in CLARK Material Handling CTM/CEM 10-20 Lot No. 7096 / 7101 with HPB1 - Control Training Manual Electr. System incl. Trouble Shooting with LC-Display ‘9M 5167 GEF GB 02/97tustrations, descriptions, diagrams and other particular only serve for elucidation and presentation of the text. They are not binding as regards details of construction, in- Stallation oF delivery We do not undertake labily for conformity of the text with nato ‘or local regulations, Subject to revision Copyright(c) 1997 by CLARK Material Handling GmbH wo a ol | 4 ww te es aeTABLE OF CONTENTS ‘SECTION NAME 1 Introduction 2 Location of the components - subassombll Layoutof HPB1 contol system Layout of Bt contro! Gable Connections - Traction Control Bt Connectors Traction Control B1 Cable Connections ~ Pump Control HP Connectors Pump Control HP Exerpts from the spare parts catalogue General repair information Fault nding in the HPB1 control LC-Display unit (Dash Panel) Mantenance- and interference input Display operation Diagnostic and adjustments 4 .Diagnostic truck periphery 2.Diagnostic pulse control Steer whee! angle acjustment Parameterist Traction Control BY Parameterist Hydraulc-Pump Control ‘Trouble-shooting ‘Table faut node How to check the components General information ‘Annual safety check lemoval control card Motors Ineulation testing Curren: measurements ‘Thermal protector FIR contactor Fuses: Accelerator unit Sensor Wiring diagrams PAGE rr 2a 22 23 24 25 26 27 34 4a 42 43 45 a6 47 47 49 410 an 412 415 415 5a BA 52 53 84 55 56 56 587 87 57 59 6aIntroduction ‘Starting with 1995 the Ft trucks of the CTM/CEM 10-20 family wil be equipped and dolivered with new electronic controls (HPB1 & LT200D). These lit trucks have the new ‘Lot No. 7096/7101 ‘The respective control are located atthe rear-part of the lit truck, protected between battery and counterweight. They are directly accessible wth opening the cover. This manual describes an HPB1 microprocessor-control. ‘That means, that the internal operations will be controlled with an microprocessor. ‘The control of drive speed, hydraulic and torque ensues with transstor-technic. ‘The faut finding and also part of the maintenance and setting work may be done with Into the Dash Panel integrated LOD (iquid-crystal display). ‘The electronic components which are not part of the actual control unit itself should bbe also checked with the LC-Display. ‘The purpose of this manual is to enable service mechanics and other technically interested statt = to become familar with the controt's components, = to learn about the internal functional sequences, + to perform fault finding by using of the LC-Display and exchange the defective components. 1 the part numbers of the controle components, which are not listed in the parts catalogue.Location of the components - subassemblies Emergency swith tentmete Lit ) Hom sich HS io sich it AUK 1 and AUX 2 Koy swicn KS LeDsplay Mero atch fomaraF Maro swtcn reverse R 2 Handbrake switches HOS Brake ti evel awh LLS Accelerator ‘no. Mero awich MSt Hom Ine, suprastr code Brak pressure switch Pump motoring. sensor | | Panel with HERS conte atery | system ‘Seat teh SSW 2aLayout of HPB1 control systemLayout of B1 control Batiery connector 23Cable Connections - Traction Control B1 ' VMNR | @ B_|_ +SHR ra SSS as a | WNL +SHL. 24 |Connectors arrangements Traction Control B1 vwnr[_|TE (oom) se} ese) [recta ] [78 (8 term) vn raceteemy “Tacton Cont! e@wmf_]snn root) en TH 10m] ty @temy[_] sh. Towle e3| [> | fousut way col regen contactor Te8|| 0 | ouput Ube regen sortacior TE7|| 6 | ouput lay co toward oh ‘€6|| 0 | ouput relay co reward itt e5|| o | output relay cl toward right ‘TE¢|| o | [ouput relay col reward right 31] 0 | ouput cock Te2|| 6 | ouput Uae for reay cos 7e1| |e | linputysniten twa|fo 1o1]| 0 teal Po te2|} 0 te1|| 0 Tas] [| finpat clare cash boat activ T87]| o | estpcin SV iemal supey 786} | 0 | |ouput supp oto cour a5|| 0 |louraue- Te]! 