic pressure When the lift lever is pulled, the logics will pulse the increases and then current increase too. pump MOSFET TP. When this change is present the logics knows that more hydraulic ﬂow is required and will supply more If the lift lever is pulled, the logic increase the pulse higher pulse ratio to TP.
Page 29: Power Circuit
Power Circuit TP Gate Input Signal After the line contactor is closed the logic generates a positive pulsing signal to the gate of TP MOSFET. This is a rapidly changing signal that can only be viewed on an oscilloscope. Because TP is N type MOSFET, the positive signal into the gate causes current ﬂow through the drain/source junction.
Page 30: Flyback Cicrcuit
Flyback Circuit Flyback Circuit DP is a ﬂyback diode for the power steering and hydraulic motor circuit. This circuit uses the current created by the collapsing magnetic ﬁeld of the ﬁeld wingdings in the pump motor to keep current ﬂowing when MOSFET TP is OFF.
Page 31: Lift Control Circuit
Lift Control Circuit Location of Components (1) Valve control card. This control panel accept a analog lift control signals When the operator pulls the lift lever, magnet (3) and tilt/aux lever signals. The analog voltage is moves closer to the lift sensor (2). The sensor controlled by valve control card (1) mounted at the top detects the increasing magnetic ﬁeld and sends an of the control valve.
Page 32: Drive Circuit
Drive Circuit Control Circuit Drive Control Circuit NOTE: The circuit diagrams have shaded lines for Selecting a direction will change the voltage from illustration of current ﬂow in each circuit. 0V to 48V on DE-3 for forward or DE-6 for reverse. Depressing the accelerator pedal will cause the With the actuation circuit complete the logics accelerator analog voltage on DC-1.
Page 33: Power Circuit
Power Circuit Drive MOSFET Gate Input Signals NOTE: The circuit diagrams have shaded lines for switch and line contactor must be closed ﬁrst. illustration of current ﬂow in each circuit. The logic generates a positive pulsing voltage to the Other circuits can be activated at the same gates of TD MOSFET.
Page 34 The percent “on-time” of the voltage at gate of TA is also the percent "on-time" of the MOSFET TA. As the “on-time” increases, the average voltage applied to the drive motor increases which increases the speed of the lift truck. The percent “on-time”...
Page 35: Flyback Cicrcuit
Flyback Circuit Flyback Circuit When the drive MOSFET TD is ON, battery current Because of this, the average drive motor armature ﬂows through the armature windings of the drive motor current will be greater than the average battery and a magnetic ﬁeld is created around the windings. current.
Page 36: Current Limit
Average Current Flow Current Limit The logics monitors the current that ﬂows through through the shunt and will increase or decrease as each 3 circuits and limit this current ﬂow to a preset current changes. The logics uses this voltage to value.
Page 37: Bypass Circuit
Bypass Circuit Bypass Circuit Activated The bypass circuit bypasses TD and connects the drive motor in series with the battery, applying full battery voltage to the drive motor. If the accelerator pedal is fully depressed, and the logics has pulsed TD through 95% “on-time”, the logic will activated the BYPASS contactor after 1.5 sec.
Page 38: Electrical Braking (Regenerative And Plugging)
Electrical Braking (Regenerative and Plugging) Electrical Braking Regenerative Circuit Electrical braking permits the lift truck operator to through the battery. This system has much better slow, stop and change the direction of travel characteristics than previous “plugging only” electrically without using the service brake. This systems.
Page 39 keeping the accelerator depressed. The logic will the armature generates it’s own current. The generated deactivate the regen and bypass contactor (if activated), current ﬂows from the armature through the direction and change the direction contactor to the new direction contactor tips, shunt, motor ﬁeld, TD, regen contactor, selected.
Page 40 combined ﬂyback and generated current decreases, the logics will turn ON the MOSFET TD and the cycle starts again. When the speed of the truck slows, the drive motor is no longer turning fast enough to generate enough current to charge the battery. The logics monitors this condition through the shunt.
