Clark GEX20-30 (RATED CAPACITY : 2000~3000kg). SERVICE MANUAL (2006)

Group 16, Electrical Motors

Section 1

Motor Specifications and Descriptions

Specifications

Drive Motors

Pump Motor

Frame Size: 240 mm (9.449in) diameter

Frame Size: 200 mm (7.874 in) diameter

Internal Bearings: Sealed and lubricated with high tem-

perature grease for the life of the bearing. The bearing at

the back end of the motor is a special encoder bearing

(sensor) that needs to be replaced every 10,000 hours, or

any time the bearings are removed from the motor rotor

shaft.

Terminal Nut Torque: 15 N.m (133 in-lb)

Rotor outside Diameter: 149 mm (5.866 in)

Rotor inside Diameter: 65 mm (2.559 in)

Rotor outside Diameter: 124 mm (4.882 in)

Number of Slots: 44

Rotor inside Diameter: 46 mm (1.811 in)

Number of Slots: 48

Stator outside Diameter: 240 mm (9.449in)

Stator inside Diameter: 150 mm (5.905 in)

Stator outside Diameter: 200 mm (7.874 in)

Number of Slots: 36

Stator inside Diameter: 125 mm (4.921 in)

Number of Slots: 36

Nominal Air Gap: 0.5 mm (.0196 in)

Nominal Battery Voltage: 80V

Nominal Air Gap: 0.4 mm (.0157 in)

Maximum Battery Voltage: 84.5V

Nominal Battery Voltage: 80V

Nominal Speed: 1800 RPM

Maximum Battery Voltage: 84.5V

Stall Current: 275A

Nominal Speed: 2160 RPM

Insulation: Class F

Stall Current: 450A

Winding: Delta

Insulation: Class F

Encoder: 64 Pulses / Rev

Winding: Delta

Encoder: 64 Pulses / Rev

SM 765, Nov ’06

Motor Specifications and Descriptions • 16-1-1

Group 16, Electrical Motors

The pump motor also has a built-in thermistor which con-

Description and Location

stantly monitors the winding temperature and reports this

The truck has three electric AC motors:

information to the control (this sensor is not serviceable).

Should it sense that the motor is approaching the tempera-

• Two identical traction motors

ture limit, the control will cutback motor current until the

• One main hydraulic/power steering pump motor.

temperature decreases. Since it is cutting back current and

not voltage, the top end speed will not be affected, unless

Drive motors

the loads are close to capacity.

The two drive motors are three-phase AC motors with

class F insulation. These motors do not use brushes and

the motors are totally enclosed, minimizing the service

requirements. Because the motors do not use brushes and

are enclosed, sealing them from outside contamination,

there is no need to blow out the inside of the motors dur-

ing a PM. Each motor has two bearings; the drive end

bearing is a ball bearing and the bearing at the rear of the

motor is a special encoder bearing (sensor) for motor

feedback to the control. One motor drives the left traction

wheel, the other the right. The electronic control system

varies the speeds to the two motors independently to

accommodate cornering.

The external connections are easily accessible from the

top of the motor where they are protected from external

damage.

Each drive motor also has a built-in thermistor which con-

stantly monitors the winding temperature and reports this

information to the control (this sensor is not serviceable).

Should it sense that the motor is approaching the tempera-

ture limit, the control will cutback motor current until the

temperature decreases. Since it is cutting back current and

not voltage, the top end speed will not be effected, unless

on a grade.

Lift/Steer pump motor

The pump motor is a three-phase AC motor with class F

insulation. It is also a brushless motor and totally

enclosed. Because the motors do not use brushes and are

enclosed, sealing them from outside contamination, there

is no need to blow out the inside of the motors during a

PM. This motor has two bearings; the drive end bearing is

a ball bearing and the bearing at the rear of the motor is a

special encoder bearing (sensor) for motor feedback to the

control. An electronic control system controls the speed of

the motor at all times. This pump runs for steering any

time the truck is in gear, or anytime a hydraulic function is

requested.

The external connections are easily accessible from the

top of the motor where they are protected from external

damage.

16-1-2 • Motor Specifications and Descriptions

SM 765, Nov ’06

Group 16, Electrical Motors

Section 2

Drive Motor Overhaul

Remove the bolts securing the lower battery plate

Inspection Procedure

and tilt the plate back against the rear battery plate.

Before performing these service procedures:

Remove all electrical cables from the motor. Tag

• Park truck safely.

cable terminals to aid in reinstallation. Position

• Fully lower the upright.

cables out of the way of motor removal.

• Apply the park brake

Remove bolts holding motor to axle. Have drain pan

• Turn the key switch OFF.

in place to catch axle oil.

• Disconnect battery from truck receptacle.

Lower motor onto floor or through the top using a

• Discharge capacitors by connecting a 200 ohm 10

suitable chain hoist or come-a-long.

watt resistor between the positive and negative

10.

Reinstall in reverse order. Use new O-ring, coated

input post of the controller for 10 seconds.

with drive axle fluid.

11.

Check and fill drive axle oil as described in Group

Motor Cleanliness

20.

Electric motors should be kept clean at all times to prevent

NOTE

shorting, minimize wear, and optimize cooling.

When removing or installing cables to motor,

• Wipe off all dust, dirt, oil, water, etc., from outer

hold the terminal's lower nut with a wrench

surface of motor.

while turning the upper fastening nut with

another wrench.

• Remove any debris from cooling fan air vents and

around motor frame to prevent overheating.

Coat O-Ring with Transmission

• Air-clean (blow off) motors using clean, dry (mois-

Fluid Prior to Installation

ture-free) compressed air at 207 kPa (30 psi) maxi-

mum air pressure.

The presence of any oil on or near the motor could indi-

Torque to 70 - 75 N-M

(51 - 55 lb/ft)

cate either bad bearings or leaking hydraulic system.

Determine cause and repair problem before extensive

motor damage occurs.

Drive Motor Removal and Installation

1. Remove the battery from the truck.

2. Tilt the steering column fully forward and remove

the floor plate.

3. Remove all electrical cables from the drive motor.

Tag cable terminals to aid in reinstallation and posi-

tion the cable out of the way.

4. Remove the mast from the truck.

5. Remove the drive axle from the truck.

SM 765, Nov ’06

Drive Motor Overhaul • 16-2-1

Group 16, Electrical Motors

Terminal Block

Mounting Bracket

Screw

Non-Drive End Frame

O-Ring

Stator

Rotor

Drive End Frame

Wave washer

Encoder Bearing

Ball Bearing

O-Ring

Shaft Seal

Ball Bearings

Encoder Bearing

Both ball bearings are maintenance free. If it becomes

The encoder bearing is used to communicate the motor

necessary to remove the bearings to repair the motor, they

speed to the controller.

should be replaced. In any case the seals (shaft oil seal and

NOTE

O-ring) must be replaced.

The encoder bearing is very sensitive to static

In general bearings should be replaced at approximately

electricity. If you are going to be working on

10,000 operating hours.

the encoder bearing you should have a

ground strap on to insure that the encoder

bearing does not get damaged.

16-2-2 • Drive Motor Overhaul

SM 765, Nov ’06

Group 16, Electrical Motors

• Insure that the encoder cables are installed cor-

Replacing Encoder Bearing

rectly and do not get pinched or touch the rotor.

• Install the end housing carefully onto the encoder

bearing and press it on with a steady pressure. The

lead from the bearing must located in the notch in

the housing frame.

Notch for Lead

In general the encoder bearing should be replaced every

time the motor is disassembled.

To replace the encoder bearing:

• Turn key OFF.

• Set park brake.

• Install the rotor into the stator housing.

• Disconnect battery.

• Tie strap the encoder bearing lead to one of the

• Remove the drive motor (see page 1 of this sec-

motor leads to prevent it from being pulled and

tion).

contacting the rotor.

• Remove motor thru bolts.

• Install the drive end onto the motor making sure

• The silicone sealing the cables into the end frame

that the terminal block mounting bracket is aligned

will need to be loosened to allow removal of the

with the slots in both end frames.

end frame.

• Remove the non-drive end housing from motor.

Terminal Block

Mounting Bracket

• Remove rotor from motor.

• Use a gear puller to remove encoder bearing from

the rotor.

• Press new encoder bearing on to rotor at the inner

ring with a steady pressure. The inner ring of the

bearing must to be pressed against the shaft shoul-

der.

Motor Reassembly

Thermal Sensor Lead

NOTE

The encoder bearing is very sensitive to static

electricity. If you are going to be working on

• Install the motor through bolts and tighten.

the encoder bearing you should have a

ground strap on to insure that the encoder

• Fill the void around the drive motor leads with Sil-

bearing does not get damaged.

icone # 1758629.

• Reinstall the motor into the truck.

SM 765, Nov ’06

Drive Motor Overhaul • 16-2-3

Group 16, Electrical Motors

Section 3

Pump Motor Overhaul

3. Have drain pan in place to catch axle oil. Remove

Inspection Procedure

the hydraulic pump from the motor (see group 29 for

Before performing these service procedures:

instructions).

• Park truck safely.

IMPORTANT

• Fully lower the upright.

The pump motor assembly weighs over 110

• Apply the park brake

pounds. A suitable lifting device may be

needed to help hold and then raise the motor

• Turn the key switch OFF.

from the truck.

• Disconnect battery from truck receptacle.

• Discharge capacitors by connecting a 200 ohm 10

4. Remove the 4 nuts securing the pump motor mount-

watt resistor between the positive and negative

ing plate to the frame bottom.

input post of the controller for 10 seconds.

5. Lift the motor assembly and place it on a bench for

service.

Motor Cleanliness

6. Reinstall in reverse order.

Electric motors should be kept clean at all times to prevent

NOTE

shorting, minimize wear, and optimize cooling.

When removing or installing cables to motor,

• Wipe off all dust, dirt, oil, water, etc., from outer

hold the terminal's lower nut with a wrench

surface of motor.

while turning the upper fastening nut with

• Remove any debris from cooling fan air vents and

another wrench.

around motor frame to prevent overheating.

• Air-clean (blow off) motors using clean, dry

(moisture-free) compressed air at 207 kPa (30 psi)

maximum air pressure.

The presence of any oil on or near the motor could indi-

cate either bad bearings or leaking hydraulic system.

Determine cause and repair problem before extensive

motor damage occurs.

Pump Motor Removal and Installation

1. Tilt the steering column fully forward and remove

the floor plate.

2. Disconnect battery and remove all electrical cables

from the motor. Tag cable terminals to aid in rein-

stallation. Position cables out of the way of motor

removal.

Torque to 40 - 45 N.m

(29.5 - 33.2 Lbs.ft)

SM 765, Nov ’06

Pump Motor Overhaul • 16-3-1

Group 16, Electrical Motors

Terminal Block

Mounting Bracket

Screw

Non-Drive

End Frame

Stator

O-Ring

Rotor

Wave Washer

Encoder

Bearing

Drive End Frame

Snap Ring

Ball Bearing

Shaft Seal

Pump Motor Exploded View

Ball Bearings

Encoder Bearing

The encoder bearing is used to communicate the motor

speed to the controller.

Both ball bearings are maintenance free. If it becomes

necessary to remove the bearings to repair the motor, they

NOTE

should be replaced. In any case the seals (shaft oil seal and

The encoder bearing is very sensitive to static

O-ring) must be replaced.

electricity. If you are going to be working on

the encoder bearing you should have a

In general bearings should be replaced at approximately

ground strap on to insure that the encoder

10,000 operating hours.

bearing does not get damaged.

16-3-2 • Pump Motor Overhaul

SM 765, Nov ’06

Group 16, Electrical Motors

Replacing Encoder Bearing

Motor Reassembly

In general the encoder bearing should be replaced every

• Press new encoder bearing on to rotor at the inner

time the motor is disassembled.

ring with a steady pressure. The inner ring of the

bearing must to be pressed against the shaft shoul-

der.

To replace the encoder bearing:

NOTE

• Turn key OFF.

The encoder bearing is very sensitive to static

• Set park brake.

electricity. If you are going to be working on

• Disconnect battery.

the encoder bearing you should have a

ground strap on to insure that the encoder

• Remove the pump motor (see page 2 of this sec-

bearing does not get damaged.

tion).

• Remove motor bolts.

• Insure that the encoder cables are installed cor-

• Loosen the silicone sealer around the cables at the

rectly and do not get pinched or touch the rotor.

end housing.

• Install the end housing carefully onto the encoder

• Remove the non-drive end housing from motor.

bearing and press it on with a steady pressure. The

• Remove rotor from motor.

lead from the bearing must located in the notch in

the housing frame.

• Use a gear puller to remove encoder bearing from

the rotor.

• Install the rotor into the stator housing.

• Tie strap the encoder bearing lead to one of the

motor leads to prevent it from being pulled and

contacting the rotor.

• Install the drive end onto the motor making sure

that the terminal block mounting bracket is aligned

with the slots in both end frames.

• Install the motor through bolts and tighten.

• Fill the void around the drive motor leads with Sil-

icone # 1758629.

• Install the fan and snap ring onto the shaft.

SM 765, Nov ’06

Pump Motor Overhaul • 16-3-3

Group 17, Electrical Contactors

Section 1

Contactors Specifications and Overhaul

Specifications

Removal and Replacement

Standard Truck: One Drive Line Contactor, one Pump

1. Disconnect power cables from contactors. Move

Line Contactor. Mounting Fastener Torque: 8-10 N.m (71-

power cables out of the way.

88 in-lb).

2. Disconnect connecting bus bars from contacts.

3. Disconnect wiring from contactor coil terminals.

4. Remove mounting bolts and contactor assembly from

truck.

5. Reverse procedure for installation.

Overhaul

! WARNING

Disconnect battery before working on contactor tips.Before attempting to disassemble a con-

tactor to install a new contact set, carefully observe location and orientation of each part.

SM 765, Nov ’06

Contactors Specifications and Overhaul • 17-1-1

Group 17, Electrical Contactors

binding and that tips are in correct orienta-

CONTACTOR INSPECTION AND

tion and tips contact correct mating parts.

TIP REPLACEMENT

Check armature and movable contacts for freedom of

movement by depressing movable arm with a screw-

driver or small rod. Check for any restrictions to

movement and for return of parts by action of spring.

Inspect contact tips. Look for any worn or eroded

surfaces. Look for evidence of tip welding.

Inspect for evidence of any contaminants on tips

(paint, dirt, paper or cloth material, etc.) which

would impair operation.

Do not use sandpaper or file tips. Any damage must

be corrected by tip replacement.

Tips must be replaced before they wear through and

damage copper base.

To remove and replace contact tips, use following

To replace tips on the contactors, loosen and remove

two cover mounting screws attaching it to coil frame.

(Observe position of positive (+) marking on cover).

Be careful not to lose return spring fitted under cover.

Remove locknut and lockwasher from contact studs

and remove contact studs from top cover. Inspect the

top cover to make sure it has not been overheated and

that the contact studs have not melted into the plastic.

Replace the studs with new.

Lift movable contact assembly off base. Remove

lock ring from armature shaft and remove moving

contact tips. Be careful not to disassemble or lose

other parts under contact tips on armature assembly.

Replace movable contacts with new and assemble

onto armature shaft. Make sure lock ring is fully

seated.

Assemble contactor by putting moving contact

assembly armature shaft into coil plunger with return

spring on top of armature shaft. Put top cover over

spring and install cover mounting screws. Be sure

return spring is in recess in top cover.

NOTE

When assembling top cover to base, make

sure it is installed with positive sign (+) mark-

ings located correctly. Use a bar or rod to

move contacts. Be sure movement is free of

17-1-2 • Contactors Specifications and Overhaul

SM 765, Nov ’06

Group 19, Motor Controls

Section 1

Description

The CLARK GEX uses a Dual AC controller to control both drive motors and a single AC controller

to control the single motor/pump combination which supplies flow to all hydraulic functions and

steering.

Traction Control and Motors

uses this information to increase motor speed in propor-

tion to the distance stroked, providing only the desired

The dual AC traction control consists of two motor con-

flow rate. Tilt and aux switches mounted on the hydraulic

trols mounted to a single heat-sink plate and enclosed by a

valve provide unique inputs to the control. The speed of

single cover. The right portion of the control is reference

each function can be programmed independently so that

to as the "slave" control and operates the left drive motor.

only the required flow rate is produced, minimizing power

The left portion of the control is referred to as the "mas-

losses. When the key is in the "ON" position and a direc-

ter" control and operates the right drive motor. The con-

tion is selected, the control will operate the motor at a

trol receives inputs from the speed control (accelerator)

fixed rpm (roughly 500~600 rpm). This provides adequate

pedal, steer tire position sensor (steer pot), direction

flow for the steering function. If the control receives an

switches, foot brake switch, motor encoders, motor ther-

input from the lift potentiometer, tilt or aux switches, then

mistors and other miscellaneous switches. The control is

it will ramp up the motor speed to match the desired

able to proportional reduce the speed of the inside tire

speed. Once the request is removed the motor speed will

when the truck is in a turn, based on the steer angle input

return to the fixed level. As with the traction control and

from the steer sensor. Once the steer angle exceeds a cer-

motors, the lift/steer control and motor have thermistors

tain value, the inside wheel will start to reverse. The

for thermal protection and the motor has a built-in encoder

speed of the vehicle is controlled by the accelerator con-

for speed feedback.

trol pedal. For a given pedal position the control will

maintain a set speed, as determined by control parameter

settings. These settings are adjustable to meet your cus-

tomer's needs. One feature that is new to the GEX is

"release braking". This feature will apply a regenerative

braking force every time the driver lifts up off the acceler-

ator pedal. The final travel speed will be determined by

the new pedal position. The control receives motor speed

feedback from the motor encoders which allow for precise

speed regulation. Every motor also has a built-in ther-

mistor which constantly monitors the winding tempera-

ture and reports this information to the control. Should it

sense that the motor is approaching the temperature limit,

the control will cutback motor current until the tempera-

ture decreases. Since it is cutting back current and not

voltage, the top end speed will not be effected, unless on a

grade. Each control also has built-in thermal protection

that will reduce output current should the control

approach the thermal limit.