0 1783|| o |loupaars ‘T22|| 0 | [inp RxD ‘81/6 | [input suply opto coupler Ta2| Fo | [ouput power stor roquost tai[Le 25 res ray ro rca} roa} ras roe 1¢7| ra rus re re most seat switch nt scclerator value loupu 12 louput ues to swiches int oot brake switch pt switch wars not switch orwars loupe data louputus- rout angle steerng po loupuesv recsCable Connections - Pump Control HP #@| +] 2) | IN, Sal ——————Pea ee| er| es es] ea| Pe Por Pod Pe Per Pos] er| as as| Pa Pas| ae ay aa| Pas| oof 4m) e[ po eter) wea ceterm Connectors Pump Control HP Pump-Contro! Pr Pc aterm) tem) 8 (term) Inout data requestrom action contol nput request testing input key switch UB out emane hycsutc Input Clark dash bard activ [restoin Sv (pian) jouw us- [output released asta for recon contol Input Mode-Signal(AXD) [oupus Mode Signal (RXD tacton contro Input sat switch Pe Pre| Pra PFs PFs PFs Joupurnour mater Josts rom tractor control [sas to sash board tock othe dash toars Cteck rom ractioncomto! 2728Exerpts from the spare parts catalogueELARK stein |ACCELERATOR PEDAL AND LINKAGE JBESCHLEUNIGUNGSPEDAL UND GESTAENGE PEDALE OACCELERATEUR ET TRINGLERIE PEDAL ACELERADOR V VARILLAJE OE ARTICULACION ex2.246 oeCLARK t=" [out POWER WIRING HAUPTSTROMKABEL |CABLE COURANT INOUCTEUR : [CABLE ELECTRICO PRINCIPAL e400 ow covucroncewe yee an nse neon gamma ny weCLARK, sizes tanaton Tea OECLARK t= re PoweR winiNa. HAUPTSTROMKABEL "ABLE COURANT INOUCTEUA, [CABLE ELECTRICO PRINCIPAL, suo gpitucroncee worn a) seme ERNE ae, recs SalCLARK ty"CLARK" ‘CONTROL WIRING KABELBAUM, BEDIENUNGSELEMENTE HARNAIS DE CABLAGE, TABLEAU D'NSTRUMENTS ‘TRONCO Dé CABLES, CONTROLES DE OPERACIONCLARK tines"? line conTacToR |RAUPTKONTAKTOR, [ENSEMBLE CONTACTEUR, (CONJUNTO CONTAGTOR PRINCIPAL e-72441 PRINCIPALCLARK sy ORIVE MOTOR CUT-OUT CONTROL [ANTFIEBSMOTOR-UNTERBTECHUNG |ARRIET MOT, TRACT. LIMITE ANGLE BRAQUAGE INTERRUPCION DEL MOTOR DE TRACCION. CONTROL PANELCLARK tsi" Eoawano ano aevens CONTACTOR IFAHRTRICHTUNGSSCHUETZ |CONTACTEUR DINVERSION [GONTAGTOR DE DIRECCION e174CLARK M223) S PUMP CONTROL PANEL PUMPEN-STEUERTAFEL [TABLEAU DE COMWANDE DE POMPE [TABLERO DE MANOO OE LA SOMBA ergoeeLARK 5)" = a! sso lcontmot paver IStevenTareL PANNEAU DE COMMANDE [TABLEO DE WANDO. evansCLARK Miia tanaten S.C. PANEL SCHALTTAFEL PANNEAU DE COMMANDE [TABLERO DE CONTROLGeneral repair information + Jack up the truck for any repair work. = Always disconnect the installation from the power supply before starting repair ‘work (Push the emergency. off switch and withdraw the battery plug). = Take off any rings, chains and bracelets before working on the electrical instalation, ‘Connect the battery ony, it this is required for checking purposes. Inspect the installation visually. Always remove any foreign matter (metal pieces) ‘rom the control unit = The interior of the housing (printed-creult board and power semiconductor) must be ary. + Caution when cleaning the truck by steam jet! Switch off the truck. Withdraw the battery plug = Do not clean the pulse control unit by steam jet, if avoidable; instead, use a brush and compressed air. 'a steam-jet cleaning has been unavoidable, its necessary to take the printed-circult board out of the housing and let It dry along with the installation. When using compressed air ensure that there are no metal parts (fings etc.) in the control area, as they may be drawn in by the blowout magnets of the relays and cause maifunctons. 