Page 41: Thermal Protection Circuits
Thermal Protection Circuits Control Panel Hydraulic Pump Motor If the MOSFETs overheat, a thermal senders If the hydraulic pump motor overheats a thermal mounted in the MOSFET heatsink will give a voltage switch mounted in the pump motor housing will signal to logic.
Page 42: Testing And Adjusting
Testing And Adjusting Troubleshooting NOTICE Damage can be caused to the control panel. Do not The following Troubleshooting Check List is an aid in switch the direction lever from one direction to the troubleshooting MicroController lift trucks. The other (plug the lift truck) when the drive wheels are troubleshooting check list, “Run Time”...
Page 43 Battery Load Test Cell Voltage Test 1. Turn the range switch on the multimeter to read With the truck powered up and the pump(Idle) motor battery voltage. running, measure the voltage at each cell. Normal voltage should be between 1.95V and 2.12V per 2.
Page 44 3. Charge the battery correctly. A battery should be 3. Visually check the parking brake switch, the discharged to 80% of its capacity then fully hydraulic switches and accelerator linkage for recharged. It should cool four to eight hours to adjustment or interference problems.
Page 45 Quick Diagnostics Mode This will enable Quick Diagnostics of some of the components without console and access to controller room. Procedure 1. Initial set - Seat switch : Open - Directional switch : Forward - Handbrake : Released - Accelerator : Depressed to above half position. 2.
Page 46: Control And Power System Operation Checks
Control and Power System Operational Checks All operational checks are to begin with the Check 5: Reverse Drive Performance battery connected, directional switch in neutral, drive wheels off the ground and the accelerator 1. Select reverse direction and depress the and parking brake released.
Page 47: Alarm Displayed On The Console & Instrument Panel
Alarm Displayed on The Console & Instrument Panel DISPLAY STATUS CONSOLE ALARM MESSAGE System normal operation No Display - Fuse blow-out After all display BRAKE CONT OPEN - Regen. contactor is not operated (two times) Wait(chat) mode (after hyd. Time without any operation in neutral) Drive motor brush is worn.
Page 48: Analysis Of Alarms Displayed On The Console
LED Diagnosis for Drive controller Analysis of Alarms Displaged on the Console Description of the alarms signalled by the diagnostic Drive controller LED. The alarm code is shown in parentheses. A detailed description is given in the next section 1) BRAKE CON CLOSED Test carried out in the passage from running to 1 BLINK = Logic anomaly (EEPROM DATA KO, initial regenerative braking.
Page 49 It may be due to 1 of following causes of motor A4) There is not a good contact on the NO of connecting interruption: REGEN CTR, clean the contact, if it is too a) brushes lift up from collector (ﬁg.1). much damaged replace the contactor.
Page 50 C5) The most probably reason is that the failure is 10) INCORRECT START inside the controller, replace it. An incorrect starting sequence. E1) If there's the bypass contactor check that it is The machine only starts if sequence is followed : not stuck or it is too much slow in opening.
Page 51 15) EEPROM PAR.KO b) Short circuit with +BATT of the wiring that comes from the contactor connector. Fault in the area of memory in which the The alarm indicates the occurrence of an adjustment parameters are stored. This alarm overload, not the breakdown of a chopper inhibits machine operation.
Page 52 5) INCORRECTSTART 11) EEPROM OFF LINE A running request is present on key startup. Fault in the non-volatile memory that contains Possible causes: data relative to the area for the hour-meter, the a) Operator error. alarms stored and the programming parameters. b) Request microswitch stuck.
Page 53 Troubleshooting Problem List TROUBLESHOOTING PROBLEM LIST Problem # CENTRAL VEHICLE MONITORING SYSTEM (CVMS) PROBLEMS CVMS does not work, with no lift truck operation. CVMS does not work at all, lift truck operation normal. Display portion of CVMS seems random or wrong. Lift truck operation normal.