Lift/Steer Control and Motor

A single motor/pump combination is used for both

hydraulic functions and steering. The motor is controlled

by a dedicated controller. The lift lever is equipped with a

linear potentiometer that measures the distance the lever is

stroked and provides this input to the control. The control

SM 765, Sep ’06

Description • 19-1-1

Group 19, Motor Controls

Operational Features

Speed Limit

Parameters MAX SPEED FORWARD and MAX SPEED

Creep Speed

BACKWARD allow for the adjustment maximum speed

that the vehicle can travel in each direction. The maxi-

Parameters THROTTLE X POINT and THROTTLE Y

mum speed is adjustable from 0 Hz to 140 Hz in 1 Hz

POINT control how the truck reacts when you first push

increments.

on the accelerator. Increasing THROTTLE X POINT will

give you more pedal stroke with less speed at the begin-

ning of the stroke. Increasing THROTTLE Y POINT will

Example: 140 Hz = approx. 11.1 mph empty

give more speed with less pedal stroke. See Chart below.

78 Hz = approx. 6.2 mph empty

SPEED f(Hz)

Stop on Ramp

When this feature is ON it lets the vehicle electrically hold

MAX SPEED

on an incline. Time is adjustable with AUXILIARY

TIME parameter.

When this feature is OFF the vehicle uses regen braking to

stop on an incline. Once the vehicle has stopped it will

TROTTLE Y

POINT

hold for 1 second then continue to creep down the incline

FREQ. CREEP

at approx. 1 mph. The vehicle can continue up the ramp at

any time without hesitation.

VACC

TROTTLE 0

TROTTLE X

VACC

MIN

ZONE

POINT

MAX

Steering Time Delay

This feature uses the AUXILIARY TIME in the pump

Control acceleration

control to delay turn off time when the directional lever is

returned to neutral. This parameter is adjustable from 0 to

Parameter ACCELERATION DELAY allows the adjust-

20 seconds of delay.

ment of the time it takes to accelerate a stop to full speed.

See parameter-programming chart later in this manual.

Static Return to Off (SRO)

Regenerative braking

This feature requires the operator to return the directional

lever to the neutral position anytime they leave the vehicle

Parameter INVERSION BRAKING allows for the adjust-

and return. If the parking brake, seat switch or key switch

ment of the amount of time that it takes to stop the vehicle

is opened, the control shuts down and can not be restarted

when changing from one direction to the other. See

parameter-programming chart later in this manual.

(The dash display will show a -79 fault code) until the

directional lever is returned to neutral. A time delay of

approximately 2 seconds is built in to allow momentary

Accelerator Pedal Position Plug braking

opening of the parking brake or seat switch.

Parameter RELEASE BRAKING allows for the adjust-

ment of the amount of time that it takes to stop the vehicle

Thermal Protector

when you remove your foot from the accelerator. See

parameter-programming chart later in this manual.

Each controller has an internal thermal protector on the

heat sink. The controllers will reduce the output current

to 50% of the set current when the heat sink temperature

Brake Pedal Regen Braking

reaches 75°C. The dash will display the following codes

Parameter PEDAL BRAKING allows for the adjustments

depending on which controller in over temperature, (Mas-

of the amount of regen braking you receive when you

ter -61 code, Slave -140 code, and Pump -203 code).

apply the service brake. See parameter-programming

chart later in this manual.

19-1-2 • Description

SM 765, Sep ’06

Group 19, Motor Controls

Standard Fault Codes

NOTE

The control has over 75 fault codes assist the service tech-

nicians and operators in the trouble shooting the vehicle.

The Handset instructions and Troubleshoot-

If mis-operation of the vehicle occurs, a fault code will be

ing can be found in Group 19, Section 3 of

displayed on the Dash Display of the vehicle, or by plug-

this manual.

ging the handset into the "B: plug of the master controller

and reading the fault code.

Protection Features

With the fault code number, follow the procedures out-

lined in Group 19, Section 03 ,"Fault Codes", section to

Reverse Battery Polarity:

determine the problem and a solution.

The MAIN CONTACTOR is there to protect the control-

ler against reverse battery polarity and for safety reasons.

Stored Fault Codes

This feature records the last 5 fault codes in controller.

Connection Errors:

The last 5 fault codes can be accessed through the alarm

log using a handset, or a laptop computer with the PcCon-

All inputs are protected against connection errors.

sole software and adapter cable. The faults are stored with

the hour meter reading when the fault first happened, the

Thermal Protection:

number of time the fault has happened, and the tempera-

ture the first time the fault happened.

If the controller temperature exceeds 80° C, the maximum

current is reduced in proportion to the thermal increase.

Hour Meter Readings

The temperature can never exceed 100° C.

When the traveling speed is less than 0.5km/h, it displays

External Agents:

the accumulated operating hour.

The controller is protected against dust and the spray of

Battery Discharge Indication (BDI)

liquid to the degree of protection meeting IP54.

Provides accurate battery state of charge information to

Protection Against Uncontrolled Movement:

the vehicle operator, Features and Functions:

• Displays 100 to 0 percent charge in 10% incre-

The main contactor will not close if:

ments.

- The power unit is not functioning

•

Lift Circuit is disabled at 10% discharge

- The controller is not functioning perfectly.

- The output of the accelerator does not fall

below the minimum voltage value stored, with

Handset

1V added

This is a multifunctional tool used with the AC controls.

- Running microswitch is in closed position.

The handset (Clark part #8033636) has a display and a

key board for data entry.

Low Battery Charge:

When the battery charge is low, -66 Code, the maximum

Features and functions:

current is reduced to half the maximum current pro-

• Monitor existing fault codes for both traction and

grammed.

pump controls.

• Monitor hour meter readings on traction and pump

Protection against accidental startup:

controls.

A precise sequence of operations is necessary before the

• Monitor or adjust the control functions

control will start (SRO). Startup cannot occur if the

• Use as a tester to monitor input and output infor-

mation.

SM 765, Sep ’06

Description • 19-1-3

Group 19, Motor Controls

sequence is not followed completely. (Request for drive,

potentiometer signal acquisition is carried out using the

must be made after closing the key switch).

handset. This enables adjustment of the minimum and

maximum useful signal level (PROGRAM VACC func-

tion), in either direction. This function is unique when it is

Capacitor Charge:

necessary to compensate for asymmetry with the mechan-

The controllers can hold an electrical charge for several

ical elements associated with the Potentiometer. Espe-

seconds, due to the power capacitor bank. A discharge

cially relating to minimum level. The sequence of

resistance is built in the controller, which ensures capaci-

procedure is described later in this manual.

tor discharge to a safe voltage in about one minute, after

the key is switched off. If it is necessary to work on the

Analog control unit

controller before that time, discharge the capacitors as

described below.

Connection C25 (PTHERMR) and C24 (NTHERMR) are

used for the right motor thermal sensor. Connection C35

(PTHERML) and C34 (NTHERML) are used for the Left

Discharging Controller Capacitors

motor thermal sensor. Sensors are analog.

It is necessary to discharge the capacitors before you work

on the controller. To discharge the capacitors, disconnect

Speed Feedback

the battery at the battery receptacle, connect a 200 ohm 10

watt resistor between the positive and negative input post

The traction motors control is based upon the motor speed

of the controller for 10 seconds.

feed back. The speed transducer is an incremental

encoder, with two phases shifted at 90°. The encoder is

supplied with +12V from the control panel.

Communications with CLARK Dash:

The traction controller communicates by CANBUS to

Steer Angle Transducer

CLARK dash. The dash shows Battery State of charge,

Hourmeter and fault code if a fault occurs.

Angular position of steered wheels in transduced to an

electric information (voltage) by means of a potentiome-

ter, with following characteristics:

Microswitches:

- Positive supply: 12V ± 2V

The micro switches must have a contact resistance lower

- Voltage potentiometer : 1V~9V

than 0.1ohm and a leakage current lower than 100 micro

- Netural : 5V

amps.

- Potentiometer is installed in a way that in the

When full load is connected, the voltage between the key

zero position (straight wheels), pot output volt-

switch contacts must be lower than 0.1 volt.

age is in the middle of the electric range corre-

sponding to a full left-to-right transition of

The micro switches send a voltage signal to the micropro-

steer wheels;

cessor when a function is requested (for example: running

- The potentiometer is installed in a way that,

request) is made.

when the truck turns right, pot voltage

increases;

Accelerator Unit:

- Use "SET STEER MIN" and "SET STEER

MAX" functions of the handset to record the

The accelerator unit consists of a potentiometer in 3 wire

extremes (minimum and maximum) of the

configuration.

potentiometer range;

- Use "SET STEER 0-POS" function of the

CPOT (C21) signal.

handset to record the pot output when the steer

EN ACC (C8) is the accelerator enable. It is fed with

wheels are straight.

+Batt from the key switch.

NPOT (C20) is the accelerator negative supply. This out-

put is feed back to the microprocessor A/D converter to

test the continuity of the accelerator unit circuit (test of

pot wire disconnection). The procedure for automatic

19-1-4 • Description

SM 765, Sep ’06

Group 19, Motor Controls

Description of Connectors - DualAC2(Power)

CAN H

High level CANBUS

CANT H

CANBUS termination output, 120 ohm internally connected to CAN_H. Connect to

CAN_L_OUT to insert termination.

CAN_POS

Positive of CAN circuit; to be used in case of optoisolated CANBUS

CAN_L_OUT

Low level CANBUS: to be used as repetition for CAN_L line or to be connected to CANT_H

to insert termination resistance

CANT_L

CANBUS termination output, 120 ohm internally connected to

CAN_L. CAN Connect to CAN_H_OUT to insert the termination.

CAN_L

Low level CANBUS.

CAN_H_OUT

High level CANBUS: to be used as repetition for CAN_H line or to be connected CANT_L to

insert termination resistance

CAN_NEG

Negative of CAN circuit, to be used in case of optoisolated

CANBUS

PCLRRXD

Positive serial reception.

NCLRRXD

Negative serial reception.

PCLRTXD

Positive serial transmission.

NCLRTXD

Negative serial transmission

GND

Negative handset power

+12

Positive handset power

FLASH

PENC_R

Positive of the right motor encoder power supply (+12V).

NENC_R

Negative of the right motor encoder power supply

KEY

Connected to +Batt through a micro switch and a 10A fuse in series

Common of FW / REV / HB / PB / SEAT / ENABLE micro switches

Seat

Seat presence input; active high.

FORWARD

Forward direction request input; active high.

REVERSE

Reverse direction request input; active high.

19-1-6 • Description

SM 765, Sep ’06

Group 19, Motor Controls

ENABLE

Traction request input; active high.

Pedal brake request input; active high.

C10

SR / HB

Speed reduction or hand brake input; active low (micro switch open).

C11

PENC_L

Positive of the left motor encoder power supply (+12V).

C12

NENC_L

Negative of the left motor encoder power supply

C13

PHA_R

Right motor encoder phase A.

C14

PHB_R

Right motor encoder phase B.

C15

NPOTST

Negative of steering potentiometer (-Batt)

C16

PPOTST

Positive of steering potentiometer (+5V)

C17

CPOTST

Steering potentiometer wiper signal.

C18

CPOTB

Brake potentiometer wiper signal.

C19

NPOTB

-Batt.

C20

NPOT

Negative of traction accelerator (test for wire disconnection)

C21

CPOT

Traction potentiometer wiper signal.

C22

PHA_L

Left motor encoder phase A.

C23

PHB_L

Left motor encoder phase B.

C24

NTHERM_R

Negative of right traction motor temperature sensor.

C25

PTHERM_R

Right traction motor temperature signal.

C26

NLC

Output of main contactor coil driver (drives to -Batt)

C27

PLC

Positive of main contactor coil.

C28

NBRAKE

Output of electric brake coil (drives to -Batt, Maximum current 3A)

C29

PBRAKE

Positive of electromechanical brake coil.

C30

PAU

Xpositive of auxiliary load.

C31

NAUX

Output of auxiliary load driver (drives to _Batt).

C32

-BATT

C33

PPOT

Traction potentiometer positive, 5V output, use load > 1K omh.

C34

NTHERM_L

Negative of left traction motor temperature sensor.

C35

PTHERM_L

Left traction motor temperature sensor.

Encoder Installation

In order to control the AC motors with the ZAPI controller an incremental encoder is installed with 2 phases shifted at

90°. The encoder power supply is 12V

C11/C1

+12V

Positive of encoder power supply.

C12/C2

GND

Negative of encoder power supply.

C22/C13

Phase A of the encoder

C23/C14

Phase B of the encoder

Connection of encoder with open collector output; +12V power supply.

SM 765, Sep ’06

Description • 19-1-7

Group 19, Motor Controls

The encoder power supply voltage and output electronic

has to be communicated to ZAPI in order to correctly set

the selection jumper in the controller.

Description of Power Connections

-B

Negative of the battery

+BT

Positive of the battery; if the power fuse is

not present,positive cable coming from

the Line contactor must be connected to

this power connection

+BTF

Positive of battery before power fuse,

must be connected to positive cable com-

ing from line contactor.

Um: Vm; Wm

Connection bars for the three phases of

the right motor; follow this sequence and

the indication on the motor.

Us, Vs, Ws

Connection bars for the three phases of

the left motor; follow this sequence and

the indication on the motor.

19-1-8 • Description

SM 765, Sep ’06

Group 19, Motor Controls

Description of Connections - Hydraulic AC3

CPOT

Accelerator potentiometer wiper.

PPOT

Potentiometer positive: 10V output; keep load > 1KW.

NPOT

Negative of accelerator unit, tested for wire disconnection diagnosis.

Common of LIFT ENABLE / 1st SPEED / 2nd SPEED / 3rd SPEED / 4th SPEED / HYDRO /

SR microswitches.

LIFT ENABLE

Input for potentiometer lifting enable input; it is active HIGH.

1st SPEED

Input for first speed request; it is active HIGH..

3rd SPEED

Input for third speed request; it is active HIGH

AN.IN

Free analog input.

PPOT

Potentiometer positive: 10V output; keep load > 1KW.

A10

-BATT

-Batt.

A11

-BATT

-Batt.

A12

HYDRO REQ

Input for hydraulic steering request. Active high.

A13

Speed reduction input. Active low (switch opened).

A14

DIG.IN

This is a digital input, free for customer request.

KEY

Connected to the power supply through a microswitch (CH) with a

10A fuse in series.

PAUX

Positive of the auxiliary output.

PHYDRO

Positive for the hydraulic steering contactor.

4th SPEED

Input for fourth speed request; it is active HIGH.

SAFETY

If not connected to -Batt the MC coil power output will be disabled.

Can also be used as a general purpose input.

PTHERM

Input for motor temperature sensor.

Common of LIFT ENABLE / 1st SPEED / 2nd SPEED / 3rd SPEED / 4th SPEED / HYDRO /

SR microswitches.

NAUX

This output can be used for drive the main contactor coil (single pump configuration) or to drive

an auxiliary load (combi configuration)

B10

NHYDRO

Output for driving an hydraulic steering contactor; drives the load to -Batt. Maximum current:

3A.

B11

2nd SPEED

Input for second speed request; it is active HIGH.

B11

GND

-Batt.

B12

NTHERM

-Batt.

CAN-L

Low level CAN-BUS voltage I/O.

SM 765, Sep ’06

Description • 19-1-9

Group 19, Motor Controls

CAN-L-OUT

Low level CAN-BUS voltage I/O.

CAN-H

High level CAN-BUS voltage I/O.

CAN-H-OUT

High level CAN-BUS voltage I/O.

-BATT

-Batt.

MODE

This input allows the customer to select the software for traction or

lifting application.

Configuration:

MODE: Open (not connected)

Traction inverter

MODE: Close (connected with A5)

Pump inverter

E1~E6

Incremental ENCODER connector (see chapter 3.6).

PCLRXD

Positive serial reception.

NCLRXD

Negative serial reception.

PCLTXD

Positive serial transmission.

NCLTXD

Negative serial transmission.

GND

Negative console power supply.

+12

Positive console power supply.

FLASH

Must be connected to F8 for the Flash memory programming (if used).

FLASH

Must be connected to F7 for the Flash memory programming (if used).

19-1-10 • Description

SM 765, Sep ’06

Group 19, Motor Controls

Section 2

Control Programming

Programming & Adjustments Using ZAPI Handset

Adjustments via Handset

Adjustments of parameters and changes to the controller's configuration are made using the digital Handset. The Handset

is connected to the "B: connector of the controller.