4aFault finding in the HPB1 control Information on how to use the fauitlocating instructions 1. You realize that thore isa faut. 2. Ifthe information given by the customer corresponds with your own checking results, follow the inspection and test procedure described in the respecive section, {3 It the information given by the customer does not correspond with the results of your own checking, you should in any case talk once more with the operetor before trying to locate the faut 4, It you have ditfcutis in cleary Identitying the components, take another look at the corresponiing components in the section "Exerpts from the spare parts cata- logue or in the circuit diagrams ofthis manual It you believe to have found the fault by means of the LC-Display, check the ‘component acording to the description in section ‘Checking components® before ‘exchanging it Only if this checking confirms that the component is defective, ‘exchange i. '5. For troubleshooting on the contol unit itself only use the CLARK fault finding display, It will show you not only the current faults but also such faults as have occured ‘during operation (intermittent faults) but have ceased in the meantime, ‘With tho display it is also possible to measure the voltage rallo on the card and ‘check the setting of the major truck functions. Additionally some of the cortrol units performance data can be changed. Hf this is the fst time you work with the fault-ocating display or if you are not yet sufficiently familar with the device, the next page of this manual willbe of help to you. 6. For tests which can only be carried out under tension, before beginning work you must: jack up the truck connect the battery plug release the Emergency-Oft switch tum the key switch to "OI choose a diving direction depress the accelerator pedal while the parking brake is released and the seat switch is closed (umpered). 7. Itis of utmost importance that you will always - even if you are pressed for time = observe all appicable safety regulations when performing this work. 42LC Display Unit (instrument panel) The microprocessor-controlled display unit comprises the microprocessor, the overvoltage-protected inputs and oupuls, the iluminated display, a red 10 mm diameter LED, the input keys and 5 yellow LEDs arranged in a semicircular array. Veritication connection plug (PY BATTERY) SQNOROAN 1004) n “The functions ofthis unit can be divided into 5 groups. 1. Display ofthe current steer angle by ‘way of 5 yellow LEDs, 2. Display ofthe battery charge and status reports. 3, Facilty or dialog-based pparameterizing and fau analysis by Way of LC display and input keys. 4. Alaim signaling by way of red LED ‘when faults occur. 65. Additional possible eonncotion of llumination functions, [Pin 1 [Not used Pin_19]Hvcrauliotheor, value to control IPin 2 [Switch reverse Pin 20/Signal pot [Pin 3 [Switch forward Pin_21|Sianal steer turning Pin 4 [Cock Pin_22[Pump sensoroutput Pin 5 IData Pin_23]Mode signal output Pin 6 [Hourmeter-signal [Pin 24|Pump sensor-siqnal input [Pin 7 [Only for test functions [Pin 25|AUX2 Pin [Only for test functions [Pin 26|AUX1 Pin_9 [Pump seneor-supply 12. [Pin a7irier. Pin_10|Not used. [Pin 28] HvD PRS iter, Pin 11 Poti it-supply SV. [Pin 29] BR LS (brake fuid) [Pin 12|Not used [Pin 30] HBS2 (parking brake switch [Pin 13|Pump sensor-supply OV. [Pin 31 Temperature traction motor [Pin_14]Potiit-suppWy ov IPin_32/Temperature pump motor [Pin 15]Only for test tunctions: [Pin_33[Brush woar traction motor IPin_16]0V for Data signals Pin_34[Brush wear pump motor [Pin 17[UB- common Pin_351KS (Kev switch) 48V Pin 18]UB+ 4av “I 43Verification plug light kit Pin [eiov Pin_2 [Relay output working fant Pin_3 [Relay output working fat Pin 4 [e12v Pin 5 [Relay output lass reverse Pin 6 [Relay output asa reverse Pin 7 |s12v Pin 8 [ov Pin 9 [Relay output reverse. Steer angle measurement Input 1.21 (steering input) causes the yellow LED corresponding to the steer angle to light up. In addlion the signal is passed to the meroprocessor so that the voltage corresponding to the ange can be displayed in diagnosis mode. Hf none of the yellow LEDs lights up the vottage signal of the potentiometer is outside the tolerance and must be re-adjusted. Status display inputs ‘When input I-90 (HBS2) Is activaled the “Handbrake* symbel appears