Page 54 TROUBLESHOOTING PROBLEM LIST Problem # FAILURE CODE PROBLEMS Display = “F0”, no lift truck operation Display = “F1”, no drive operation, pump and steering operation normal Display = “F2” no lift truck operation Display = “F3”, no lift truck operation Display = “F4”, no lift truck operation.
Page 55 PROBLEM 1 Central Vehicle Monitoring System (CVMS) does not work, with no lift truck operation. POSSIBLE CAUSE Battery polarity not correct on control panel; Key fuse open circuit; Key switch defect; Logics defect. CHECKS With battery connected, check control panel battery connections for correct polarity. Positive battery connected to line fuse and negative battery connected to B - on controller.
Page 56 PROBLEM 2 CVMS does not work at all, lift truck operation normal. If only part of CVMS works. POSSIBLE CAUSE Open circuit from PB-6 to CVMS connector PIN 1; Open circuit from PB-5 to CVMS connector PIN 5; CVMS defect. CHECKS Make sure CVMS connector is connected to CVMS.
Page 57 PROBLEM 3 Display portion of the CVMS seems random or wrong. Lift truck operation normal. POSSIBLE CAUSE Connection defect; Wiring defect; Logics defect; Display defect. CHECKS Check continuity from logics to CVMS connector (wire RD / WH / GN / YL / BK). Continuity No continuity Check for shorts to battery negative from...
Page 58 PROBLEM 4 Display all symbols two times when the drection lever is selected and accelerator is depressed and then blank, no lift truck drive or pump motor operation. POSSIBLE CAUSE Line contactor defect; Drive fuse open circuit; Regen contactor defect;Logics defect. CHECKS Does the line contactor close and remain closed ? See Problem 15.
Page 59 PROBLEM 5 Display = “F”, no lift truck operation. POSSIBLE CAUSE Wiring defect; Logics defect. CHECKS With the key on, check the voltage at logic DD-1, wire #5. Battery voltage No voltage Check continuity from control panel battery Repair or replace open wire. negative to battery negative.
Page 60 PROBLEM 6 Display = “A3” and “ accelerator symbols”, no lift truck operation. POSSIBLE CAUSE The truck goes into Quick Diagnostic. CHECKS Release the accelerator pedal and move direction switch to neutral. Key switch off and on. Still problem Normal Check voltage from logic DE-3 to battery negative.
Page 61 PROBLEM 7 Seat switch circuit defect. POSSIBLE CAUSE Seat switch defect; Wiring to seat defect; Logics defect. CHECKS Disconnect the battery. Disconnect DD or DE connector. Check continuity from DD-2 harness connector to DE-4. Should be closed circuit when seat is pressed on and open circuit when seat is released. No continuity Constant continuity Check OK...
Page 62 PROBLEM 8 Direction switch circuit defect. POSSIBLE CAUSE Direction switch defect; Wiring to direction switch defect; Logics defect.. CHECKS Disconnect the battery. Disconnect DD or DE connector. Check continuity from DD-2 to DE-3 harness connector; With direction lever in forward should have a closed circuit, in neutral should be open.
Page 63 PROBLEM 9 Lift sensor circuit defect. POSSIBLE CAUSE Lift sensor not adjusted properly or defective; Lift sensor wiring defect; Valve control card (board) defect; Logics defect. CHECKS Retest lift sensor circuit in quick diagnostics. Circuit passes Circuit fails “Quick-Diagnostics” “Quick-Diagnostics” Perform Problem 11,12 Tilt or Key switch ON.
Page 64 PROBLEM 10 Tilt switch circuit defect. POSSIBLE CAUSE Tilt switch defect; Wiring defect; Logics defect. CHECKS Disconnect PD or PE connector. Pull tilt lever to maximum. Check continuity from PD-2 to PE-5. Continuity No continuity Replace logics. Check continuity of wire #89. Continuity No continuity Check continuity from PD-2 of wire #44 to Pin1 of...