Start with the battery disconnected at the battery receptacle, key switch in the OFF position.

Disconnect the dash display harness from the Master Control and connect the handset cord into this "B" connector.

Plug in the battery and turn the key switch ON.

Description of Handset & Connections

Digital Handsets used to communicate with the AC Controllers must be fitted with EPROM CK ULTRA, minimum

"Release Number 3.07, CLARK part number 8033636.

The Handset “Release Number” will be displayed on the

Handset display momentarily when the key switch is first

turned ON.

SM 765, Sep ’06

Control Programming • 19-2-1

Group 19, Motor Controls

The Handset display will than show a screen simular to the one shown below.

DA2M2BGCPE CK 0.13

80V 280A 00000

As shown in this Example; the “M” in DA2M2BGCPE, indicates the the Handset is now monitoring the Master control.

The slave control is represented with a :”S”, and the Pump control would be indicated with a “P”.

The last 6 digits of the top line in the example above indicate the current software revision loaded into the Master control.

The CK indicates CLARK and the 0.13 is the software revision level.

The bottom line on the display indicates the Battery Voltage and the current level that has been set and the current internal

hour meter reading of the control.

At the bottom of the Handset there are 6 push buttons used to navigate to a different control (Master, Slave or Pump), or to

navigate through the control functions and to make changes to the paramaters.

A flow chart of the Handset functions is shown on the following page.

The Handset is used to make adjustments to the parameters, used to view test functions within the electrical system of the

truck and to view the alarms (fault codes) that are present or stored in the memory of the controls.

See Group 19, Section 4 for GEX Factory Control Settings

19-2-2 • Control Programming

SM 765, Sep ’06

Group 19, Motor Controls

Gex Handset

Master Control Configuration

DA2M2BGCPE CK 0.13

DISPLAY

80V 280A 00000

DISPLAY

80V 280A 00000

KEYBOARD

HEADING

Enter

Main Menu

Set Model

Connected to 3 (Master), 4 (Slave), 5 (Pump)

Enter

Parameter

Enter

Acceleration Delay

0-9

Set Options

Hour Meter

Running / Key On

Change

Release Braking

0-9

Battery Check

On/Off

Inverse Braking

0-9

Hydraulic Key On

On/Off

Pedal Braking

0-9

Stop On Ramp

On/Off

Speed Limit Braking

0-9

Roll

Aux Input #1

Exclusive Hyd / Option #1 / Option #2

Brake Cutback

0-9

Pedal Braking

Analog / Digital / None

Roll

Max Speed Forward

Steer Table

Option #1 / Option #2

Max Speed Reverse

Curve Cutback

Enter

Frequency Creep

Adjustments

Set Pot Brake Minimum

... V

Maximum Current

0-9

Set Pot Brake Max

... V

Auxilary Time

Sec

Set Battery Type

80V

Seat Micro Delay

Sec

Adjust Battery

... V

Acc Smooth

Sec

Max Steer Right

... V

Inv Smooth

Sec

Max Steer Left

... V

Stop Smooth

Set Steer 0-Position

... V

Idle Time

Min

Set Steer Right

...”

Set Steer Left

...”

Throttle 0 Zone

...%

Enter

Throttle Y Zone

...%

Tester

Motor Voltage

Throttle X Zone

...%

Frequency

Adjustment #04

”C

Encoder

Adjustment #01 (Display)

0-9

Slip Value

Adjustment #02 (Shut Down)

0-9

Current RMS

Main Contactor Voltage

... V

Temperature

”C

Aux Output Voltage

... V

Roll

Temperature #1

”C

Temperature #2

”C

Maintenance Done

On/Off

Maintenance

None / Opt #1 / Opt #2

Accelerator

1 X 10,000 Hours

0-6

Steer Angle

...”

1 X 1,000 Hours

0-9

Brake Pedal Pot

1 X 100 Hours

0-9

Inner Wheel Cutback

Seat Switch

On/Off

1 X 10 Hours

0-9

1 X 100 Hours

0-9

Forward Switch

Reverse Switch

Enable Switch

On/Off

Brake Switch

On/Off

Cutback Switch

On/Off

Exclusive Hydraulics

On/Off

Hand Brake

On/Off

Voltage Booster

Battery Voltage

Battery Charge

Save

Parameter

Roll

Restore

Parameter

Roll

Enter

Alarms

Code, h, N”, ”C

Roll

Program

Enter

VACC

VACC Settings

Min/Max

Roll

Enter

Motor Data

Not Available

SM 765, Sep ’06

Control Programming • 19-2-3

Group 19, Motor Controls

Master Control - "Dualac2 Power 80V"

SUBMENU "SET OPTIONS"

1. HOUR COUNTER

RUNNING:

the counter registers any motor running.

SEAT:

the counter registers when the "key" is closed and operator is sitting on the seat.

2. BATTERY CHECK

ON:

the battery discharge level check is carried out; when the battery level reaches 10%, a fault is sig-

naled (-66 code) and the maximum current is reduced to half th programmed value.

OFF:

the battery discharge level is carried out but no fault is signaled.

3. HYDRO ON

ON/OFF

Controller manages the power steering function when the "key" is switched on.

4. STOP ON RAMP

the stop on ramp feature (truck electrically held on a ramp) is managed for a time established by "

auxiliary time" parameter.

OFF

the stop on ramp feature is not performed.

5. AUX INPUT #1

EXCLUSIVE

input C10 activates power steering function, output A31 is activated.

HYDRO:

OPTION #1

input C10 is the input for the handbrake switch, active low (open switch)

OPTION #2

input C10 is input for a speed reduction switch, active low (open switch)

6. PEDAL BRAKING

ANALOG:

The mechanical brake pedal has a switch and potentiometer installed. When the accelerator is

released and the pedal brake is pushed the controller performs an electrical braking whose intensity

is proportional to the brake pedal potentiometer. The minimum intensity is established by the

"Release braking" parameter, when the brake pedal is slightly pressed (brake switch closed but

brake potentiometer at minimum). The maximum intensity is established by the "Pedal Braking"

parameter, when the brake pedal is fully pressed (brake potentiometer at maximum). In the middle

positions, the electrical braking intensity is a linear function between minimum and maximum

intensity.

Digital:

The truck does not have a potentiometer installed on the mechanical brake pedal, but only a micro

switch; when the accelerator is released and the brake pedal is pushed (brake switch closed), the

controller performs an electrical braking following "Pedal Braking" parameter.

7. SET TEMPERATURE

DIGITAL:

A digital (ON/OFF) motor thermal sensor is connected C25 (C35) input.

ANALOG:

An analog motor thermal sensor is connected to C25 (C35) (the curve can be customized on cus-

tomer request).

None

No motor sensor switch connected.

8. STEER TABLE This parameter is used to set the correct steering table.

8. MODE SELEC- Used to set up the working mode of truck. (0=Economy, 1=Normal, 2=Power, 3=Turtle mode)

TION

19-2-4 • Control Programming

SM 765, Sep ’06

Group 19, Motor Controls

SUBMENU "ADJUSTMENTS"

1. SET POT BRK MIN:

Records the minimum value of the braking pedal potentiometer when the braking pedal

(Not Used)

switch is closed; the procedure is similar to the "Program VACC" function. This proce-

dure is only used if the "pedal braking" option is programmed as "Analog".

2. SET POT BRK MAX:

Records the maximum value of the braking pedal potentiometer when the braking pedal

(Not Used)

is fully pressed; the procedure is similar to the "Program VACC" function. This proce-

dure is only used if the "pedal braking" option is programmed as "Analog".

3. SET BATTERY TYPE:

Selects nominal battery voltage.

4. ADJUST BATTERY:

Fine adjustment of the battery voltage measured by the controller.

5. MAX STEER RIGHT:

Records in the controller EEPROM the steer potentiometer output voltage when the

steering wheel is turned fully right (maximum of the steering potentiometer range).

6. MAX STEER LEFT:

Records in the controller EEPROM the steer potentiometer output voltage when the

steering wheel is turned fully left (minimum of the steering potentiometer range).

7. SET STEER 0 POS:

Records in the controller EEPROM the steer potentiometer output voltage when the

steering wheels are straight.

8. SET STEER RIGHT:

Sets the max steering angle in the right direction.

9. SET STEER LEFT:

Sets the max steering angle in the left direction.

10. THROTTLE 0 ZONE:

Establishes a deadband in the accelerator input curve

11. THROTTLE X POINT:

This parameter changes the characteristics of the accelerator input curve

12. THROTTLE Y POINT:

This parameter changes the characteristics of the accelerator input curve

SPEED f(Hz)

MAX SPEED

TROTTLE Y

POINT

FREQ. CREEP

TROTTLE X

VACC

TROTTLE 0

MIN

POINT

MAX

ZONE

VACC MIN and VACC MAX are values programmable by the "PROGRAM VACC" function.

This VACC procedure programs the actual minimun and maximum input voltages from the accelerator control.

See Group 13, Section 4 for setup procedure.

SM 765, Sep ’06

Control Programming • 19-2-5

Group 19, Motor Controls

13. ADJUSTMENT #04:

Determines the motor temperature level at which the "Motor Temperature" fault is

(Do Not Change)

signaled. The default temperature is 130° C. Icon on dash will illuminate at this

temperature.

14. MOTOR SHUTDOWN:

This parameter determines the motor temperature level at which the "Motor Shut-

(Do Not Change)

down" fault is signaled. The default temperature is 145° C.

15. ADJUSTMENT #01

Adjust the upper level of the battery discharge table.

16. ADJUSTMENT #02

Adjust the lower level of the battery discharge table.

17. ADJUSTMENT #3

Adjust percentage of battery change it take to reset battery state of charge on dash

display.

18. MAIN CONT VOLTAGE:

Adjusts the Line contactor coil voltage (PWM output C26).

19. AUX OUTPUT VOLTAGE:

Adjusts the Electric brake coil voltage (PWM output C28).(Not Used)

20. MAINTENANCE DONE:

OFF is the default Setting. When a maintenance warning occurs, the operator can

cancel the warning setting this parameter ON. When the truck is turned on again

this parameter becomes OFF.

21. MAINTENANCE:

-NONE:

When truck reaches maintenance time, if this parameter is set as NONE, the con-

troller gives a maintenance warning but does not reduce performance.

OPTION #1:

When truck reaches maintenance time, if this parameter is set as OPTION #1, the

controller gives a maintenance warning and reduces truck performance

OPTION # 2:

When truck reaches maintenance time, if this parameter is set as OPTION #2, the

controller gives a maintenance warning and stops the truck.

22. MAINTENANCE TIME:

Sets the number running truck hours before setting the maintenance fault. This is a

count down timer, it must be reset after each PM.

23. 1x 10, 000 HOURS:

Sets the ten thousands units of the hour meter displayed on the dash display. This

will not change the hour meter of the controller.

24. 1x 1, 000 HOURS:

Sets the thousands units of the hour meter displayed on the dash display. This will

not change the hour meter of the controller.

25. 1x 100 HOURS:

Sets the hundreds units of the hour meter displayed on the dash display. This will

not change the hour meter of the controller.

26. 1x 10 HOURS:

Sets the ten units of the hour meter displayed on the dash display. This will not

change the hour meter of the controller.

27. 1x 1 HOURS:

Sets the units of the hour meter displayed on the dash display. This will not change

the hour meter of the controller.

19-2-6 • Control Programming

SM 765, Sep ’06

Group 19, Motor Controls

Parameter Regulation

The following parameters can be modified( See Group 19, Section 4 for Clark factory recommended settings)

1. ACC DELAY:

Determines the acceleration ramp

2. RELEASE BRAKING:

Controls the deceleration ramp when the travel request (accelerator) is released

The higher the setting, the more aggressive the braking.

3. INVERSION BRAKING:

Controls the deceleration ramp when the direction is changed (FWD to REV or

REV to FWD) during travel.

The higher the setting, the more aggressive the braking.

4. PEDAL BRAKING:

Determines the deceleration ramp when the travel request is (accelerator) released

and the brake pedal switch is closed.

The higher the setting, the more aggressive the braking.

5. SPEED LIMIT BRAKING:

Deceleration ramp when the pedal position is changed but not completely released

6. BRAKE CUTBACK:

Determines the deceleration ramp when the speed reduction input becomes active

and the motor slows down.

7. CURVE BRAKING:

Determines the rate of the decelleration ramp in a curve as the steer wheel is

(Do Not Change)

turned.

8. MAX SPEED FORWARD:

Determines maximum speed in forward direction.

9. MAX SPEED BACKWARD:

Determines maximum speed in reverse direction.

10. CURVE CUTBACK:

Speed reduction when the truck in a turn. The parameter sets the speed set point

(CLARK Special)

when the truck driving wheels are running in opposite direction (3 wheel truck,

steering angle greater than roughly 67°); or when the maximum steering angle is

reached (4 wheel truck, the internal wheel is stopped). In intermediate steering

angles, the speed set point will be within a range between the straight wheel speed

and the CURVE CUTBACK SPEED.

11. CURVE CUTBACK #1:

Determines the speed of the inside wheel as the steering wheel is turned.

12. CUTBACK SPEED1:

Speed reduction when cutback switch1 is active.

(Not Used)

13. FREQUENCY CREEP:

Minimum speed when the forward or reverse switch is closed, but the accelerator

(Do Not Change)

is in a minimum position.

14. MAXIMUM CURRENT:

Changes the maximum current of the controller

(Do Not Change)

15. AUXILIARY TIME:

Determines the time that the truck will hold on a ramp if the "stop on ramp" option

(Do Not Change)

is ON.

16. SEAT MICRO DELAY:

Used to set up the Delay value to open the seat switch.

17. ACC SMOOTH

ACC SMOOTH controls the acceleration rate, when the speed request is between 0

Hz and the frequency setting defined by STOP SMOOTH. When the speed request

is above the STOP SMOOTH value, then the parameter ACCELERATION

DELAY controls the acceleration rate. Adjusting this level changes the time (in

seconds) required to accelerate the truck. The lower the acceleration level the

more aggressive the acceleration is.

18. INV SMOOTH

INV SMOOTH is similar to ACC SMOTH but it controls the acceleration rate after

the truck is plugged to a complete stop and starts to accelerate in the opposite

direction.

19. STOP SMOOTH

Sets the frequency point where ACC SMOOTH stops and ACCELERATION

DELAY starts.

20. IDLE TIME

Sets the main line Contactor open time.

SM 765, Sep ’06

Control Programming • 19-2-7

Group 19, Motor Controls

PARAMETERS

PROGRAM LEVEL

Unit

Acceleration Delay (*)

Sec.

1.5

1.8

2.0

2.5

3.5

4.5

Release Braking (**)

Sec.

Inversion Braking (**)

Sec.

5.5

4.5

3.5

2.5

1.5

Pedal Braking (**)

Sec.

5.5

4.5

3.5

2.5

1.5

Speed Limit Barking (**)

Sec.

8.9

8.3

7.7

7.1

6.6

5.5

4.9

4.4

3.8

Brake Cutback (**)

Sec.

5.5

4.5

3.5

2.5

1.5

Curve Braking

Sec.

1.5

1.4

1.3

1.2

1.1

0.9

0.8

0.7

0.6

Max speed Forw

0 ~ 200

Max speed Back

0 ~ 200

Dual

Cutback Speed

100

AC2

Cutback Speed 2

0 ~ 100

PW(8

0V)

Curve Cutback

0 ~ 100

Curve Cutback #1

100

Frequency Creep

0.3

0.6

0.9

1.2

1.5

1.8

2.1

2.4

2.7

Maximum Current

% IMAX

100

Auxiliary Time

Sec.

1.5

3.0

4.5

6.0

7.5

9.0

10.5

Seat Micro Delay

Sec.

2.0

2.1

2.3

2.4

2.6

2.8

2.9

3.1

3.3

3.5

Acc. Smooth

Sec.

1.0

1.2

1.5

1.7

2.0

2.2

2.5

2.7

3.0

3.5

Inv. Smooth

Sec.

1.0

1.2

1.5

1.7

2.0

2.2

2.5

2.7

3.0

3.5

Stop Smooth

Idle time

Min

(***)

*)The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp calculated by the software; the real

ramp could change as afunction of motor control parameter setting and, obviously, a function of the load.

(**)The braking feature is base on deceleration ramps. The value shown in the table is the time to decrease the speed from

100 Hz to 0 Hz. This is the ideal ramp calculated by the software; the real ramp could change as afunction of motor con-

trol parameter setting and, obviously, a function of the load.

(***)(Always closed).

PARAMETERS

SPEED EMPTY MPH

MPH

11.1

MAX SPEED FORWARD

101

114

126

140

MAX SPEED REVERSE

101

114

126

140

NOTE

Maximum speed for the GEX20/30 can not exceed 140 Hz.

Maximum speeds are adjustable from 0 Hz to 140 Hz in 1 Hz increments. Forward speed and reverse speeds can be set

independently (Forward speed can be set to 8 MPH and Reverse speed can be set at 5MPH if desired)

19-2-8 • Control Programming

SM 765, Sep ’06

Group 19, Motor Controls

TESTER MENU

The most important input or output signals can be measured in real time using the TESTER function of the handset. The

handset acts as a multimeter able to read voltage, current and temperature. The following is a list of measurements for

different configurations.