on the display to the left ofthe battery irdicato. ‘When the I-6 signal "HM occurs the hour meter status is increased. When the 1-2 signal is active (reverse direction signal) a backward-pointing arrow appears in the left-hand segment of the display. When the [3 signal is active (forward direction signal) a forward-pointing arrow appears in the lef-hand segment ofthe display. A voltage of UB+ at I-35 stats the microprocessor program. Supply outputs 1-9 and 1-11 are both 12 V voltage supplies. They are intended only for sensor connection. (0 V potentials are appliod at pins I-19 and I-14. Data transfer Information between the pulse control and LC display unit is exchanged via connectors 1-16 (0V reference), M4 (clock), FS (data) and I-23 (mode). ‘Setpoint hydraulic values The signals at inputs 127 (Tit), 1:26 (AUX1) and 1-25 (AUX2) are generated by ‘switches on the hydraulic lovers. Input 20 (It) is the output value of a potentiometer linked tothe lng lever. From these inputs the processor generates the respective setpoint values for the hydraulic motor rotation speed. This setpoint value is fed from pin I-19 to the pulse contro. It corresponds to a voltage of < 0.8 V for the highest possible rotation speed, and up to> 43 V for motor standstil. 44Maintenance and malfunction inputs “So | “os | (EEE S) Tea TRAGNOH [aiBE rience “cron “oe ensued When at least one of the following inputs ie activated the red 10 mm LED is actuated (On the display the “PUSH MODE" prompt appears above the battery indicator. In addition a message is stored which is displayed when the MODE key is pressed. When input I-28 (HYDPRS) is activated the processor loads the value "60 hours" into an internal meter. This meter counts downwards during ‘operation. When zero is passed the count starts ascending with a negative preceding sign, The stored message is “FIL. BLOCKED (meter reading) 60 STO. REST. ‘When input 1-33 (brush wear, traction motors) or 134 (brush wear, pump motor) is activated the same meter as under “HYDPRS" Is loaded, but with a value of 150 hours. The stored message is "FAMOT or PUMOT BRUSH (meter reading) 150, HRS REST" It both messages appear at the same time the lowest moter reading is adopted. When an active signal is detected at smperature, traction motor) message “TEMP TRACMOT PLEASE STOP is stored. 45When an active signal Is detected at input +32 (lemperature, pump mot the required pump motor rotation spe is raised to 80% of the maximum speed in order to provide better motor cooing, Pr Faure. coun) wot and the message @ Cd! "TEMP PUMOT AUTOCOOLING" . is stored. SEH ™ @) | When input 1-29 (BALLS) ts activated Owe tho message “BRAKE FLUID CALL enit” SERVICE] SERVICE’ is stored “oO =| SEH @ How to use the LC display When the unit is switched on the hour land service meter readings are shown (| Brtowescncte a The display then swiches to operating Benvice ‘5H mode, The first ino now displays the word "BATTERY". |. Inthe second tine a bar representing the battory charge. appears, fllowed by a Percentage figure. 1 the charge fas below 30% the display flashes. [At <10% charge the hydraulic outpu: is reduced tl the requirement steering ide. When the parking brake is applied the “Parking brake" symbol lights up at the tet. When the forklift Is moving the pre- selected direction is shown in the lot. hand segment ofthe dsplay. 46Diagnosis and settings ‘There are two diferent diagnosis options. 1. Diagnosis, forklift periphery ‘The forklift remains operational during diagnosis, To switch to this mode the "LIGHT" key ‘must be pressed while switching on the keyswitch, (On the display the prompt "Enter code (o000. 