Page 65 PROBLEM 11 Auxiliary switch circuit defect. POSSIBLE CAUSE Wiring defect; Auxiliary switch defect; Logics defect. CHECKS Disconnect PD or PE connector. Pull auxiliary lever to maximum. Check continuity from PD-2 to PE-2 or PE-3. Continuity No continuity Replace logics. Check continuity of wire #88 or #87. Continuity No continuity Check continuity from PD-2 of wire #44 to Pin1 of...
Page 66 PROBLEM 12 Park brake switch circuit defect. POSSIBLE CAUSE Wiring defect; Park brake switch defect; Logics defect. CHECKS Disconnect DD or DE connector. Release park brake lever. Check continuity from DD-2 to DE-1. Continuity No continuity Replace logics. Check continuity of wire #71. Continuity No continuity Check continuity from DD-2 of wire #4 to...
Page 67 PROBLEM 13 Pedal brake switch circuit defect. POSSIBLE CAUSE Wiring defect; Pedal brake switch defect; Logics defect. CHECKS Disconnect DD or DE connector. Push down the brake pedal. Check continuity from DD-2 to DE-5. Continuity No continuity Replace logics. Check continuity of wire #70. Continuity No continuity Check continuity from DD-2 of wire #4 to...
Page 68 PROBLEM 14 Accelerator circuit defect. POSSIBLE CAUSE Wiring defect; Accelerator defect; Logics defect. CHECKS With the key switch on, the seat switch closed, park brake released and connect multimeter positive lead to DC-3, negative lead to DC-2. Measure the voltage. 8~12 volts Other voltage Connect multimeter positive lead to DC-1,...
Page 69 PROBLEM 15 Incorrect line contactor operation. POSSIBLE CAUSE Wiring defect; Line contactor defect; Logics defect. Disconnect the battery. Check for free mechanical movement of contactor tips Movement OK Movement not free Connect the battery. Key switch ON. Replace contactor. Measure voltage between coil terminal X and Y.
Page 70 PROBLEM 16 Display = “EE”, no lift truck drive operation. POSSIBLE CAUSE Static Return to Off (SRO) circuit activated by improper operation sequence; Direction switch defect; Accelerator linkage not fully released; Accelerator control defect; Logics defect. CHECKS Check for SRO by release of accelerator, release park brake, move the direction lever to neutral, reselect direction and press the accelerator.
Page 71 PROBLEM 17 Display = “EE” (Flashing), no lift truck drive operation. POSSIBLE CAUSE No opterator in seat; Seat switch defect; Open wiring; Logics defect. CHECKS See Problem 7, seat switch circuit defect. MicroController Control System Troubleshooting...
Page 72 PROBLEM 18 Display = “E1” lift truck operation normal. POSSIBLE CAUSE Worn brushes; Short wiring; Display defect. CHECKS Disconnect the respective wire from the motor. Wire #31 for drive motor or wire #72 for pump motor. Connect the battery and close the key switch and seat switch.
Page 73: Pump
PROBLEM 19 Overtemperature is ON and Display = and EC or Ec. Lift truck accelerates slower than normal or lifting speed is slower than normal. Power steering operation normal. POSSIBLE CAUSE Control panel overheated; Control thermostat (thermal senders) defect; Logics defect. CHECKS Let the truck cool for 15 minutes.
Page 74 PROBLEM 20 Overtemperature is ON and Display = and Ed. Pump and power steering operation normal. Acceleration slow. POSSIBLE CAUSE Drive motor overheated; Drive motor thermostat (thermal switch) defect; Open wiring; Display defect; Logics defect. CHECKS Let the truck cool for 15 minutes. Overtemperature indicator ON Normal display Disconnect the battery.
Page 75 PROBLEM 21 Overtemperature is ON and Display = and EP. Lifting performance slow. Drive and power steering operation normal. POSSIBLE CAUSE Pump motor overheated; Pump motor thermostat (thermal switch) defect; Open wiring; Display defect; Logics defect. CHECKS Let the truck cool for 15 minutes. Overtemperature indicator ON Normal display Disconnect the battery.