Handset Tester: user can verify the state of the following parameters:

MASTER CONTROL

Truck Hour Meter(HRs)

Accelerator (V)

Brake switch (ON/OFF)

Motor voltage (%)

Steer Angle (°)

Exclusive hydro (ON/OFF)

Frequency (Hz)

Int wheel cutback (%)

Brake pedal poti (%)

Encoder (Hz)

Forw switch (ON/OFF)

Hand brake (ON/OFF)

Slip Value (Hz)

Back switch (ON/OFF)

Voltage booster (%)

Current RMS (A)

Enable switch (ON/OFF)

Battery voltage (V)

Temperature (°C)

Seat switch (ON/OFF)

Battery charge (%)

Temperature #1 (°C)

Cutback switch (ON/OFF)

Temperature #2 (°C)

Cutback switch2 (ON/OFF)

Master Control - "Dualac2 Power 80V"

1) TRUCK HOUR METER:

Shows truck hour meter

2) MOTOR VOLTAGE:

This is the voltage supplied to the motor by the controller; it is expressed as a percent-

age of full battery voltage.

3) FREQUENCY:

This is the frequency of the voltage and current supplied to the motor.

4) ENCODER:

This is the speed of the motor, expressed in the same unit of the frequency; this infor-

mation comes from the speed sensor.

5) SLIP VALUE:

This is the difference of speed between the rotating field and the shaft of the motor,

expressed in the same unit of the frequency.

6) CURRENT RMS:

Root Mean Square value of the motor current.

7) TEMPERATURE:

The temperature measured on the aluminum heat sink holding the MOSFET devices.

8) TEMPERATURE #1:

This is the temperature of the right motor; if this option is programmed "None" it

shows 0°.

9) TEMPERATURE #2:

This is the temperature of the left motor; if this option is programmed "None" it shows

0°.

10) ACCELERATOR:

The voltage of the accelerator potentiometer's wiper (CPOT). The voltage level is

shown on the left-hand side of the Handset display and the value in percentage is

shown on the right-hand side.

11) STEER ANGLE:

This is the indication off the angular position of the steer wheel.

12) INTERNAL WHEEL

This is an indication of the speed reduction applied to the inside wheel; in other words,

CUTBACK:

it shows the ratio of the two speeds.

13) FORWARD SWITCH:

The level of the Forward direction digital input FW.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

14) BACKWARD SWITCH:

The level of the Reverse direction digital input BW.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

SM 765, Sep ’06

Control Programming • 19-2-9

Group 19, Motor Controls

15) ENABLE SWITCH:

The level of the Enable digital input.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

16) SEAT SWITCH:

The level of seat microswitch digital input.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

17) CUTBACK SWITCH:

The level of the Speed Reduction microswitch.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

18) CUTBACK SWITCH2:

The level of the Speed Reduction microswitch.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

19) BRAKE SWITCH:

The level of the brake microswitch.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

20) EXCLUSIVE HYDRO:

Status of the exclusive hydro switch.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

21) BRAKE PEDAL POTI:

Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if

the "PEDAL BRAKING" parameter is set to "ANALOG".

22) HAND BRAKE:

The level of the Handbrake microswitch.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open

23) VOLTAGE BOOSTER:

This is the booster voltage supplied to the motor in load condition; It is expressed in a

percentage of the full voltage.

24) BATTERY VOLTAGE:

Level of the battery voltage measured at the input of the key switch.

25) BATTERY CHARGE:

The percentage charge level of the battery.

19-2-10 • Control Programming

SM 765, Sep ’06

Group 19, Motor Controls

Slave Control - "Dualac2 Power (80V)"

Submenu "Adjustments"

1. SET BATTERY TYPE: Selects nominal battery voltage

2. ADJUST BATTERY: Fine adjustment of the battery voltage measured by the controller.

GEX Handset

Slave Control Configuration

DISPLAY

DM2S2BGCPE CK 0.13

80V 280A 00000

DISPLAY

80V 280A 00000

KEYBOARD

HEADING

Enter

Main Menu

Set Model

Connected to 4 (Slave) (3 = Master, 5 = Pump)

Roll

Parameter

Enter

Not Available

Change

Enter

Set Options

Not Available

Roll

Enter

Adjustments

Set Battery Type

48/72/80/96

Tester

Motor Voltage

Adjust Battery

Frequency

Aux Output Voltage

Encoder

Slip Value

Current RMS

Roll

Temperature

Seat Switch

On/Off

Forward Switch

Reverse Switch

Enable Switch

On/Off

Voltage Booster

Battery Voltage

Save

Parameter

Roll

Restore

Parameter

Roll

Enter

Alarms

Roll

Program

Enter

VACC Settings

Min/Max

VACC

Roll

Enter

Motor Data

Not Available

See Group 19, Section 4 for GEX Factory Control Settings

SM 765, Sep ’06

Control Programming • 19-2-11

Group 19, Motor Controls

TESTER MENU

The most important input or output signals can be measured in real time using the TESTER function of the handset. The

handset acts as a multimeter able to read voltage, current and temperature. The following is a list of measurements for

different configurations.

Handset Tester: user can verify the state of the following parameters:

SLAVE CONTROL

Motor voltage (%)

Current RMS (A)

Back switch (ON/OFF)

Frequency (Hz)

Temperature (°C)

Enable switch (ON/OFF)

Encoder (Hz)

Seat switch (ON/OFF)

Voltage booster (%)

Slip Value (Hz)

Forw switch (ON/OFF)

Battery voltage (V)

Slave Control - "Dualac2 Power 80V"

1) MOTOR VOLTAGE:

This is the voltage supplied to the motor by the controller; it is expressed as a percentage

of full battery voltage.

2) FREQUENCY:

This is the frequency of the voltage and current supplied to the motor.

3) ENCODER:

This is the speed of the motor, expressed in the same unit of the frequency; this informa-

tion comes from the speed sensor.

4) SLIP VALUE:

This is the difference of speed between the rotating field and the shaft of the motor,

expressed in the same unit of the frequency.

5) CURRENT RMS:

Root Mean Square value of the motor current.

6) TEMPERATURE:

The temperature measured on the aluminum heat sink holding the MOSFET devices.

7) SEAT SWITCH:

The level of seat microswitch digital input.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

8) FORWARD SWITCH:

The level of the Forward direction digital input FW.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

9) BACKWARD SWITCH:

The level of the Reverse direction digital input BW.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

10) ENABLE SWITCH:

The level of the Enable digital input.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

11) VOLTAGE BOOSTER:

This is the booster voltage supplied to the motor in load condition; It is expressed in a per-

centage of the full voltage.

12) BATTERY VOLTAGE:

Level of the battery voltage measured at the input of the key switch.

19-2-12 • Control Programming

SM 765, Sep ’06

Group 19, Motor Controls

PUMP CONTROL

Using the configuration menu of the programming console, the user can configure the following functions.

GEX Handset

Pump Control Configuration

AC3P2BIG CK0.09

DISPLAY

80V 450A 00000

DISPLAY

80V 450A 00000

KEYBOARD

HEADING

Enter

Main Menu

Set Model

Connected to 5 (Pump) (3 = Master, 4 = Slave)

Roll

Parameter

Enter

Acceleration Delay

0-9

Change

Decelleration Delay

0-9

Enter

Acc delay Tilt

0-9

Set Options

Hour Meter

Running / Key On

Dec delay Tilt

0-9

Set Temperature

Analog / Digital / None

Aux1 Acc delay

0-9

Roll

Therm Protection

On/Off

Roll

Aux1 Dec delay

0-9

Hour Meter Truck

On/Off

Aux2 Acc delay

0-9

Pressure Funct

On/Off

Aux2 Dec delay

0-9

Digital lift

On/Off

Max Speed Up

Min Speed Up

Cutback speed

1st Speed

Enter

Adjustments

Set Battery Type

48/72/80/96

2nd Speed

Adjust Battery

3rd Speed

Adjustment #04

4th Speed

Adjustment #03

Hydro Speed

Throttle 0 Zone

Idle Speed

Throttle Y Zone

Idle Time

Sec

Throttle X Zone

Maximum Current

0-9

Motor Shutdown

Auxilary Time

Sec

IMAX Protection

Enter

Tester

Motor Voltage

Frequency

Encoder

Slip Value

Current RMS

Temperature

Roll

Motor Temperature

Accelerator

Lift Switch

On/Off

1st Speed Switch

On/Off

2nd Speed Switch

On/Off

3rd Speed Switch

On/Off

4th Speed Switch

On/Off

Save

Hydro Speed Req

On/Off

Parameter

Voltage Booster

Battery Voltage

Roll

COS FI

Battery Current

Restore

Battery Charge

Parameter

Roll

Enter

Alarms

Roll

Program

Enter

VACC

VACC Settings

Min/Max

Roll

Enter

Motor Data

Not Available

SM 765, Sep ’06

Control Programming • 19-2-13

Group 19, Motor Controls

SUBMENU "SET OPTIONS"

1 HOUR METER TRUCK

RUNNING:

The meter registers when the "key" is ON

KEY ON:

The meter registers travel time only.

2 SET TEMPERATURE

DIGITAL:

A digital (ON/OFF) motor thermal sensor is connected to F6 input.

ANALOG:

An analog motor thermal sensor is connected to F6(the curve can be customized on customer

request).

None:

No motor sensor switch connected.

3 THERMO PROTECTION

ON:

When motor winding temperature is over 90°…, reduce the torque

OFF:

Always pull torque should be provided.

4 HOUR METER TRUCK

ON:

Equipment usage time should be shared between travel and hydraulic controller.

OFF:

Equipment usage time should not be shared.

5 PRESSURE FUNCT

ON:

Use pressure sensor to operate steering motor.

OFF:

Operate steering motor by ahead/astern lever without pressure sensor.

6 DIGITAL LIFT

ON:

Operate lift without potentiometer(operated by ON/OFF switch)

OFF:

Lift speed is relative to the output value of potentiometer.

19-2-14 • Control Programming

SM 765, Sep ’06

Group 19, Motor Controls

SUBMENU "ADJUSTMENTS"

1. SET BATTERY TYPE:

Selects nominal battery voltage.

2. ADJUST BATTERY:

Fine adjustment of battery voltage measured by the controller.

3. ADJUSTMENT #4:

Used to decide the motor temp level on which the motor temp abnormal signal is dis-

played. The temp range will be adjusted from 70°C to 160°C in the unit of 10°C. This

parameter shall be adjusted only when the “Temp Adjustment” (“Option” menu) parame-

ter has been programmed in analog.

MOTOR

SHUT-

Used to shut down the hydraulic operation when the set value is reached. (However, the

DOWN:

steering can work.)

5. THROTTLE 0 ZONE:

Establishes a deadband in the accelerator input curve.

6. THROTTLE X POINT:

This parameter changes the characteristics of the accelerator input curve.

7. THROTTLE Y POINT:

This parameter changes the characteristics of the accelerator input curve.

8. IMAX PROTECTION:

The value to start the current reduction when the motor temperature reaches adjustment

#4 value.

SPEED f(Hz)

MAX SPEED

TROTTLE Y

POINT

FREQ. CREEP

TROTTLE X

VACC

TROTTLE 0

MIN

POINT

MAX

ZONE

VACC MIN and VACC MAX are values programmable by the "Program VACC" function.

This VACC procedure programs the actual minimun and maximum input voltages from the lift potentiometer.

See Group 13, Section 4 for setup procedure.

SM 765, Sep ’06

Control Programming • 19-2-15

Group 19, Motor Controls

Parameter Regulation: Pump Configuration

The following parameters can be modified:

1. Acceleration Delay

Acceleration ramp for lift(See Tables Below).

2. Deceleration Delay

Deceleration ramp for lift(See Tables Below).

3. Acceleration Delay Tilt

Acceleration ramp for tilt(See Tables Below).

4. Deceleration Delay Tilt

Deceleration ramp for tilt(See Tables Below).

5. Acceleration Delay Aux1

Acceleration ramp for Aux1(See Tables Below).

6. Deceleration Delay Aux1

Deceleration ramp for Aux1(See Tables Below).

7. Acceleration Delay Aux2

Acceleration ramp for Aux2(See Tables Below).

8. Deceleration Delay Aux2

Deceleration ramp for Aux2(See Tables Below).

9. Max Speed Up:

Determine the maximum lifting speed with a Potentiometer control (See Tables Below).

10. Min Speed Up:

Determine the minimum lifting speed with a potentiometer control when the lifting

enable switch is closed (See Tables Below).

11. Cutback Speed

Speed when cutback switch is activated

12. 1st Speed Fine:

First speed (Tilt Speed), fine adjustment (See Tables Below).

13. 2nd Speed Fine:

Second speed, fine adjustment (See Tables Below).

14. 3rd Speed Fine:

Third speed, fine adjustment (See Tables Below).

15. 4th Speed Fine:

Fourth speed, fine adjustment.

16. Hyd Speed Fine:

Hydro speed, fine adjustment.

17. Idle Speed:

Set speed when steer on demand is active but pressure sensor is not moving. (Not used)

18. Idle Time:

The set time delay before stopping the motor when steer demand is active and pressure

sensor is not moving. (Not used)

19. Max Current:

Maximum current of the controller (See Tables Below).

20. Auxilary Time:

Time delay when power steering function request is switched off (See Tables Below).

The following tables show the different value at which the parameters can be set.

PROGRAM LEVEL

PARAMETERS

UNIT

Acceleration Delay

Sec.

0.5

0.7

1.4

1.9

2.5

3.2

4.8

5.5

Deceleration Delay

Sec.

0.5

0.7

1.4

1.9

2.5

3.2

4.8

5.5

Acceleration Delay Tilt

Sec.

0.5

0.7

1.4

1.9

2.5

3.2

4.8

5.5

Deceleration Delay Tilt

Sec.

0.5

0.7

1.4

1.9

2.5

3.2

4.8

5.5

Acceleration Delay Aux1

Sec.

0.5

0.7

1.4

1.9

2.5

3.2

4.8

5.5

Deceleration Delay Aux1

Sec.

0.5

0.7

1.4

1.9

2.5

3.2

4.8

5.5

Acceleration Delay Aux2

Sec.

0.5

0.7

1.4

1.9

2.5

3.2

4.8

5.5

Deceleration Delay Aux2

Sec.

0.5

0.7

1.4

1.9

2.5

3.2

4.8

5.5

AC3

Max Speed Up

0-200

Min Speed Up

13.5

16.5

19.5

22.5

25.5

(80V)

Cutback Speed

100

1st Speed Fine

0-200

2nd Speed Fine

0-200

3rd Speed Fine

0-200

4th Speed Fine

0-200

Hyd Speed Fine

0-200

Idle Speed

Idle Time

Sec.

Max Current

% IMAX

100

Auxilary Time

Sec.

19-2-16 • Control Programming

SM 765, Sep ’06

Group 19, Motor Controls

TESTER MENU

The most important input or output signals can be measured in real time using the TESTER function of the handset. The

handset acts as a multimeter able to read voltage, current and temperature. The following is a list of measurements for

different configurations.

Handset Tester: user can verify the state of the following parameters:

PUMP CONTROL

Motor voltage (%)

Accelerator (V)

Hydro speed req. (ON/OFF)

Frequency (Hz)

Lifting switch (ON/OFF)

Voltage booster (%)

Encoder (Hz)

1st speed switch (ON/OFF)

Battery voltage (V)

Slip Value (Hz)

2nd speed switch (ON/OFF)

Cos fi

Current RMS (A)

3rd speed switch (ON/OFF)

Battery Current (A)

Temperature (°C)

4th speed switch (ON/OFF)

Battery charge (%)

Motor Temperature (°C)

1) MOTOR VOLTAGE:

This is the voltage supplied to the motor by the controller; it is expressed as a percent-

age of full battery voltage.

2) FREQUENCY:

This is the frequency of the voltage and current supplied to the motor.

3) ENCODER:

This is the speed of the motor, expressed in the same unit of the frequency; this infor-

mation comes from the speed sensor.

4) SLIP VALUE:

This is the difference of speed between the rotating field and the shaft of the motor,

expressed in the same unit of the frequency.

5) CURRENT RMS:

Root Mean Square value of the motor current.

6) TEMPERATURE:

The temperature measured on the aluminum heat sink holding the MOSFET devices.

7) MOTOR TEMPERATURE:

This is the temperature of the right motor; if this option is programmed "None" it

shows 0°.

8) ACCELERATOR:

The voltage of the accelerator potentiometer's wiper (CPOT). The voltage level is

shown on the left-hand side of the console display and the value is in percentage is

shown on the right-hand side

9) LIFTING SWITCH:

Status of lifting switch.

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

10) TILT SPEED SWITCH:

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

11) AUX1 SPEED SWITCH:

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

SM 765, Sep ’06

Control Programming • 19-2-17

Group 19, Motor Controls

12) AUX2 SPEED SWITCH:

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

13) AUX3 SPEED SWITCH:

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

14) HRYDRO SPEED REQ.:

ON /+BV = input active, switch closed.

OFF / GND = input non-active, switch open.