10000" appears. wet, With keys Ft and F2 the individual digits @ ; can now be entered by counting up or down as appropriate, ‘The cursor moves on one position each time the MODE key is pressed, Input is terminated with the LIGHT key. (On entry of the correct code the display “SET LANGUAGE" appears. Keys F1 and F2 can now again be used to scroll trough all possible setings. To select the option currently displayed, press the LIGHT key. ‘Acknowledge entries with the LIGHT key. SET LANGUAGE: Language setting for all displays. (From 1996 all EC languages possible) PUMOT SENSOR: ‘To check the pump motor rotation speed the mark-to-space ratio in % and the motor speed in rpm are displayed here.(STEER POT. 2,5 V LIFT POT. 2.8 V TILT AUX1 AUX ON. OFF _OFF. (RESET FAULT TIMER (SeT IcouNT DOWN SOFTWARE VERSION] oo1 [RESET TRAC. TEMP. l00_ MIN STEER POTI: Steering potentiometer display in Volts. ‘With the rar wheel in the straight-ahead position 2.5 V + 0.1 V. With wheel set for left comering less than 2.5 V to min, 0.9 V = 0.2 V; with whee! set for right comering ‘greater than 2.5 V to max, 4.0V + 02 V. UFT POT: LLiting potentiometer display in Votts. ‘When the liting lover is not actuated, >2.8V; with 100% it, < 08 V. TILT AUX! AUX2 Under the lever symbol "ON" appears when the microswitch is activated, and “OFF* when itis deactivate RESET FAULT MEMORY (TIMER) By pressing the MODE key, entries made in the countdown meter for clogged fiter ‘and brush wear can be reset here. The key must be held down for 10 ‘seconds, SET COUNT DOWN: Here the sarvice meter reading can be set in 10-hour inerements. The meter counts downwards during ‘operation, and when zero is passed the ‘count starts ascending with a negative preceding sign The reading is shown for a fow seconds ‘every time the fork is switched on. ‘SOFTWARE VERSION: The release number of 1 display software is displayed, builtin Le OVERHEATING, ‘TRACTIONPUMP MOTOR Hore is indicated how much time the traction motor was overheated longer than § minutes. 48Here is indicated how much time the RESET HVMOT TEMP) Bump motor was overeat nge than loo_MIN 2, Diagnosis, Puise contro! During this diagnosis the forklift is not operational To switch to this mode the "MODE" key must be pressed while switching on the keyswitch, Ho0 appears on the display. With keys Ft and F2 the code can bo set Move to the next position by pressing Ener cone ‘he MODE ty. so Pressing 1 and F2 accesses he vous abs For explanations of the individual Ist poston vere paranetr shoots Fhe corer of layed potion is shown non the MODE hey proses Win tha two function Kays he vale tlesed eoding canbe mod For rapid alteration, the increment is greater than 1. When the MODE kay is pressed twice in immediate succession the display counts dow from 9 f0 0, This countdown ean be interrupted by pressing the MODE key again. When 0 is, reached the altered value Is wrtlen to the momory. ‘When the MODE xey is pressed once the control returns to display ofthe list position after 1 second, It the MODE key is pressed during display of the fauit memory, the fauit memory is. cleared on completion ofthe countdovin 49‘Steer angle adjustment First option: ‘Switch-on with Keyswitch while simultaneously pressing the Ft Key to the steering and liting potentiometers. To adjust the steer angle potentiometer set the wheel to straight-ahead and then adjust the potentiometer to 2.5 V+ 0.1 V. In the same mode the iting potentiometer can also be adjusted (> 4.9. V- <0.8 V), in neutral position 2,8 -3V. display jumps ‘Second option: ‘Set wheel to straight-ahead and adjust ist postion 056 to.2.5 V+ 0.1 V. ‘The full range is between 0.9 V and 4.0V.Parameterlist Traction Control B1 “standard Unsiplace | Paranetar Siandard[— Wis [Wa] Raa L[Descrpion ‘Value | —Vahie—|-—Vaue | ~ code 3 [ose wot | — oot Sone 61 [recitation aoe | ooo Sener 2 [Fs Poot a [016 Senien 3 |Poting bake w25 | 000 Soni Irma 350 | a7 Seroe 5a Sp00d% Too | aso —| 00% —| “Somes Toure seed max 2% — Fie Pur al speed ma Ex Fi spice Pa ‘Siandard_[— Win. [Woe | Ratease- [Description alos [Vale —|~Vaue [coe ai [ost “ac | ~ car] — 063 [Seve 61 [accion wee [ 000 | ote | “series 3 [Rotng bake O15 | 000 | 030 | Serie [rma a0 [470] ex |“ sarcn 35 [ax Speed — tox | 050% | “To0e | “Sewer Gave specs rac 0% Be (rr a seed ra Oe Fe hard” Uspce Paramelor oa Release: [Deseiion Vale cose lust. cr Sone (eceoaton ooo —| Seven Tr rooteake oT Eevee Roling Brake oo Sovn mae S10 | a7 Seven sx Sood 70% —| ps0 Seves [uve speed rac 0% Be Pure al speed a ey Be antParameterlist Hydraulic-Pump Control HP standard” Lisiplace | Parameter [Standard [ — win [Wax “Retour [—t|oeseripien [Value | Value | —Vatue | ~ code [st oot aot 003 | Served 51 — [RM Siang TO) O19 70 40 | Senion 152 [Stetng Curve 005 00 203 | Server 53__[Sterng Delay | 000 oo 20 | Service ‘s4__|RPMTANCS) 0 060 ~ Senin 35 [acune 0 009 | Servier 38 [RPMAUKT EH) [0 070 ~ sence 57 |RPMALK2 60) ore oe 80 | Seniot 58 [Baty Oharactor | Weasunng | 404 0 | Seven a a [re [isiiace rameter ‘Standard | — Win. | — Wax. —[Retease= _[Deseripion Tale —|~Vatue | ~Vatue |code 0 [istNe. 02 wot 51 [RPA Staing 16 ora 32 [Sierra care 05 200 53 |ieeing Dey G) 08 200 58 [RPM TANG) oe 020 55___[TW cue 5 000 56 |RPW ALK GH) 50 0 57 [RPM AUK? Ge) 72 080 58 [Bary Charecier Wesuing | #00 (ax RPA ao rz] Paraneier Seandar| — an. —[ — War (Bescon Vaiue —| Value [Este oF ‘03 51 [Rw Seating Go) 70 ‘940 52 [Steering Cure ~o00 008 53._|Sterng Daley) co) 220 54 IRM TH) 20 060 55 [TmCuve 0 008 56 [RW ALXT GH) —— oo —| —o70 57 |RPWALK? Cs) oe 020 58 [Bator Oraracier toa] — 600 Imax RPS 08 Fe * The no loaded voltage ofthe battery would be checked and write inthis place au- tomatically. Shoud this value not correspond with really vollage, itcan be corrected by hand, aneAcceleration L61 100% o% ‘Actuation of accelerator peda from 0% to 100% RPM-curves: L52 and L54 eM 4 ‘Curve Nr." Cunve Nr 2" Curve Neo" ote curent ‘Should the control through the current recognize, that an power increase Is re ‘quired, s0 the pump motor rpm automatically willbe raised, ‘The size of raising could be adjusted into the lstplaces. 4.13Notes 434Trouble-shooting ‘When switching the instalation on, the functioning ofthe essential components in the power circuit wil bo checked. I the tolerances predefined in the program are ‘exceeded, the diving operation cannot be startod. In case of a fault the program Sequence will branch into a subroutine which will show the fauit on the LC-Display. While being displayed the fault will be continuously monitored. As soon as the source of error is eliminated, the program will continue with regular operation, In additon, ‘any faut occurred will be stored in sequence of his occurrence, in the memory of th printed-circuit board, TABLE FAULT CODE Fraction Contra [Description ‘Code | Count [aesateaon pedal AW RNS oad a ‘Scoring potoniomatar ouloT ange 1V at MS1 closed LCD Display: As0 lat actuating the accelerator pedal MS1 closed, the drive sensor value will be mere than 1V. Possible causes: 1. Drive sensor is detective. 2. B-minus- line tothe drive sensor is interrupted 3. Insulation faut inthe cable hamess to drve sensor. 4, Printed-circult board is detective, 4182. Shunt-value incorrect Le Display: Ast Current flow into the power circuit at switched of transistors, or no current flow into the power circuit at switched on transistors and contactors Possible causes: 1. Power circuit interrupted causes through + Power cables interrupted + Plug of power cable defective, + Interruption ito the motor. = Contactor combusted or Contactor pressure to low. 2, Insulation faut 3, Steering potentiometer out of range <0,8V or > 4,1 Le bispi Value of Steering potentiometer is smaller than 0,8V of more than 4,1. Possible causes: Potentiometeris defective, ‘No contact at potentiometer plug. Hamess is defective. Insulation fault Printed-ciruit board is detective, err Watch dog timer or MOSFET-Driver Le Disp As3 Watch dog timer as find an faut or the inter control of transistor has a faut. Possible causes: 1. Printed-cirout board is defective 5. EE-PROM-Checksum Le Disp Faulty contents into parameter memory (EEPROM), Possible causes: 1, Printed-crcult board is detective. 