Page 76 PROBLEM 22 Display = “EL”. No hydraulic (lift and tilt). Steering normal. Battery discharge indicator (BDI) circuit defect. POSSIBLE CAUSE Battery discharged or has a defect; Logics defect. CHECKS Connect battery, turn on key switch, close seat switch and measure voltage from BATT+ to BATT- on controller.
Page 77: Key
PROBLEM 23 Hourmeter does not work. POSSIBLE CAUSE Key switch and seat switch ON. The hourmeter requires battery voltage to run. Measure voltage at hourmeter to ensure that it is battery voltage. No voltage Battery voltage Check continuity from seat switch to Replace hourmeter.
Page 78 PROBLEM 24 Normal hydraulic operations, display is normal and drive current limit is half. POSSIBLE CAUSE Pedal brake switch shorted. Check continuity from DD-2 to DE-1. Continuity No continuity Disconnect wire from pedal switch. Replace logics. Check pedal brake switch. Shorted Replace switch.
Page 79 PROBLEM 25 Drive motor does not operate or operates with low power or is erratic. Pump and power steering systems operation normal. POSSIBLE CAUSE Accelerator defect; Direction control circuit defect ; Current limit set too low; Wiring defect ; Logics defect. CHECKS Perform Quick-diagnostics.
Page 80: Horn
PROBLEM 26 Horn does not function correctly. Lift and drive operation normal. POSSIBLE CAUSE Open fuse; Faulty wiring; Defective horn switch; Horn defect. CHECKS With the faulty horn circuit activated, check for voltage on the load side of the horn fuse. Battery voltage No voltage Check for voltage on the load side of...
Page 81 PROBLEM 27 Auxiliary lighting and/or alarm does not function correctly. Lift and drive operation normal. POSSIBLE CAUSE Open fuse; Faulty wiring; Defective switch; Shorted load; Open load; Loss of input voltage to DC-DC converter; Defective DC-DC converter. CHECKS Connect the battery and close the key switch. Measure from the DC-DC converter 12V positive terminal to the 12V negative terminal.
Page 82: Dc-Dc Converter
Problem 27 (continued) No voltage output. Measure the voltage from (POS INPUT) to (NEG INPUT). Battery voltage 0 volt Replace the DC-DC converter. Measure the voltage from the B+ cable at the line contactor to the (NEG INPUT) terminal of the DC-DC converter. Battery voltage 0 volt Check for open fuse or wiring between the line...
Page 83 Problem 27 (continued) Voltage bellow 11 volts. Measure the voltage from the (+IN) terminal to (-IN) terminal of the DC-DC converter. 28.8 volts or above Below 28.7 volts Remove all connections at the (+OUT) and (-OUT) Check the battery and DC-DC converter terminals of the DC-DC converter.
Page 84 PROBLEM 28 Display = “F0”, no lift truck operation. POSSIBLE CAUSE Excessive drive motor currents due to pushing or ramp application. Failed drive motor. Failed logics. Weak or discharged battery. CHECKS Measure the maximum drive current at A2 cable in stall condition.
Page 85 PROBLEM 29 Display = “F1”, no lift truck operation. POSSIBLE CAUSE Accelerator circuit defect; Logics defect. CHECKS Key to ON, close seat switch, release park brake and accelerator, direction lever to neutral. Display should show battery charge. Place in forward, and depress accelerator.
Page 86 PROBLEM 30 Display = “F2”, no lift truck operation. POSSIBLE CAUSE Opened the motor cable (A1, A2, S1, S2). Opened the armature coil or ﬁeld coil in drive motor. Contactor failure. Shorted MOSFET TD in Drive Module. CHECKS Check conditions under which faults is detected. Running with As soon as the accelerator pedal contactors on running...
Page 87 PROBLEM 31 Display = “F3”, no lift truck operation. POSSIBLE CAUSE Pump fuse open. Shorted MOSFET TP in Pump Module.; Open the pump motor cable (P1, P2) during the operation. Open the armature coil or the ﬁeld coil in pump motor during operation.