15) VOLTAGE BOOSTER:

This is the booster voltage supplied to the motor in load condition; It is expressed in a

percentage of the full voltage.

16) BATTERY VOLTAGE:

Level of the battery voltage measured at the input of the key switch.

17) COS FI:

This is cosj (real time calculated) of the motor.

18) BATTERY CURRENT:

This is the battery current (not measured but calculated.

19) BATTERY CHARGE:

The percentage charge level of the battery

OTHER HANDSET FUNCTIONS

Save and Restore Function

SAVE Function allows the transfer of controller parameters to the PC memory. With this function, a copy of the control-

ler's set of parameters can be retained in a Pc and downloaded to another controller (see restore).

RESTORE Function allows you to download controller parameters from the PC memory to the controller Eeprom. Thus

a copy of the parameters stored in the Pc can be downloaded in a controller avoiding the parameter setting operation.

SETUP for INSTALLING A NEW CONTROL PANEL

Sequence for AC Traction Controller Setting

When the "Key Switch" is turned ON, if no faults are present, the Zapi Handset Display will be showing the standard

Opening Display.

If the controller is not configured to your requirements, follow the sequence detailed below. Remember to cycle the key

switch if you make any changes to the controller configuration.

1) Select the options required.

2) Select and set battery voltage.

3) Confirm correct installation of all wires. Use Handset's TESTER function to assist.

4) Perform the accelerator signal acquisition procedure using the Handset "PROGRAM VACC".(See Group 13, Sec-

tion 4 for programming procedures).

5) Perform the steering potentiometer signal acquisition, using the parameters in "Adjustment" menu.(See Group 13,

Section 4 for programming procedures).

Remember: when turning the wheel to the right the voltage will increase.

19-2-18 • Control Programming

SM 765, Sep ’06

Group 19, Motor Controls

Section 3

CONTROL TROUBLESHOOTING

FAULT CODES FOR GEX

This is the list of codes that the CLARK dash display may show

Fault

Fault Name

Control

Fault

Fault Name

Control

Code

140

" HIGH TEMPERATURE"

SLAVE

"NO SEAT SWITCH"

MASTER

148

"ENCODER ERROR"

SLAVE

"CHOPPER RUNNING"

MASTER

150

"WATCHDOG"

PUMP

"WATCHDOG"

MASTER

151

"CHOPPER RUNNING"

PUMP

"INPUT MISMATCH"

MASTER

155

"EEPROM KO"

PUMP

"WAITING DISPLAY"

MASTER

159

"LOGIC FAILURE #3

PUMP

"EEPROM KO"

MASTER

160

"LOGIC FAILURE #2

PUMP

"LOGIC FAILURE #3

MASTER

161

"LOGIC FAILURE #1

PUMP

"LOGIC FAILURE #2

MASTER

171

"MOTOR SHUTDOWN"

PUMP

"LOGIC FAILURE #1

MASTER

172

"VMN LOW"

PUMP

"VMN LOW"

MASTER

173

"VMN HIGH"

PUMP

"VMN HIGH"

MASTER

174

"TH MOTOR SENSOR KO"

PUMP

"IDLE TIME"

MASTER

182

"MOTOR LOCKED"

PUMP

"CONTACTOR CLOSED"

MASTER

195

"STBY I HIGH"

PUMP

"CONTACTOR OPEN"

MASTER

196

"THERMIC SENSOR KO"

PUMP

"STBY I HIGH"

MASTER

201

"ENCODER ERROR"

PUMP

"CAPACITOR CHARGE"

MASTER

202

"CAP CHARGE"

PUMP

" HIGH TEMPERATURE"

MASTER

203

" HIGH TEMPERATURE"

PUMP

"MOTOR TC START"

MASTER

204

"VACC NOT OK"

PUMP

"BATTERY LOW"

MASTER

205

"INCORRECT START"

PUMP

"MOTOR SHUTDOWN"

MASTER

206

"PEDAL WIRE KO"

PUMP

"MOTOR LOCKED"

MASTER

207

"MOTOR TC START"

PUMP

"DRIVER SHORTED"

MASTER

208

"BATTERY LOW "

PUMP

"CONTACTOR DRIVER"

MASTER

211

"COIL SHORTED"

PUMP

"COIL SHORTED"

MASTER

212

"COIL INTERUPTED"

PUMP

"MAINTENANCE HOURS"

MASTER

217

"WRONG SET BATTERY"

PUMP

"VACC NOT OK"

MASTER

218

"SAFETY"

PUMP

"INCORRECT START (SRO)"

MASTER

222

"NO CAN MSG"

PUMP

"FORWARD + REVERSE"

MASTER

225

"AUX OUTPUT KO"

PUMP

"TH MOTOR SENSOR KO"

MASTER

232

"MASTER KO"

SLAVE

"ENCODER ERROR"

MASTER

233

"NO CAN MSG 3"

SLAVE

"STEER SENSOR KO"

MASTER

235

"THERMIC SENSOR KO"

SLAVE

"PEDAL WIRE KO"

SLAVE

236

"INPUT MISMATCH"

SLAVE

"WATCHDOG"

SLAVE

243

"NO CAN MSG 5"

MASTER

"WATCHDOG"

SLAVE

245

"WRONG SET BATTERY"

MASTER

"LOGIC FAILURE #3

SLAVE

246

"SLAVE KO"

MASTER

"LOGIC FAILURE #2

SLAVE

247

"NO CAN MSG 4"

MASTER

"LOGIC FAILURE #1

SLAVE

248

"CHECKUP NEEDED"

MASTER

"TH MOTOR SENSOR KO"

SLAVE

249

"THERMIC SENSOR KO"

MASTER

109

"VMN LOW"

SLAVE

253

"AUX OUTPUT KO"

MASTER

110

"VMN HIGH"

SLAVE

255

"HANDBRAKE"

MASTER

132

"STBY I HIGH"

SLAVE

Blank

"DASH DISPLAY"

MASTER

139

"CAPACITOR CHARGE"

SLAVE

SM 765, Dec ’06

CONTROL TROUBLESHOOTING • 19-3-1

Group 19, Motor Controls

Fault Code Charts

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

"NO SEAT

No input from seat

MASTER

• Controller detects the seat switch is open

SWITCH"

switch

or SLAVE

during operation.

• Check seat switch wiring and connec-

tions

Repair seat

• Check for inoperative seat switch.

switch wiring

Replace seat

switch

“CHOPPER

FET is running

MASTER

• XXXX

RUNNING”

"WATCH-

Watchdog circuit

MASTER

•

It is a self-diagnosing test within the

DOG"

has been triggered

logic between Master and Slave micro

controllers.

• This fault could also be caused by a

CAN-BUS malfunction, which blinds

Master -Slave communication. So

before replacing the controller , check

the Canbus

"INPUT

Seat Switch mis-

MASTER

• The seat switch input for traveling is dif-

MIS-

matched

ferent from that of hydraulic system.

MATCH"

• Check the seat switch line connected to

travelling controller and hydraulic con-

troller.

"WATCH-

Watchdog circuit

MASTER

It is a self-diagnosing test within the logic

DOG"

has been triggered

between Master and Slave micro controllers.

• This fault could also be caused by a

CAN-BUS malfunction, which blinds

Master -Slave communication. So

before replacing the controller , check

the Canbus

"EEPROM

Warning: EEprom

MASTER

• Fault in the area of memory in which the

KO"

fault controller

adjustment parameters are stored;

will use default

• This fault does not inhibit truck opera-

parameters

tion, but the controller will use default

parameters.

Replace con-

•

If fault persists when key is switched

troller

OFF and ON again.

•

If the fault disappears, remember that

the parameters stored previously have

been cancelled and replaced by the

default values.

"LOGIC

Failure in overload

MASTER

• Fault in the hardware section of the logic

Replace con-

FAILURE #3

protection hard-

board that manages the hardware current

troller

ware circuit

protection.

19-3-2 • CONTROL TROUBLESHOOTING

SM 765, Dec ’06

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

"LOGIC

Failure in U,V,W

MASTER

•

Fault in the hardware section of the logic

Replace con-

FAILURE #2

voltage feedback

board that manages the phase 's voltage

troller

circuit

feedback.

"LOGIC

An over voltage or

MASTER

•

This fault signals that the under voltage /

FAILURE #1

under voltage con-

over voltage protection interrupt has

dition has been

been triggered

detected

•

A real under voltage / over voltage key

input (C3) happened. Voltage has been

below 30V

•

A real over voltage on the power capaci-

tors happened, voltage has been 115V.

•

Fault in the hardware section of the logic

Replace con-

board that manages the over voltage pro-

troller

tection.

•

Possible plugging in or unplugging of

battery or charger with the key switch on.

"VMN

Wrong voltage on

MASTER

•

This test is carried out during initial diag-

Replace con-

LOW"

motor power out-

nosis and in standby. Possible causes

troller

puts; failure in the

•

problem with motor connections or the

power section or

motor power circuit; check if the

in the mosfet

phases are correctly connected; check if

driver circuit or in

there's chassis ground of the motor to

the motor

truck frame.

•

A problem with motor connection or

power circuit.

- Check if all 3 phases are correctly

connected.

- Check for short between motor ter-

minal and chassis

- Perform diode test

- unhook battery at controller and do

a diode check between Batt + and

Batt - (should read .3 to .5 volts)

•

Diode test

-Disconnect all power and motor leads

from control.

-Select diode test on your multi meter.

-Place positive meter lead on control -

Battery terminal place negative meter

lead on terminals U,V,W meter should

read .3V to .5V if not replace control.

-Place negative meter lead on control +

Battery terminal place positive meter

lead on terminals U,V,W meter should

read .3V to .5V if not replace control.

-If code presist replace control

• Fault in the inverter power section.

SM 765, Dec ’06

CONTROL TROUBLESHOOTING • 19-3-3

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

"VMN

Wrong voltage on

MASTER

•

This test is carried out during initial diag-

HIGH"

motor power out-

nosis and in standby. Possible causes:

puts; failure in the

•

Problem with motor connections or the

power section or

motor power circuit; check if the

in the mosfet

phases are correctly connected; check if

driver circuit or in

there's chassis ground of the motor to

the motor

truck frame.

•

Unhook battery at controller and do a

diode check between Batt + and Batt -

(should read .3 to .5 volts)

Replace con-

•

Fault in the controller power section.

troller

•

Possible bad battery, Excessive voltage

to case of battery.

"IDLE

Displayed when

MASTER

•

The main line contactor open function

TIME"

the Idle time con-

starts.

dition starts

•

Any traction inputs (Accelerator, pedal

brake, direction S/W-ON) need to close

the contactor.

"CONTAC-

Line contactor

MASTER

•

Before driving the line contactor coil, the

TOR

power contact

controller checks if the line contactor is

CLOSED"

closed at power up

stuck. The controller drives the bridge

for a while, trying to discharge the capac-

itor bank. If they don't dis charge, the

fault condition is entered. It is suggested

to check the contactor contact, see if it is

mechanically stuck.

"CONTAC-

Line contactor

MASTER

•

The controller has driven the line contac-

TOR OPEN"

power contact

tor, but the contactor did not close.

does not pull in

•

The wires to the coil are open or a loose

connection.

•

The contact does not pull in properly

"STBY

Wrong voltage in

MASTER

•

The microprocessors verify if the feed-

HIGH"

current sensor

back of current sensor device output is

feedback circuit

within the zero current window. Possible

causes of the fault.

•

Current sensor failure.

•

Failure in the controller : if the fault per-

sists, replace the power unit.

19-3-4 • CONTROL TROUBLESHOOTING

SM 765, Dec ’06

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

"CAPACI-

Power Capacitor

• When key is switched on, the controller

TOR

Voltage does not

tries to charge the capacitors through a

CHARGE"

increase when the

power resistor, and check if the capacitor

key is turned ON;

is charged (1/2 battery volts) within a

failure in power

timeout. If they do not charge, an fault is

section, or in

signaled; the line contactor does not

Logic PCB, or in

close.

driver PCB, or in

• The charging resistor is open

the motor MAS-

• The charging circuit has a failure

TER

• There is a problem in the power section.

• Possible Motor connection open.

HIGH

Warning: Master

MASTER

• Temperature of control is greater than

TEMPERA-

or Slave or both

75°C. Maximum current reduced propor-

TURE"

temperature higher

tionally to the temperature increase. At

that 75 degrees C

100°C the maximum current of both con-

trols is reduced to zero.

"MOTOR

Warning: Right or

MASTER

• Right or left or both drive motors analog

TC START"

left or both

or SLAVE

temperature sensor is greater than the

motors tempera-

temperature set in ADJUSTMENT #4

ture high (over

(130°C) in the ADJUSTMET submenu.

Adj #4)

Check tempera-

• When this fault occurs. Maximum cur-

ture shown on

rent is reduced to half and maximum

handset in tester

speed is reduced to 60Hz.

mode

• If it happens when the motor is cold,

Replace con-

check the wring. If all is ok,

troller

"BATTERY

Warning: Battery

MASTER

• When battery level reaches 20% or less

LOW"

charge level below

or (10% on the dash display), the current

20%

level for the drive motors is reduced to

50% of the programmed level and the lift

function is locked out.

"MOTOR

Warning: Right or

MASTER

This fault occurs when the right or left or both

SHUT-

left or both motors

motor temperature switches are open (digital

DOWN"

temp. are very

sensor), or if the analog sensor temperature

high (over

overtakes the cut off level.

MOTOR SHUT-

The cut off level is adjusted with the MOTOR

DOWN param.)

SHUTDOWN parameter

(145°C) in the

ADJUSTMENT submenu.

If this fault occurs, maximum current is

reduced to zero and the motor is stopped.

If the shutdown occurs when the motor is cold

Replace con-

check the wiring. If wiring is ok

troller

"MOTOR

Drive motor

MASTER

• After 15 seconds the motor stalled with

LOCKED"

locked up

maximum current, controller reduces

maximum current to 50%.

• Check if Line Contactor is pulled in.

SM 765, Dec ’06

CONTROL TROUBLESHOOTING • 19-3-5

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

"DRIVER

Line contactor coil

MASTER

•

When the key is turned ON, the micro-

SHORTED"

driver is shorted

processor checks that the line contactor

coil driver is not shorted

•

If it is, this fault is signaled.

•

Check if there is an external short or low

impedance pull-down between NLC

(C26) and -Batt.

Replace con-

•

If no external causes can be found.

troller

"CONTAC-

Line contactor coil

MASTER

•

When the initial diagnosis is finished, the

TOR

driver is open (not

traction logic closes the line contactor

DRIVER"

able to drive the

and checks the voltage drain of the

coil to the correct

driver.

voltage)

•

If this is not low, the driver is unable to Replace con-

close and the fault is signaled.

troller

"COIL

Init: Line contac-

•

When the key is turned on, the micropro-

SHORTED"

tor coil driver pro-

cessor checks that the line contactor coil

tection circuit is

driver short circuit protection hardware If

damaged or Stby

it does not react in a correct way to the

or running: short

microprocessor stimulus, the fault is sig-

on line contactor

naled.

MASTER

Replace contac-

•

When the fault occurs while the line con-

tor coil

tactor is closed this, indicates a short cir-

cuit across the line contactor coil. check

if there is an external short circuit and if

the ohmic value (xxx Omhs) of the line

contactor coil is correct

"MAINTE-

Displayed when

MASTER

•

This is just an indication that the vehicle

NANCE

the normal hour

is due for its Periodic Maintenance.

HOURS"

meter exceeds the

maintenance

hours set for the

vehicle

19-3-6 • CONTROL TROUBLESHOOTING

SM 765, Dec ’06

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

"VACC NOT

Warning: Accel-

MASTER

•

This fault indicates that the accelerator

OK"

erator signal

voltage is 1volt greater than the mini-

(CPOT) voltage

mum value programmed by PROGRAM

higher than

VACC function.

VACC MIN+1V

•

The potentiometer is not correctly cali-

While the trac-

brated.

tion enable

Replace accel-

•

The potentiometer is defective.

switch is open

erator

•

Use tester mode to check for voltage

change when accelerator is depressed,

should be approx 1.5volts (0.4~1.9volts

accelerator),

2.7volts

(0.4~3.1volts

accelerator) of change. If not 1.5volts

(0.4~1.9volts accelerator),

2.7volts

(0.4~3.1volts accelerator) check for wir-

ing shorts, if no shorts, replace accelera-

tor. If accelerator still doesn’t change

and voltage is greater than 2.0volts

(0.4~1.9volts accelerator) & 3.2volts

(0.4~3.1volts accelerator) replace con-

trol.

"INCOR-

Warning: Wrong

MASTER

•

If SRO FUNCTION is active, every time

Replace con-

RECT

traction request

work is stopped the operator must put the

troller

START

sequence This

truck in neutral.

(SRO)"

fault indicates an

•

If forward, reverse or seat switch is

incorrect start-

active when key switch is turned on.

ing sequence

•

If forward, reverse closed without seat

switch input.

•

If the fault persist after checking the wir-

ing,

"FOR-

Warning: For-

MASTER

•

Processor is continuously checking for a

Replace con-

WARD

ward and reverse

request for forward and reverse at the

troller

REVERSE"

inputs are both

same time.

active

•

Defective wiring.