6. Thermal protection Le Display Ass ‘Temperature at power transistors more than 80°C, (current re-regulaton at 80°C, cut off at 85°C) 416Possible causes: 1. Current flow to high through isolation faut 2. Current flow to igh through defective motorwinding 8. Bad temperature derivation, for instance control not correct mounted, 7. Test voltage on VMN(R}(L) not between 20% to 70% Le bispi Ass ‘The voltage at the power connection VMINR or VMINL is al switched off drection con- {actor and switched off trensistors not 30% until 70% ofthe battery voltage. Possible causes: 1. Insulation faut 2. Direction contactor is defective. 8, Power transistor or power diode 8, NoUB- connection delay detective (Trans. don’t ewitch on) Le Dispia AST With switch on the direction contactors ensues no connection to baltery-minus, Possible causes: 1. Direction contactor (F or R) is detective, 2. Control (control cable) atthe contactor coll faulty 3. Power cables interrused. 4, Bad contact at the power cable connections. 9, No UB+ connection delay detective (Relais not correct) LC Display: Asa No connections to UB+ past switch on of the retum feeder contactor. Possible causes: 1, Retu feeder contactor TFR daectve 2. Control (control cable) atthe contactor coll faulty. 3, Power cable s interrupted, 4. Bad contact at the powor cable connections. 4a7Fault description PUMP Control "HP" 10. Power circuit open (tested on M-) Le Display: 160 ‘Current flow betwoen battery + to connection M- are not closed. Possible causes: 1. Power circuit iterupted causes through ~ Power cable ie intorrupted = Connection of power cable detective. ~ Interruption into the motor. 11, Thermal protection LC Display: Ast ‘Temperature at power transistors to high (current control on 80°C, cut off 85°C). Possible causes: 1. Current flow to high through insulation faut 2. Current flow to high through defective Motorwinding 8. Bad temperature derivation, for instance control not correct mounted. 12, Shunt-value incorrect Le bispl Current flow into the power circuit at switched of transistors, or no current flow into the power circuit at switched on transistors an contactor. Possible causes: 1. Power circuit interrupted causes through = Powor cable is interrupted. = Connection of power cable defective. + Interruption into the motor. 2, Insulation faut. 19. Watch dog timer or MOSFET-driver Le Dispia Watch dog timer has find an fault or the inter contro! of transistor has a faut Possibla causes: Printed-circit board is defective. 41814, EE-PROM-Checksum LC Display Faulty contents ino parameter memory (EEPROM). Possible causes: Printed-clrout board is detective, 419Checking of demand val at the accordingly connections (pins) a - *Deseaton Fin uci: Tas] [Output power steer request Tage | > av <05V ns irene Soe Toot av anw| sav ee por ater ae Sut aa ea ae ee cae 8 [Sapa non ano ar Teoe| ava |chesoonoarst por | saa sev a — [800] coat aay tives Teor | Uae tty UB ei comarca Tee | ues eee — He ee a at ie eect REV Teor | sos Uaten ut aces FD a Teo: | —usatt-2v | 4V (ean ob stataaa - tat inouae Thar] ana rage vee arvaay frtctot sive aavaraw Vavav | tovaay aA Saal na weal Ina oes oat erm ne | 10V ve. - 8.05 | <0 [outpt suppiy natu) B08 Tavs (Checkpoint suey SV (ony in ture) BOT 345V <55¥) Input dlagrosto to cash bard acti Paos | <0av | >0sv Input Poot >4av LIFT pot inte range mary >4avszv| <10v Mieroewte foreton 2 c2avs2.2v Meroe fureton 8 sive 12V _| UB not use) Poo = 0507 (Curent geraraio, max SSA ok used) Poos | vavsiay | <10v Input keyswich UB e001 | UBate [ouaputkeyswten UBe (oot used 002 | Batt -1V {trou steering request PE os | >8v =08v Inout data request puri fam clon conv peor | sev. ‘<05V [Outpu now metr request ero [ev >aV, [ouput cata orver PE azo] <08v >a [output coe arver PE 050s] < 0.5 Sav [Check Points Traction Control 81 —____ Description ‘code [Demand [Atal [Sorters version ce t [Acceleration Peal value, NST wiched on, 2-10 Maximal valve css |» avs ov! steering potentomatorsvaigh 56 [2544 oV| [steering max. ere |aoveory steering max tt soVv-01V. Direction swich or car_| onset [Dict switch emarcs (056 | en/ott am [Broke svc cso | on ot Seat wich — Te 60 not (Actua Contoter om. cot [020/006] (Check Points Pump Control HP T_ = Descrstion Cede | Demand | —Aewal ‘Sowers - Version - C50 \Ltoteniometer, range minimalto maximal 051 |>aav- 48 V: 1,000 v Test petiod of 1 sec. with 1.1 times the rms. value. Test period of 1 see. with a dc. tes voltage with 1.6 times the value, Readings should be taken between the chassis and points B+, B- and V and Fon. the travel direction contactor assembly. 2. Checking the insulation resistance ‘This should be carried out with @ DC current of 250V rated voltage if possible. Minimal permited insulation resistance, 4k @ per 1V rated battery voltage Readings should be taken between the chassis and points B+, B the travel direction contactor assembly ‘The minimum value must not fall below 25 KA in olderlused trucks. Otherwise faults in the electronics cannot be ruled out 3nd V and Rion Possible faults: = Intertum fault between field andior armature winding and the housing in the 250 A. Lifting during moton without load 120-160, Ling against mex. pressure > 250A Thermal protector TP 1-Transistor module The thermal protector TP is a constituent of the transistor module; so, in case of a fault it cannot be exchanged as an individual component; instead, the complete mod- hla must ha axchangeat in such a casa. The values: Cold resistance at 25° 0 smaller 250.0 \ Hot resistance at 105°C larger 1,930 ka Insulation resistance against basoplate larger 500 ka. ‘The testing Is performed by a resistance measurement at the corresp. temperature. ‘TP2, TPS - Traction motor I ‘The temperature sensors TP2 and TPS are buit into the traction motors. If one of the ‘motors overheais, one of the sensors is activated. The information “MOTOR TOO HOT" is passed to the microprocessor in the LC display. There is no adjustment to the motor. ‘The testing is performed by measuring the resistance at the corresponding tempera- 1 ture, ‘TP4- Pump motor | ‘The temperature sensor TP4 is bul into the pump motor, Ifthe pump motor over- heats ‘=the appropriate faut message Is displayed, and 2+ the “Power steering” stage speed is raised to 80% of max. speed to ensure i adequate ccoling. | Cold resistarce at 25°C = 500 Hot resistance on 150°C = 2.5k0 ‘The testing is performed by taking a resistance reading atthe corresp. temperature » 56 |FIR contactor Coll resistance at 25° C = 200 0 ‘To check the erosion reserve and easy movernent ofthe mechanical parts, remove the cover. Fuses 1 FU = Main fuse 4258 2FU = Controlfuse 168A Accelerator unit ‘The accelerator uit is attached undemesth the foctplate. The pedal movement is transmitted to the control as a voltage between 0 - 4 V. When the pedal is prassed MSt closes frst. Electrical data = Supply voltage against battery minus = 4820.5 V (Sevcon-pedal); 1240.5 V (Zap-pedal) ~ Supply vottage at contact F1-4, lead 106 B-fo contact F1-3, lead 56A, A8. If Zapr-pedal 12V al port F1-1, cable 78A. ~ Output votage F1-2, lead 29, A10, MS 1 closed 0.2V-- 0.4V up to max. 4V + 1V, rising continuously depending on position of pedal. ~ Fortaking measurements also see Code C55 Sensor ‘The pump motor rotation speed sensor is an inductive proximity switch. When metal approaches the proximity the voltage level is changed. Location ‘Screwin depth ‘Sensor. On pump motor beayng plate, fan motor side —_0.8- 1.2mm gap width Measured values: Input: tev Output: approx. 0-1 (air gap) approx. 8-12V (metal) ‘Voltage supply and evaluation by the LC display unit. 8758Wiring diagrams