Page 88 PROBLEM 32 Display = “F4”, no lift truck operation. POSSIBLE CAUSE Shorted MOSFET TD in Drive Module and MOSFET TP in Pump Module. CHECKS See Problems 30 and 31, Display = “F2” and “F3”. Do both procedures. MicroController Control System Troubleshooting...
Page 89 PROBLEM 33 Display = “F5”, no lift truck operation. POSSIBLE CAUSE Opened the MOSFET TD in Drive controller; Frame voltage on S1 or S2 drive motor cable. CHECKS Disconnect the battery, and disconnect the S1, S2 cables from the drive controller and measure the voltage of S1 terminal. Frame Voltage Replace the drive controller.
Page 90 PROBLEM 34 Display = “F6”, no lift truck operation. POSSIBLE CAUSE Opened the P1, P2 cables when the key switch turn to on. Opened the MOSFET TP in Pump Module; Opened armature or ﬁeld coil in pump motor when the key key switch turn to on.
Page 91 PROBLEM 35 Display = “F7”, no lift truck operation, line contactor closes and opens. POSSIBLE CAUSE Failure in both the drive and pump circuits. CHECKS See Problem 33 and 34, Display = “F5” and Display = “F6”. Do both procedures. MicroController Control System Troubleshooting...
Page 92 PROBLEM 36 Display = “FA”, no lift truck operation. POSSIBLE CAUSE Welded regen contactor tips ; Shorted wire #15 to negative ; Logics defect. CHECKS Disconnect the battery, check regen contactor for welded tips. Check contactor for free tip movement. Not welded Welded Check for a short of wire #15 to negative.
Page 93 PROBLEM 37 Display = “Fb”, no lift truck operation. POSSIBLE CAUSE Battery defect; Logics defect. CHECKS Disconnect battery, measure voltage at battery connector terminal. Voltage must be higher than 40 volts or lower than 60 volts. Voltage OK Wrong voltage With key on, seat switch and line contactor Check battery connections;...
Page 94 PROBLEM 38 Display = “Fc”, no lift truck operation. POSSIBLE CAUSE Direction contactor defect; Drive motor defect; Power connection defect; Faulty of contactor coil wire; Logic defect ; CHECKS Check conditions under which fault is detected. Only at forward Only at reverse at both running running request running request...
Page 95 E) Reverse contactor is supplied with a correct voltage but it doesn't close : everything said at point D) for forward contactor is valid here. F) Reverse and forward contactor are supplied with a correct voltage but they doesn’t close ; See point D). G) Supply don’t come up to forward contactor, please check cabling and connections from forward contactor coil to connectors X and Y.
Page 96 PROBLEM 39 Display = “FL”, no hydraulic operation, but drive operation and steering is normal. POSSIBLE CAUSE Valve control card defect ; wiring defect ; Logics defect. CHECKS Key switch ON. Seat switch ON. Measure voltage at PC-1. Over than 0.1V No voltage Adjust the value control card.(P113) Replace logics.
Page 97 System Tests and Adjustments Potentiometer Adjustment Tool -Trimmer Available from most electronic suppliers, this Test Equipment insulated tool allows for fast and easy adjustments of potentiometers. Hydrometer Hydrometers are usually available from any battery supplier. Battery maintenance is a crucial part of maintaining the electric vehicle.
Page 98 Logics Removal 4. Loosen 6 screws (8) that hold logic cover. WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.
Page 99 4. Remove the controller ass’y. 5. Loosen 4 screws (6) that hold logic cover and remove the side cover (7) & connector PG (8). 6. Remove the plate (9). 7. Remove logics to right. MicroController Control System Testing And Adjusting...
Page 100 “Run Time” Tests Static Return to off (SRO), Display = “EE” WARNING 1. Connect the battery and sit on the seat. Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and 2. Select a direction before turning key to ON. discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.