•

Running micro switch failure.

•

Incorrect operation.

•

If defect persist

"TH

Warning:Motor

MASTER

•

The range of the motor temperature ana-

MOTOR

Master tempera-

log sensor is always checked and a fault

SENSOR

ture sensor is out

is signaled if it's out of range

KO"

of range

•

When this fault occurs. The maximum

current is reduced to half and maximum

speed is reduced to 60 Hz.

SM 765, Dec ’06

CONTROL TROUBLESHOOTING • 19-3-7

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

"ENCODER

Motor speed sen-

MASTER

•

This fault indicates that the frequency

ERROR"

sor (encoder) does

supplied the motor is greater that 20 Hz,

not work properly

and the signal feedback from the encoder

has a jump higher than 20 Hz in less than

ten milliseconds. This condition clearly

shows a malfunctioning of the encoder

signal.

•

Check encoder wiring; if no fault is

found in the wiring it is necessary to

replace the encoder.

•

Check voltage on wire #47, should be

approx 12VDC. If not 12VDC unplug

right + left encoders, recheck wire #47

for 12VDC. If 12VDC is present now,

check encoders and encoder wiring for

shorts. If still no 12VDC replace control

"STEER

Steering Potenti-

MASTER

•

This fault indicates an out of range steer-

SENSOR

ometer signal out

ing potentiometer signal.

KO"

of range

•

The fault comes up under the following

two conditions:

•

The "set Steer

0 pos" (programmed

straight wheel pos) parameter is wrong

(lower than "set steer min) or higher than

Replace con-

"set steer max")

troller

"PEDAL

Fault in Accelera-

SLAVE

•

Check accelerator wiring and connec-

Repair wiring as

WIRE KO"

tor negative

tions for opens

required

(NPOT) Input cir-

•

Check accelerator input voltage using

If accelerator

cuit.

PcConsole handset in tester mode (volt-

voltage is greater

This fault indi-

age should range from 2.0 VDC to

than 2.0 VDC or

cates that accelera-

approx. 0.30 VDC).

less than 0.30

tor wiring (NPOT

•

Check voltage between NPOT (pin C20)

VDC replace

or PPOT) wire is

Battery Neg. (pin C12) voltage should be

accelerator

open.

greater than 0.30 VDC. This voltage

If voltage is not

should remain constant all the way

greater than 0.3

through the pedal stroke.

VDC proceed to

•

Check if controller input NPOT (C20) is

the next step

good. Remove pins (C20, C21, C8) from

If it sill read 0

connector, now connect a 4.7K ohm

VDC the control-

resistor between PPOT (C8) and NPOT

ler has a failed

(C20) now plug the connector back in,

input

this will polarize NPOT. Now check volt-

age between (C12) -Batt and (C20)

If it reads cor-

NPOT the reading should be approx. 0.6

rectly 0.6 VDC

VDC

the problem is in

the accelerator or

the harness

19-3-8 • CONTROL TROUBLESHOOTING

SM 765, Dec ’06

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

"WATCH-

Watchdog circuit

SLAVE

•

It is a self-diagnosing test within the

DOG"

has been triggered

logic between Master and Slave micro

controllers.

•

This fault could also be caused by a Can-

bus malfunction, which blinds Master -

Slave communication. So , before replac-

ing the controller , check the Canbus

“CHOPPER

FET is running

SLAVE

•

XXXX

RUNNING”

"LOGIC

Failure in overload

SLAVE

•

Fault in the hardware section of the con-

Replace con-

FAILURE #3

protection hw cir-

troller that manages the hardware current

troller

cuit

protection.

"LOGIC

Failure in U,V,W

SLAVE

•

Fault in the hardware section of the con-

Replace con-

FAILURE #2

voltage feedback

troller that manages the phase 's voltage

troller

circuit

feedback.

•

Line contactor not closing, check param-

eter setting for main contactor.

"LOGIC

An over voltage or

•

This fault signals that the under voltage /

FAILURE #1

under voltage con-

over voltage protection interrupts been

dition has been

triggered

detectedSLAVE

•

A real under voltage / over voltage situa-

tion happened.

•

Verify battery setting.

•

Fault in the hardware section of the con-

troller that manages the over voltage pro-

tection. Replace logic Card.

•

Possible plugging in or unplugging of

battery or charger with the key switch on.

"TH

Warning:Motor

SLAVE

•

The range of the motor temperature ana-

MOTOR

Slave tempera-

log sensor is always checked and a fault

SENSOR

ture sensor is out

is signaled if it's out of range

KO"

of range

•

When this fault occurs. The maximum

current is reduced to half and maximum

speed is reduced to 60 Hz.

109

"VMN

Wrong voltage on

SLAVE

•

This test is carried out during initial diag-

LOW"

motor power out-

nosis and in standby. Possible causes:

puts; failure in the

•

Problem with motor connections or the

power section or

motor power circuit; check if the

in the mosfet

phases are correctly connected; check if

driver circuit or in

there's chassis ground of the motor to

the motor

truck frame.

•

unhook battery at controller and do a

diode check between Batt + and Batt -

(should read .3 to .5 volts)

Replace con-

•

Fault in the controller power section.

troller

SM 765, Dec ’06

CONTROL TROUBLESHOOTING • 19-3-9

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

110

"VMN

Wrong voltage on

SLAVE

•

This test is carried out during initial diag-

Replace con-

HIGH"

motor power out-

nosis and in standby. Possible causes:

troller

puts; failure in the

•

Problem with motor connections or the

power section or

motor power circuit; check if the

in the mosfet

phases are correctly connected; check if

driver circuit or in

there's chassis ground of the motor to

the motor

truck frame.

•

Unhook battery at controller and do a

diode check between Batt + and Batt -

(should read .3 to .5 volts)

•

Fault in the controller power section.

132

"STBY

Wrong voltage in

SLAVE

•

The microprocessors verify if the feed-

Replace con-

HIGH"

current sensor

back of current sensor device output is

troller

feedback circuit

within the zero current window. Possible

causes for the fault.

Replace the

power unit

•

Current sensor failure.

•

Failure in the controller

•

If the fault persist.

139

"CAPACI-

Power Capacitor

SLAVE

•

When key is switched on, the inverter

TOR

Voltage does not

tries to charge the capacitors through a

CHARGE"

increase when the

power resistor, and check if the capacitor

key is turned ON;

is charged (1/2 battery volts) within a

failure in power

timeout. If they do not charge, an fault is

section, or in

signaled; the line contactor does not

Logic PCB, or in

close.

driver PCB, or in

•

The charging resistor is open

the motor

•

The charging circuit has a failure

•

There is a problem in the power section.

•

Possible Motor connection open.

140

HIGH

Warning: Mas-

SLAVE

•

Temperature of control is greater than

TEMPERA-

ter or Slave or

75°C. Maximum current reduced propor-

TURE"

both tempera-

tionally to the temperature increase. At

ture higher that

100°C the maximum current of both con-

75 degrees C

trols is reduced to zero.

148

"ENCODER

Motor speed sen-

•

This fault indicates that the frequency

Replace

ERROR"

sor (encoder) does

supplied the motor is greater that 20 Hz,

encoder

not work properly

and the signal feedback from the encoder

SLAVE

has a jump higher than 20 Hz in less than

ten milliseconds. This condition clearly

shows a malfunctioning of the encoder

signal.

•

Check encoder wiring; if no fault is

found in the wiring.

19-3-10 • CONTROL TROUBLESHOOTING

SM 765, Dec ’06

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

150

"WATCH-

Watchdog circuit

PUMP

•

It is a self-diagnosing test within the

DOG"

has been triggered

logic between Master and Slave micro

controllers. This fault could also be

caused by a CAN-BUS malfunction,

which blinds Master -Slave communica-

tion. So , before replacing the controller ,

check the CAN-BUS

151

“CHOPPER

FET is running

PUMP

•

XXXX

RUNNING”

155

"EEPROM

Warning:

PUMP

•

Fault in the area of memory in which the

KO"

Eeprom fault

adjustment parameters are stored; this

controller will

fault does not inhibit truck operation, but

use default

the controller will use default parame-

parameters

ters.

•

If defect persists when key is switched

OFF and ON again, replace the logic

board. If the fault disappears, remember

that the parameters stored previously

have been cancelled and replaced by the

default values.

160

"LOGIC

Failure in U,V,W

PUMP

•

Fault in the hardware section of the con-

Replace con-

FAILURE #2

voltage feedback

troller that manages the phase 's voltage

troller

circuit

feedback.

161

"LOGIC

An over voltage or

PUMP

•

This fault signals that the under voltage /

Replace con-

FAILURE #1

under voltage con-

over voltage protection interrupt has

troller

dition has been

been triggered. Two possible reasons:

detected

•

A real under voltage / over voltage situa-

tion happened.

•

Verify battery setting.

•

Fault in the hardware section of the con-

troller that manages the over voltage pro-

tection. Replace logic Card.

•

Possible plugging in or unplugging of

battery or charger with the key switch on.

171

"MOTOR

Warning: Pump

PUMP

•

This fault occurs when the pump motor

SHUT-

motor temp. are

temperature switches are open (digital

DOWN"

very high (over

sensor), or if the analog sensor tempera-

MOTOR SHUT-

ture overtakes the cut off level.

DOWN param.)

•

The cut off level is adjusted with the

MOTOR

SHUTDOWN parameter

(145°C) in the ADJUSTMENT sub-

menu.

•

If this fault occurs, maximum current is

reduced to 130 amps needed for steering.

•

If the shutdown occurs when the motor is

cold check the wiring. If wiring is ok

replace logic board.

SM 765, Dec ’06

CONTROL TROUBLESHOOTING • 19-3-11

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

172

"VMN

Wrong voltage on

• This fault signals that the under voltage /

LOW"

motor power out-

over voltage protection interrupt has

puts; failure in the

been triggered Two possible reasons:

power section or

• A real under voltage / over voltage situa-

in the mosfet

tion happened.

driver circuit or in

• Fault in the hardware section of the con-

the motorPUMP

Replace con-

troller that manages the over voltage pro-

troller

tection.

• A problem with motor connection or

power circuit.

• Check if all 3 phases are correctly con-

nected.

• Check for short between motor terminal

and chassis

• Perform diode test

• Diode test

-Disconnect all power and motor leads

from control.

-Select diode test on your multi meter.

-Place positive meter lead on control -

Battery terminal place negative meter

lead on terminals U,V,W meter should

read .3V to .5V if not replace control.

-Place negative meter lead on control +

Battery terminal place positive meter

lead on terminals U,V,W meter should

read .3V to .5V if not replace control.

-If code presist replace control

173

"VMN

Wrong voltage on

PUMP

• This test is carried out during initial diag-

HIGH"

motor power out-

nosis and in standby. Possible causes:

puts; failure in the

• Problem with motor connections or the

power section or

motor power circuit; check if the

in the mosfet

phases are correctly connected; check if

driver circuit or in

there's chassis ground of the motor to

the motor

truck frame.

• unhook battery at controller and do a

Replace con-

diode check between Batt + and Batt -

troller

(should read .3 to .5 volts)

• Fault in the inverter power section.

• Possible bad battery, Excessive voltage

to case of battery.

174

"TH

Warning:Motor

PUMP

• The range of the motor temperature ana-

MOTOR

Pump tempera-

log sensor is always checked and a fault

SENSOR

ture sensor is out

is signaled if it's out of range

KO"

of range

• When this fault occurs. The maximum

current is reduced to half and maximum

speed is reduced to 60 Hz.

19-3-12 • CONTROL TROUBLESHOOTING

SM 765, Dec ’06

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

182

“MOTOR

Pump motor

PUMP

• After 15 seconds of the motor being

LOCKED”

locked up

stalled with maximum current, controller

reduces maximum current to 50%.

• Check to see that the pump contactor is

pulled in

• Possible bad encoder(Sensor, Bearing)

195

"STBY I

Wrong voltage in

PUMP

• The microprocessors verify if the feed-

HIGH"

current sensor

back of current sensor device output is

feedback circuit

within the zero current window. Possible

causes of the fault;

• Current sensor failure.

• Failure in the logic card: If the fault per-

sist, replace the power unit.

196

"THERMIC

Warning: Pump

PUMP

• The range of the temperature sensor is

SENSOR

temperature sen-

always checked and a warning is sig-

KO"

sor is our of

naled if it is out of range. This fault will

range

reduce the maximum current output of

the controller to 50%.

201

"ENCODER

Motor speed sen-

PUMP

• This fault indicates that the frequency

ERROR"

sor (encoder) does

supplied the motor is greater that 20 Hz,

not work properly

and the signal feedback from the encoder

has a jump higher than 20 Hz in less than

ten milliseconds. This condition clearly

shows a malfunctioning of the encoder

signal. Check encoder wiring; if no fault

Replace

is found in the wiring.

encoder

202

"CAP

Power Capacitor

PUMP

• When key is switched on, the inverter

CHARGE"

Voltage does not

tries to charge the capacitors through a

increase when the

power resistor, and check if the capacitor

key is turned ON;

is charged (1/2 battery volts) within a

failure in power

timeout. If they do not charge, a fault is

section, or in

signaled; the line contactor does not

Logic PCB, or in

close.

driver PCB, or in

• The charging resistor is open

the motor

• The charging circuit has a failure

• There is a problem in the power section.

• Possible Motor connection open.

203

"HIGH

Warning: Pump

PUMP

• Temperature of control is greater than

TEMPERA-

Controller tem-

75°C. Maximum current reduced propor-

TURE"

perature higher

tionally to the temperature increase. At

that 75 degrees C

100°C the maximum current of both con-

trols is reduced to zero.

SM 765, Dec ’06

CONTROL TROUBLESHOOTING • 19-3-13

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

204

"VACC NOT

Warning: Accel-

PUMP

•

This fault indicates that the accelerator

OK"

erator siganal

voltage is 1volt greater than the mini-

(CPOT) voltage

mum value programmed by PROGRAM

higher than

VACC function.

VACC MIN+1V

•

The potentiometer is not correctly cali-

While the trac-

brated.

tion enable

•

The potentiometer is defective.

switch is open

•

Tilt or sideshift switch activated at star-

tup

205

"INCOR-

Warning: Wrong

PUMP

•

This fault indicates an incorrect starting

RECT

traction request

sequence.

START"

sequence

•

Lift or enable switch failure

•

Error in sequence made by operator.

•

Incorrect wiring.

•

If the fault persist after checking the wir-

ing,

Replace con-

troller

•

Pot partially activated at startup

206

"PEDAL

Fault in Accelera-

PUMP

•

Check accelerator wiring and connec-

WIRE KO"

tor negative

tions for opens

(NPOT) Input cir-

•

Check accelerator input voltage using

cuit.

PcConsole handset in tester mode (volt-

age should range from xx VDC to

approx. xx VDC).

207

"MOTOR

Warning: Pump

PUMP

•

Pump motor analog temperature sensor

TC START"

motors tempera-

is greater than the temperature set in

ture high

ADJUSTMENT #4

(130°C) in the

ADJUSTMET submenu.

•

When this fault occurs, current goes

down to IMX PROTECTION value and

Check tempera-

motor rpm begins to decrease. Motor

ture shown on

current and speed decrease linearly as the

handset in tester

temperature increases until MOTOR-

mode

SHUTDOWN is reached.

Replace con-

•

If it happens when the motor is cold,

troller

check the wring. If all is ok,,

208

"BATTERY

Warning: Battery

PUMP

•

When battery level reaches 20% or less,

LOW "

charge level

the current level for the drive motors is

below 20%

reduced to 50% of the programmed level

19-3-14 • CONTROL TROUBLESHOOTING

SM 765, Dec ’06

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

211

"COIL

Init: Line contac-

PUMP

•

When the key is turned on, the micropro-

SHORTED"

tor and EB coil

cessor checks that the line contactor coil

driver protection

driver short circuit protection hardware If

circuit is damaged

it does not react in a correct way to the

or Stby or running:

micro processor stimulus, the fault is sig-

short on line con-

naled. When the fault that occurs while

tactor or EB coil

the line contactor is closed this indicates

a short circuit across the line contactor

coil. check if there is an external short

circuit and if the ohmic value (xxx

Omhs) of the line contactor coil is cor-

rect

217

"WRONG

Battery voltage

PUMP

•

This fault indicates that actual battery

SET BAT-

does not corre-

voltage is 20% higher or 20% lower than

TERY"

spond to pro-

"SET BATTERY" parameter setting.

grammed "SET

Replace battery with correct battery.

BATTERY"

218

"SAFETY"

Input F5 is not

PUMP

xxx

connected to Batt-

222

"NO CAN

Pump has lost Can

PUMP

•

This Fault is present in combi Systems

MSG"

communication

(traction + Pump). The traction has

with Master

detected a fault and has informed the

pump controller through the can-bus line.

The pump is waiting for the traction ok.

The fault must be looked for in the trac-

tion controller or can-bus circuit.

225

"AUX OUT-

EB coil driver

PUMP

•

The microprocessor checks the driver of

PUT KO"

shorted or open

the electromechanical brake coil. If the

(Not used)

status of the driver output does not corre-

spond to the signal coming from the

microprocessor, the fault is signaled. It

is suggested to check for an external

short or a low impedance pull-down

between NHYDRO (F9) and -Batt.