Page 101: Component Tests
Component Tests Conductor and Switch Continuity 1. Set the multimeter to the 200 Ω range. WARNING 2. Use the multimeter to perform the continuity test. lf continuity exists, the measurement will be less Battery voltage and high amperage are present. than 1 ohm.
Page 102: Contactor
Contactor Coil Resistance WARNING 2. Disconnect all leads to both terminals of the coil. The lift truck can move suddenly. Injury to 3. Set the multimeter to the 200 Ω range. personnel or damage to the lift truck is possible. Safely lift the drive wheels off the ﬂoor.
Page 103 Electrical System Adjustments Parking Brake Switch Accelerator Control Linkage Method A (Mechanical) WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Safely lift the drive wheels off the ﬂoor. Put blocks of wood under the frame so both drive wheels are free to turn.
Page 104 Lift Sensor Valve Control Card Adjustment 1. Disconnect the battery and discharge the head capacitor. WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Safety lift the drive wheels off the ﬂoor. Put blocks of wood under the frame so both drive wheels are free to turn.
Page 105 8. Pull the lift lever all the way back. A “10” must be Tilt and Auxiliary Switch Adjustment displayed. Because each tilt and auxiliary switch can turn on the 9. If a “10” is not displayed, adjust P2 (2) clockwise pump motor, it is recommended that only one be until it is.
Page 106: Digital Console
Digital Console CONSOLE CONNECTOR DISPLAY A284220 1 PARM. 2 TESTER 3 SAVE 4 RESTORE I MOX V.POT TEMP V.BATT 5 ALARMS V.MOT VMN.MOT M.SW.TEST 6 ACCELERATOR 7 MOTOR DATA ROLL ENTER PARAM. BUTTONS ROLL MicroController Control System Testing And Adjusting...
Page 107: Using Digital Console
Using Digital Console VIEW A CONNECTOR B VIEW A <Pump controller (A174950)> <Drive controller (A174900)> 1. Key switch off. 1. Key switch off. 2. Open the rear controller room door. 2. Open the side controller room door. 3. Remove the connector DB of Harness As. 3.
Page 108: Description Of Standard Console Menu
Description of Standard Console Menu <DRIVE CONTROLLER> HEADING MAIN MENU CONFIG. MENU PARAMERER ACCELER. DELAY 0 ~ 9 CHANGE INVERS BRAKING 0 ~ 9 MODEL TYPE REGENERATIVE TR. SET MODEL RELEASE BRAKING 0 ~ 9 / NONE / PEDAL BRAKING 0 ~ 9 STANDARD PUMP / BREAKING...
Page 109 <PUMP CONTROLLER> HEADING MAIN MENU CONFIG. MENU PARAMERER ACCELER. DELAY 0 ~ 9 CHANGE DECELER. DELAY 0 ~ 9 MODEL STANDARD PUMP / EV. ACCELER. DEL 0 ~ 9 SET MODEL PUMP + HYDRO EV. DECELER. DEL 0 ~ 9 HYD SPEED COARSE 0 ~ 9 HYD SPEED FINE...
Page 110: Description Of Set Options Functions
Description of SET OPTIONS Functions The options can be set on the “SET OPTIONS” Menu. Function Option Meaning 1. HOUR COUNTER RUNNING Hour meter enabled when running. KEY ON Hour meter enabled when the key is on. 2. BATTERY CHECK Battery voltage check activated on stand by.
Page 111 Description of SET OPTIONS Functions <DRIVE CONTROLLER> Function Option Meaning BYPASS Bypass contactor adopted. 1. BYPASS CONTACTOR WEAKENING NOT AVAILABLE 2. SPEED CONTROL NOT AVAILABLE Activates the check that reads the battery voltage in standby. When the residual charge is less than 10%, the maximum 3.
Page 112: Adjustments : Set Battery Type
ADJUSTMENTS : SET BATTERY TYPE (Drive and Pump Controller) Using this function it is possible store the nominal value of the battery. How to execute SET BETTERY TYPE with the console. DISPLAY P.STD DHX.XX 1. Opening HEADING. 600A XXXXXX KEYBOARD 2.
Page 113: Adjustments : Adjust Battery
ADJUSTMENTS : ADJUST BATTERY (Drive and Pump Controller) Using this function it is possible to calibrate the internal voltmeter to a ﬁne level. lt is necessary to input the battery voltage value after measurement using an external calibrated digital voltmeter. Procedure showing how to carry out ADJUST BATTERY operation by console.
Page 114: Description Of Program Vacc Function
Description of PROGRAM VACC Function (Drive and Pump) This function looks for and remembers the minimum and maximum accelerator output voltage over the full mechanical range of the pedal or lift lever. It enables compensation for non symmetry of the mechanical system. The operation is performed by operating the pedal or lift lever after entering the PROGRAM VACC function.
Page 115: Description Of Tester Functions
Description of TESTER Functions 13. HANDLE/SEAT SW. = the level of the Seat microswitch. ON/ +VB = active entry of the Seat microswitch. The most important input or output signals can be OFF/ GND = non active entry of the Seat measured in real time using the TESTER function of microswitch.
Page 116: How To Use The Tester Functions
How to use the TESTER Functions Flow Chart showing how to use the TESTER function of the Digital Console. 1. Opening HEADING. DISPLAY DHX.XX 600A XXXXXX 2. Press ENTER to go into the MAIN MENU. KEYBOARD 3. The Display will show : MAIN MENU PARAMETER CHANGE 4.
Page 117: Description Of Alarms Functions
Description of ALARMS Functions The microprocessor in the chopper remembers the last ﬁve Alarms that have occurred. Items remembered relative to each Alarm are : the code of the alarm, the number of times the particular Alarm occurred, the Hour Meter count, and the chopper temperature. This function permits deeper diagnosis of problems as the recent history can now be accessed.
Page 118: Description Of Save Param. Function
Description of SAVE PARAM. Function The SAVE PARAM. function allows the operator to transmit the Parameter values and Conﬁguration data of the chopper into the Console memory. It is possible to load 32 different programms. The information saved in the Console memory can then be reloaded into another chopper using the RESTORE function.
Page 119: Description Of Restore Param. Function
Description of RESTORE PARAM. Function The RESTORE PARAM. function allows transfer of the Console’s stored data into the memory of the chopper. This is achieved in a fast and easy way using the method previously used with the SAVE PARAM. function.
Page 120: Description Of Parameter Change Menu
Description of PARAMETER CHANGE 11. WEAK DROPOUT = threshold of current for opening the weakening contactor (if programmed Menu That may be Programmed as such and not as bypass, in which case the (PARAMETER CHANGE MENU) output threshold is ﬁxed and not programmable. 12.
Page 121 7. HYDRO COMPENS. = Compensation in current for hydrodrive request. 8. HYDRO TIME = Idle off delay. 9. SPEED LIMIT = Maximum pump speed. 10. 1ST SPEED CORSE = Tilt speed coarse. 11. 1ST SPEED FINE = Tilt speed ﬁne. 12.
Page 122: Parameter Settings
PARAMETER Settings < DRIVE CONTROLLER > PROGRAMMED LEVEL PARAMETERS UNIT ACCELER. DELAY 0.41 0.82 sec. INVERS BRAKING RELEASE BRAKING PEDAL BRAKING BRAKING BRAKING MODUL CURVE BRAKING CURVE TIME sec. CUT BACK SPEED 1 BATT COMPENSATION K(I) WEAK DROPOUT MAXIMUM CURRENT amp.
Page 123: How To Use The Parameter Change Menu
How to use the PARAMETER CHANGE Menu Flow Chart showing how to make Programme changes using Digital Console. 1. Opening HEADING. DISPLAY DHX.XX 600A XXXXXX 2. Press ENTER to go into the MAIN MENU. KEYBOARD 3. The Display will show : PARAMETER CHANGE. MAIN MENU PARAMETER CHANGE 4.

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