SM 765, Dec ’06

CONTROL TROUBLESHOOTING • 19-3-15

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

232

"MASTER

Slave micro pro-

SLAVE

•

Slave and Master microprocessor per-

KO"

cessor detects

form a crosscheck in order to verify

Master processor

functionality. There are two conditions

malfunctioning

under which the slave enters this fault

condition:

•

The SLAVE microprocessor receives an

incoherent Can message from the MAS-

TER microprocessor.

•

The SLAVE microprocessor compares

the inputs status and the related MAS-

TER operations and finds they are not

coherent. In both cases, the SLAVE

brings the controller to a safe status

opening the power bridge and the line

contactor.

233

"NO CAN

Slave has lost Can

SLAVE

•

Slave (node #4) signals that it has lost

MSG 3"

communication

communication with the Master (node

with Pump

#3) This fault could be determined to be

a problem in the truck CAN-BUS line or

be an internal problem in the controller

logic card. First check the CAN_BUS

connection.

235

"THERMIC

Warning: Slave

SLAVE

•

The range of the temperature sensor is

SENSOR

temperature sen-

always checked and a warning is sig-

KO"

sor is our of

naled if it is out of range. This fault will

range

reduce the maximum current output of

the controller to 50%.

236

"INPUT

Slave micro pro-

SLAVE

•

Safety related inputs (Fwd direction, Rev

MIS-

cessor has

direction, accelerator Enable, Seat

MATCH"

detected a mis-

switch) are inputs to both micro proces-

match between

sors by independent hardware circuit.

inputs status and

The two microprocessors read these

the input status

inputs and compare by exchanging

transmitted Via

related status on the Canbus. If the

Canbus by master

SLAVE microprocessor finds a mismatch

micro processor

between its inputs and MASTER inputs,

it brings the controller to a safe status

opening the power bridge and the line

contactor.

243

"NO CAN

Master has lost

MASTER

•

Master (node #3) signals that it has lost

MSG 5"

Can communica-

communication with the Pump (node #5)

tion with Pump

This fault could be determined to be a

problem in the truck CAN-BUS line or

be an internal problem in the controller

logic card. First check the CAN_BUS

connections.

19-3-16 • CONTROL TROUBLESHOOTING

SM 765, Dec ’06

Group 19, Motor Controls

Fault

Action

Fault Name

Fault Description

Control

Troubleshooting

Code

Required

245

"WRONG

Battery voltage

MASTER

•

This fault indicates that actual battery

SET BAT-

does not corre-

voltage is 20% higher or 20% lower than

TERY"

spond to pro-

"SET BATTERY" parameter setting.

grammed "SET

Replace battery with correct battery.

BATTERY"

246

"SLAVE

Master micro pro-

MASTER

•

Slave and Master microprocessor per-

KO"

cessor detects

form a crosscheck in order to verify

Slave micro pro-

functionality. If the MASTER detects

cessor Malfunc-

SLAVE microprocessor malfunctioning,

tioning

it brings the controller to a safe status

opening the power bridge and line con-

tactor.

247

"NO CAN

Master has lost

MASTER

•

Master (node #3) signals that it has lost

MSG 4"

Can communica-

communication with the Slave (node #4)

tion with Slave

This fault could be determined to be a

problem in the truck CAN-BUS line or

be an internal problem in the controller

logic card. First check the CAN_BUS

connections.

249

"THERMIC

Warning: Mas-

MASTER

•

The range of the temperature sensor is

SENSOR

ter temperature

always checked and a warning is sig-

KO"

sensor is our of

naled if it is out of range. This fault will

range

reduce the maximum current output of

the controller to 50%.

253

"AUX OUT-

EB coil driver

MASTER

•

The microprocessor checks the driver of

PUT KO"

shorted or open

the electromechanical brake coil. If the

(Not used)

status of the driver output does not corre-

spond to the signal coming from the

microprocessor, the fault is signaled. It

is suggested to check for an external

short or a low impedance pull-down

between NAUX (C31) and -Batt.

Replace con-

troller

•

If no external cause is found

255

"HAND-

Handbrake switch

MASTER

•

Indicate that handbrake is activated

Repair wiring or

BRAKE"

closed

replace switch if

•

Check wiring and handbrake switch.

needed

Blank

"DASH DIS-

Dash

Display

MASTER

•

Check 5 volt power supply for dash dis-

Replace 5 V

PLAY"

blank

play If no 5 volts

power supply

•

Check wiring and connector at control

Replace dash

and display. If not wiring or connections

display

SM 765, Dec ’06

CONTROL TROUBLESHOOTING • 19-3-17

19, Motor Controls

Section 4

GEX Factory Control Settings

Parameters in White are customer preference adjustable.

Parameters in Orange are factory preset and not adjustable.

Refer to Section 2 for Handset Programming Instructions

Name

Scaled Value

Master (DUALAC2)

PARAMETER CHANGE

Turtle Mode

Economic Mode

Normal Mode

Power Mode

ACCELER. DELAY

LEVEL = 6

LEVEL = 5

LEVEL = 4

RELEASE BRAKING

LEVEL = 3

LEVEL = 2

LEVEL = 1

INVERS. BRAKING

LEVEL = 4

LEVEL = 5

LEVEL = 6

PEDAL BRAKING

LEVEL = 7

SPEED LIMIT BRK.

LEVEL = 0

BRAKE CUTBACK

LEVEL = 5

CURVE BRAKING

LEVEL = 5

MAX SPEED FORW

47 Hz

79 Hz

119 Hz

143 Hz

(Do Not adjust to a higher HZ)

MAX SPEED BACK

47 Hz

79 Hz

119 Hz

143 Hz

(Do Not adjust to a higher HZ)

CUTBACK SPEED 1

80%

90%

100%

CURVE CUTBACK

40%

CURVE CUTBACK 1

100%

FREQUENCY CREEP

0.30 Hz

MAXIMUM CURRENT

LEVEL = 9

AUXILIARY TIME

4.5

SEAT MICRO DELAY

3.5

ACC. SMOOTH

2.5

2.0

1.5

INV. SMOOTH

2.0

2.5

2.0

1.5

STOP SMOOTH

20Hz

15Hz

10Hz

IDLE TIME

SET OPTION

HOUR COUNTER

RUNNING

BATTERY CHECK

HYDRO KEY ON

OFF

STOP ON RAMP

OFF

AUX INPUT #1

OPTION #1

PEDAL BRAKING

DIGITAL

SET TEMPERATURE

ANALOG

STEER TABLE

OPTION #2

MODE SELECTION

LEVEL = 3

LEVEL = 0

LEVEL = 1

LEVEL = 2

SM 765, Nov ’06

GEX Factory Control Settings • 19-4-1

Group 19, Motor Controls

PARAMETER CHANGE

Turtle Mode

Economic Mode

Normal Mode

Power Mode

SET MODEL

CONNECTED TO

3 (Master)

ADJUSTMENTS

SET POT BRK MIN

0.5 V

SET POT BRK MAX

4.5 V

SET BATTERY TYPE

80V

ADJUST BATTERY

MAX STEER RIGHT

MAX STEER LEFT

SET STEER 0-POS.

SET STEER RIGHT

83 Degrees

SET STEER LEFT

60 Degrees

THROTTLE 0 ZONE

THROTTLE X POINT

54%

THROTTLE Y POINT

47%

ADJUSTMENT #04

130℃

MOTOR SHUTDOWN

145℃

ADJUSTMENT #02

LEVEL = 4

ADJUSTMENT #01

LEVEL = 4

ADJUSTMENT #03

20%

MAIN CONT. VOLT.

80 V

AUX OUTPUT VOLT.

36 V

MAINTEN. RESET

OFF

MAINTENANCE

NONE

MAINTENANCE TIME

250

1X10000 HOURS

1X1000 HOURS

1X100 HOURS

1X10 HOURS

1X1 HOURS

DISP. GEAR RATIO

SLAVE (DUAL AC2)

SET MODEL

CONNECTED TO

4 (Slave)

ADJUSTMENTS

SET BATTERY TYPE

80V

ADJUST BATTERY

AUX OUTPUT VOLT.

12V

PUMP (AC2)

19-4-2 • GEX Factory Control Settings

SM 765, Nov ’06

Group 19, Motor Controls

PARAMETER CHANGE

Turtle Mode

Economic Mode

Normal Mode

Power Mode

ACCELER. DELAY

LEVEL = 0

DECELER. DELAY

LEVEL = 0

ACCELER. DELAY TILT

LEVEL = 0

DECELER. DELAY TILT

LEVEL = 0

ACCELER. DELAY AUX1

LEVEL = 0

DECELER. DELAY AUX1

LEVEL = 0

ACCELER. DELAY AUX2

LEVEL = 0

DECELER. DELAY AUX2

LEVEL = 0

MAX SPEED UP

60 Hz

75 Hz

100 Hz

MIN SPEED UP

16.50 Hz

CUTBACK SPEED

100%

1ST SPEED FINE*

40 Hz

2ND SPEED FINE*

25 Hz (S/Shift)

3RD SPEED FINE*

50 Hz

4TH SPEED FINE*

50 Hz

HYD SPEED FINE

21 Hz

IDLE SPEED

12 Hz

IDLE TIME

LEVEL = 5

MAXIMUM CURRENT

LEVEL = 9

AUXILIARY TIME

SET OPTION

HOUR COUNTER

RUNNING

SET TEMPERATURE

ANALOG

THERM PROTECTION

OFF

HOUR METER TRUCK

PRESSURE FUNCT.

OFF

DIGITAL LEFT

OFF

SET MODEL

CONNECTED TO

5 (PUMP)

ADJUSTMENTS

SET BATTERY TYPE

80V

ADJUST BATTERY

THROTTLE 0 ZONE

THROTTLE X POINT

63%

THROTTLE Y POINT

36%

ADJUSTMENT #04

130 °C

MOTOR SHUTDOWN

145 °C

IMAX PROTECTION

100%

ADJUSTMENT #03

55 °C

* See AUX Hydraulic Settings in Section 3

SM 765, Nov ’06

GEX Factory Control Settings • 19-4-3

Group 20, Drive Axle

Section 1

Specification and description of drive axle

Specifications

Torque specification

General specification

Boss bearing and plate housing socket bolt, tightening

Reduction ratio

torque : (330 kgf.cm) 12T

Speed

Forward/Reverse 1

Brake piston and plate housing socket bolt, tightening

Oil capacity

1.0 liter

torque : (130 kgf.cm) 8T

Gear type

Plant gear

Brake stopper fixing socket bolt, tightening torque: (130

kgf.cm)

Drive axle oil

Torque fluid 56(SAE 80W)

Wheel bearing free load adjusting nut, tightening torque :

Weight

60kg (excl. oil)

(2000 kgf.cm)

Final housing socket bolt, tightening torque : (330 kgf.cm)

12T

Brake specification

Wheel cap fixing socket bolt, tightening torque : (330

Service brake type

Wet brake

kgf.cm) 12T

Required flow of service brake: 3.9cc

Master hinge mounting bolt: M16X2.0X40

Service brake setting stroke: 0.9mm

Brake oil

Hydraulic fluid

DESCRIPTION

Parking brake lever ratio :

1:8.27

Drive axle ass'y

Fitting specification

Brake port

: M10X1.0P

Oil drain plug

: PT 1/4, PT 3/8

Wheel Ass'y

Air bleeder

: PT 1/8

Air bleeder (Brake): M12X1.25P

Oil port

: PT1/2

Nipple

: M6X0.75P(grease)

Stud bolt (Wheel bolt): M14X1.5P

Loctite specification

Bolt

Loctite 277

Fitting

Loctite 572

SM 765, Nov ’06

Specification and description of drive axle • 20-1-1

Group 20, Drive Axle

Drive axle

As this drive axle is power transmission system that is

installed to driving wheel for electric forklift, it includes

service brake and parking brake systems. It transmits the

rotating force from the driving motor to the drive

shaft(01). The gear(03) meshed in drive gear(02), which is

locked to the shaft with key, and the sun gear shaft(04) are

one body type as locking with key. The sun gear shaft(04)

and the planetary gear(05) are meshed in the ring

gear(06), so that the third reduction will be occurred. The

final reduced rotating force will be applied to wheel

adapter(08) through the carrier shaft(07) in order to rotate

the shaft.

20-1-2 • Specification and description of drive axle

SM 765, Nov ’06

Group 20, Drive Axle

Section 2

Troubleshooting of wheel drive axle

Troubleshooting for wheel drive axle

Maintenance period

Following contents help to solve the problem of wheel

• Replacement period of wheel drive axle oil: 1,000

drive axle that does not perform right functions.

hours

• Wheel drive axle oil volume: 1.0 liter

Please make sure that the wheel drive axle is just a key

part of related power train components group, when han-

• Replacement period of service brake disc: 4,000

dles the problem of wheel drive axle. The wheel drive axle

hours

is in normal operation based on the condition of other

related components of power train. Therefore, examine

the problems and maintain the wheel drive axle oil, wheel

drive axle assembly, control system, brake system and

driving motor to be the perfect system.

To check and repair the defectiveness of wheel drive axle,

please refer to the description based on the symptom and

cause.

For the inspection of doubtable components, please refer

to the maintenance manual.

Symptom and Cause

Following is general defectiveness of wheel drive axle and

possible causes.

When the forklift does not move.

• Poor contact of battery.

• Check the operational condition of parking brake

• Check the electric control system

• Check the direction-control switch

• Check the connecting unit of connector

• Check the normal operation of driving motor

• Check the condition of bearing

When the forklift is overheated

• Check if the oil level is low or is polluted

• Check the overloading of fork

• Check the condition of bearing

• Check if there is dragging to service brake

SM 765, Nov ’06

Troubleshooting of wheel drive axle • 20-2-1

Group 20, Drive Axle

Section 3

General operation of drive axle

General operation

Cleaning of part

Following procedure shall be applied to disassembly,

Do not use gasoline because it is very combustible. It is

inspection, washing, repair, installation and assembly pro-

also not safe to the working environment.

cess of wheel drive axle component. Especially, disas-

To complete the disassembly, appropriate cleaning is

sembly and reassembly procedures are described at the

required.

latter part of this section. Those procedures have to be

observed.

Clean the processing surface of steel part with industrial

solvent.

Disassembly of components

Wash out inside and outside of bearing, cap and housing.

Before disassemble the wheel drive axle, drain out the

It is possible to clean the unprocessed or unpolished cast

wheel drive axle oil, remove the required hydraulic line

iron part with steam.

and take off the wheel drive axle from the forklift as illus-

Treat the part or cast iron that is being washed by solvent

trated to the manual to disassemble the wheel drive axle.

or steam at the light alkali liquid tank. Complete dry the

Please observe followings.

part before rinsing.

Cleanness - Work at the clean place. Make sure that

For the part with rough surface like castings, do not clean

impurities or dirt should not get into the unit while repair-

with dust cloth.

ing. The bearing can be worn and damaged by the dirt.

Before start the disassembly, always keep clean the out-

Rinse all parts completely. Clean all part except rough-

side of unit.

surfaced part with clean cloth and dry it. Slightly apply

the oil to the part and wrap it with anti-corrosive paper for

Assembly - When disassemble many assemblies, place all

store. Keep it to clean and dry place.

parts with the same order of disassembly on the clean

bench. It makes the assembly simple and there is no

Until the bearing gets clean, wash out with clean solvent.

chance to lose the part.

When dry the bearing with compressed air without mois-

ture, make sure that the bearing does not get out of its

Use of part-disassembly tools

- Always control the

place or damaged because of compressed air.

load that is applied to the shaft, bearing and housing. The

removal of these parts is limited. Never apply the power to

Do not rotate the bearing while drying. It is no problem to

drive the parts when they are completely stopped. For

slowly rotate it with hands for faster dray.

removal, it is recommended to use soft hammer, bar and

NOTE

wooden hammer.

Do not wash out the emulsion product with

Bearing - Use designated puller when takes off the reus-

solvent.

able bearing. Apply the clean oil to bearing and cover it

with clean cloth without fuzz or clean paper when store it.

Part checking

Snap ring - Take off the snap ring with designated pliers.

Check all wheel drive axle components before reassemble

This snap ring is reusable if there is no groove and it is not

after cleaning, and decide it if it needs to be replaced.

loosened.

It is important to carefully and completely check all parts.

When replace all he parts that seem to be worn, stressed or

damaged, it saves money and time.

SM 765, Nov ’06

General operation of drive axle • 20-3-1

Group 20, Drive Axle

Checking: Check the steel part if there is mark, deforma-

When it needs to be replaced, use official product of

tion or discoloration that is related to inappropriate lubri-

CLARK to maintain the unit performance and extend the

cating work, notch, and step or scratch.

life.

Check the fitting, discoloration and broken area of bearing

The checking procedure that is advised to various parts is

ball, cage or retainer, roller and raceway

as follows.

Check the abnormal contacting pattern of gear that has

serious symptom of abrasion, fitting and crack across to

Bearing

the contacting line.

Replace the bearing if there is hole or it is broken or dis-

Check the crack, scratch and abrasion of processed sur-

colored. Always replace one set of bearing cup and cone.

face for casting or malleable parts, wider drill hole and

Do not separately replace the bearing and race.

crack or burr of contacting surface.

Replace the bearing with considerable gap.

Check the fastener if it has rounded head or damaged spi-

Check the fitting of bearing. The internal race of bearing

ral area or is curved or cracked.

has to be firmly inserted into the shaft. Tighten the outer

IMPORTANT

race to the housing bore. If the bearing gets out from the

All damaged parts that affect to the align-

bore, replace the housing.

ment and structure should be replaced. The

repair with welding or correction is not

Gear and Shaft

allowed. These works can cause the malfunc-

tion when the load is applied because it

Check the frosting and fitting of gear tooth. The frosting

affects the housing of casting product.

on the tooth surface of gear does not affect to the malfunc-

Curved head, crack or leakage, loosen stud,

tion of transmission. When continuously uses unit, the

crossed-type screw hole of all housings

frosting of gear won't be developed to the fitting condi-

tion. Most likely, the gear tooth that is a little bit fitted can

be reusable. However, if the fitting is serious, the gear has

Repair and replacement of part

to be replaced.

Protect the wheel drive axle such as seal and washer from

If it is possible to use Magnaflux, check the damage of

the early abrasion, and replace it with low-priced parts

part with it.

that do not give big cost of repair.

If the heat-treated part of gear tooth is worn or cracked,

Replace the seriously worn part even though it is not bro-

replace the gear.

ken.

Check all shafts if the tooth is curved or cracked or the

The steel parts such as shaft or gear can't be repaired. If it

spline is broken.

is worn or damaged, it should be replaced.

The seal and washer has to be periodically replaced. For

Spline

the fastener with auto-locking patch, it is possible to reuse

if it is fixed by dropping the heavy duty thread locker for

Check the abnormal abrasion from the spline of all gear

many times.

and shaft. If the spline is excessively worn or fitted,

replace the relevant part.

The repair of wheel drive axle housing is limited to the

removal of scratch or burr on the processing surface or

replacement of damaged stud. Because the cost of new

O-Ring

part is very small in comparison to the total cost of labor

power and malfunction time of machine and it may

Replace all O-ring whenever overhauling. Lubricate the

require more cost after the repair, it is better avoiding the

O-ring and seal with gear oil before the reassembly.

reuse of the damaged parts. To decide reuse or replace-

ment of drive axle part, the internal force, time to use and

application of unit shall be considered.

20-3-2 • General operation of drive axle

SM 765, Nov ’06

Group 20, Drive Axle

Section 4

Disassembly and Reassembly of drive axle

Disassembly of drive axle ass'y

Disassembly of service brake

D-ring

Cautions to disassemble the drive axle

D-ring

Drive shaft assembly

Piston

Stopper brake

Mounting plate

Return spring

Spacer

Socket bolt

Service brake piston

Driven gear

Hexagon bolt

Shaft sun gear

Driven assembly

Guide pin

Return spring

Mast hinge

Reaction plate

Key

Parking lever

Paper disc

• Remove the shaft sun gear and driven gear from

the bearing bore.

Disc and plate set

• Remove twelve stopper fixing socket bolts with

Wheel assembly

relevant tools.

• Arrange the parts under the order of disassembly.

• Remove the reaction plates (4EA) and the brake

• Pay attention to the parts and removal order when

discs (4EA) from the housing.

disassemble.

NOTE

• Record with irremovable pen if necessary and dis-

Pay attention not to lose or damage the

tinguish the parts.

springs (16EA).

• Place the disassembled units to the clean area. Dis-

assembly of service brake

• Remove the piston fixing hexagon bolts from the

housing by using spanner or wrench box.

NOTE

When remove the piston, apply the air pres-

sure into the brake port.

SM 765, Nov ’06

Disassembly and Reassembly of drive axle • 20-4-1

Group 20, Drive Axle

Disassembly of bearing boss

Disassembly of parking lever and

drive shaft

Thrust needle bearing

Spacer (shim)

Housing plate

Bolt

Needle roller bearing

Bearing boss

O-ring

Plate housing

Pin spring

King brake pin

O-ring

Parking brake lever

Disassembly of bearing boss

Disassembly of parking brake lever and

•

Remove the thrust needle bearing and shim from

the bearing boss.

drive shaft

•

Remove the bearing boss fixing bolts (3EA) from

• Remove the spring pin by using pliers.

the plate housing with appropriate tool.

• Remove the parking brake pin and O-ring from the

•

Pay attention to the damage or separation of O-

plate housing by using rubber hammer and screw

ring from bearing boss.

driver.

NOTE

When reassembly, use new O-ring.

Pay attention not to damage the O-ring of

parking brake pin.

•

Remove the parking brake lever from the plate

housing.

20-4-2 • Disassembly and Reassembly of drive axle

SM 765, Nov ’06

Group 20, Drive Axle

Disassembly of drive shaft ass'y

Disassembly of master hinge,

brake fitting and plug

Bearing

Brake air bleeding port

Gea(13T)

Brake port

Bearing

Plug

Drive shaft

Level plug

Key

Bolt

Snap ring

Master hinge

•

Remove the snap ring from the drive shaft.

•

Remove the gear (13T) and key from the drive

shaft.

Disassembly order of brake fitting and plug

•

Remove the ball bearing from the drive shaft by

using gear puller.

•

Remove the master hinge fixing socket bolts

(When install the gear puller, fix it to inner ring of

(2EA) from plate housing by using appropriate

bearing and remove it)

tool.

•

Remove the fittings of brake port and brake air

bleeding port.

•

Remove the level plug and insertion plug.

SM 765, Nov ’06

Disassembly and Reassembly of drive axle • 20-4-3

Group 20, Drive Axle

Section 5

Disassembly and Reassembly of axle end

NOTE

Disassembly of carrier and hub bear-

Arrange all the parts under the order of dis-

ing

assembly.

Pay attention to the parts and removal order

when disassemble.

Plant gear shaft

Record with irremovable pen if necessary

Pin spring

and distinguish the parts.

Taper roller bearing

Spacer

Housing final

Removal of axle end from the drive axle

Bearing taper

Oil seal

Bolt stud

Adaptor

Washer

Needle bearing

Planetary gear

Spacer

Lock nut

Washer

O-ring

Lock washer

Wheel cap

Lock nut

Bolt

Remove hexagon socket bolts from the plate housing by

using appropriate tool to disassemble the wheel assembly

and drive axle.

SM 765, Nov ’06

Disassembly and Reassembly of axle end • 20-5-1

Group 20, Drive Axle

Disassembly of axle end

Disassembly of carrier shaft ass'y

Taper roller bearing

Spacer

Housing final

Taper roller bearing

Oil seal

Stud bolt

Adaptor

Stud bolt

Lock nut

O-ring

Wheel cap

Bolt

Disassembly of wheel sub assembly

Disassembly of carrier shaft ass'y

•

Remove the wheel cap fixing socket bolts (4EA)

•

Set the carrier shaft ass'y on the flat bottom place.

from the wheel adaptor with appropriate tool.

•

Remove the planetary gear shaft fixing pin spring

•

Remove the fixing bolts of lock nut.

by using pliers or tool.

•

Remove the lock nut fixed to the wheel adaptor

•

Remove the planetary gear shaft by tapping two or

from the carrier shaft.

three times with hammer or tool.

•

Remove the wheel adaptor from the carrier shaft.

• -Repeat the removal to three places.

NOTE

CAUTION

Pay attention not to do damage the oil seal

assembled to the wheel adaptor.

When reassemble, the pin spring can be

omitted.

•

Place the axle end on the press and remove the

Check if the pin spring is assembled when the

taper roller bearing.

assembly is completed.

The way to assemble the oil seal: Use jigDisassembly of

carrier shaft ass'y

20-5-2 • Disassembly and Reassembly of axle end

SM 765, Nov ’06

Group 20, Drive Axle

Section 6

Adjustment

• Re-measure the assembly product with dial gauge.

Preloading and adjustment of hub

• When compare the measured value with gauge, if

taper roller bearing

the space is plus value based on the gap, insert

Lock nut

spacer with small width and if it is minus value,

insert the space with big width. Apply different

spacer based on the measured value.

Measuring master

Lock nut

Oil Seal

Taper roller

bearing

Spacer

Carrier ass'y

Required tool for assembly

- Lock nut assembly adaptor

- Torque wrench, 20kgf.m setting

(-) Screwdriver

− Rubber hammer

Adjustment order of preloading

•

Place the bearing cup into final housing and press-

How to measure the space

fit it to the housing with assembled jig.

Measurement when the space isn't assembled

•

Locate the measuring spacer as shown in the

•

Use measuring master to measure the space.

above figure.

(Refer to the figure 14 for measurement of space)

•

Press-fit the outer ring of bearing to the housing.

•

Place the taper roller bearing as shown in the fig-

•

Assemble the taper roller bearing to carrier shaft,

ure 15.

set the preload adjustment nut up to 2000kgf.m and

measure and record with dial gauge.

•

Press-fit the bearing with press and pressurizing

jig.

•

Hit it with plastic hammer and rotate the wheel

Measurement when the space is assembled

adaptor two or three times.

• Assemble the spacer based on the above method

Set the torque value by tightening the preloading

and apply the preload.

adjustment nut.

(Torque wrench, torque setting: 20kgf.m)

SM 765, Nov ’06

Adjustment • 20-6-1

Group 20, Drive Axle

•

Tighten the bolt to prevent the looseness.

•

Install the jig for measurement to contact on the

disc and plate housing surfaces.

•

Measure the preloading value with push-pull

gauge as shown in the figure 16.

•

Place the dial gauge on the jig.

(Specification: Push-pull gauge torque: 12kgf.cm

•

Measure the stage differences between jig sur-

~15kgf.cm)

faces.

(Caution: measure it when apply the preload to

brake disc[150kg.cm])

•

The gap when the deviation of dial gauge is "0".

(It accurately sets to 0.9mm)

•

Set the gap adjustment according to the measured

value of gap based on the thickness of back plate.

•

Refer to the specification to set the stroke.

•

When measuring gap is based on 0.9mm, if it is

plus value, apply the thicker plate.

•

When measuring gap is based on 0.9mm, if it is

minus value, apply the thinner plate.

Measured value and stroke specification

Measured value

Setting stroke

-0.15

0.95

-0.10

0.9

-0.05

0.85

0.8

0.05

0.75

Adjustment of brake disc gap

0.1

0.7

0.15

0.65

Specification: 0.85~0.9mm

Required tool for setting

- Measuring jig

- Dial gauge

Preloading adjustment order

•

Assemble the disc and plate to the plate housing.

20-6-2 • Adjustment

SM 765, Nov ’06

Group 20, Drive Axle

•

Record the value that the dial gauge shows.

Adjustment of thrust needle bear-

•

Calculate the stage differences of drive axle and

ing gap

wheel, and set the gap of shaft direction.

•

Set the thrust needle bearing based on gap specifi-

cation.

(Specification : 0.05~0.1mm)

Calculation of measured value and shim

adjustment

•

Adjust it by summing the measured values of

wheel and drive axle and deducting the existing

shim (3t).

•

If the summed value is "0", set the gap with

0.1mm.

Apply the different spacer based on the measured

Figure 18. Drive axle assembly

value (for example, 3T, 3.1T, 3.2T)

Required tool for setting

- Measuring jig

- Dial gauge

How to measure the gap

•

Install the assembled axle ass'y to the exclusive jig

or flat bottom.

•

Set the measuring jig as shown in the figure 18.

•

Place the dial gauge on the measuring jig and mea-

sure the stage differences of jig.

•

Record the value that the dial gauge shows.

•

Install the assembled wheel ass'y to the exclusive

jig or flat bottom as above method.

• Set the measuring jig to axle end assembly as

shown in the figure 19.

Figure 19. Axle end assembly

SM 765, Nov ’06

Adjustment • 20-6-3

Group 22, Wheels and Tires

Section 1

Wheels and Tires Specifications and Description

Specifications

Description

Steer Tire Types : Pneumatic rubber/Cushion rubber, non-

The wheels and tires used on the truck come in pneumatic

marking, and urethane.

or cushion types in a variety of sizes depending on truck

model and application. Pneumatic tires are mounted on

Drive Tire Types : Pneumatic rubber/Cushion rubber, non-

multi-piece rims with locking rings.

marking, and urethane.

Pneumatic Drive and Steer Tire Inflation Pressure :

WARNING

Drive GEX20/25/30: 800 kPa (116psi)

For your safety and the safety of others,

before you do tire or rim maintenance or ser-

Steer GEX20/25/30: 1000 kPa (145psi)

vice, read the OSHA rules regarding owner

responsibility. Do not work on tires or rims

Fastener Torques

unless you have been trained in the correct

procedures. Read and understand all mainte-

Steer Tire Mounting Nut Torque : Check mounting proce-

nance and repair procedures on tires and

dure in Sections 2 and 3 for cushion and pneumatic tires

rims. Serious injury or death can result if

and wheels.

safety messages are ignored.

Drive Wheel Mounting Nut Torques :

1 Piece (black) 155-180 N⋅m (114-133 lb⋅ft)

The Occupational Safety and Health Act (OSHA) speci-

fies required procedures for servicing multi-piece rim

wheels in 29 CFR Section 1910.177. It is the owner’s

Service Intervals

responsibility to comply with OSHA.

Wheel Mounting Bolts Check and Tightening : Every 50-

In accordance with OSHA, the owner must provide a

250 hours of operation and each PM.

training program to train and instruct all employees who

service multi-piece rim wheels in the hazards involved

Tire Condition : Daily inspection.

and the safety procedures to be followed. Do not let any-

Tire Pressure Check : Daily inspection.

one mount, demount, or service multi-piece rim wheels

without correct training.

The owner should obtain and maintain in the service area

current copies of the United States Department of Trans-

portation, National Highway Traffic Safety Administra-

tion publications entitled “Safety Precautions for Mount-

ing and Demounting Tube-Type Truck/Bus Tires,” and

Multi-Piece Rim/Wheel Matching Chart” or other similar

publications applicable to the types of multi-piece rim

wheels being serviced.

SM 765, Nov ’06

Wheels and Tires Specifications and Description • 22-1-1

Group 22, Wheels and Tires

Section 2

Pneumatic Wheels and Tires

in this manner can result in damage to the rim and

! CAUTION

truck tip-over and driver injury.

SAFE PARKING. Before working on truck :

Do not fill a tire with air that has been run flat with-

1. Park truck on a hard, level, and solid

out first inspecting the tire, rim, and wheel assembly.

surface, such as a concrete floor with no

Double check the lock ring for damage. Make sure

gaps or breaks.

that it is secure in the gutter before filling the tire

with air.

2. Put upright in vertical position and fully

lower the forks or attachment.

Always remove all air from a single tire and from

both tires of a dual assembly prior to removing any

3. Put all controls in neutral. Turn key switch

rim components, or any wheel components, such as

OFF and remove key.

nuts and rim clamps. Always remove the valve core

4. Apply the parking brake and block the

to remove air from tire. Be sure all air is removed.

wheels.

Check rim components periodically for fatigue

cracks. Replace all cracked, badly worn, damaged,

Pneumatic Tire Maintenance

and severely rusted components.

Precaution

Do not, under any circumstances, attempt to rework,

weld, heat, or braze any rim components that are

The following instructions supplement the OSHA require-

cracked, broken, or damaged. Replace with new parts

ments. In the event of any conflict or inconsistency

or parts that are not damaged, which are of the same

between these instructions and the OSHA requirements,

size, type, and make.

the OSHA requirements shall be controlling.

Never attempt to weld on an inflated tire/rim assem-

bly.

! WARNING

Before you do tire or rim maintenance, read

Clean rims and repaint to stop detrimental effects of

the OSHA rules regarding owner responsib-

corrosion. Be very careful to clean all dirt and rust

lilty. Read and understand all maintenance

from the lock ring gutter. This is important to secure

and repair procedures on tires and rims. Do

the lock ring in its proper position.

not work on tires or rims unless you have

A Filter on the air filling equipment to remove the

been trained in the correct procedures. Seri-

moisture from the air line prevents a lot of corrosion.

ous injury or death can result if the safety

The filter should be checked periodically to make

messages are ignored.

sure it is working properly.

10.

Make sure correct parts are being assembled. Ask

1. Do not let anyone mount or demount tires without

your distributor or the manufacturer if you have any

proper training.

doubts.

2. Never sit on or stand in front of a tire and rim assem-

11.

Do not be careless or take chances. If you are not

bly that is being filled with air. Use a clip-on chuck

sure about the proper mating of rim and wheel parts,

and make sure the hose is long enough to permit the

consult a wheel and rim expert. This may be the tire

person filling the tire with air to stand to the side of

man who is servicing your fleet, the rim and wheel

the tire, not in front or in back of the tire assembly.

distributor in your area, or the CLARK dealer.

3. Never operate a vehicle on only one tire of a dual

12.

Mixing parts of one manufacturer’s rims with those

assembly. The carrying capacity of the single tire and

of another is potentially dangerous. Always ask man-

rim is dangerously exceeded, and operating a vehicle

ufacturer for approval.

SM 765, Nov ’06

Pneumatic Wheels and Tires • 22-2-1

Group 22, Wheels and Tires

13. Do not use undersized rims. Use the right rims for

handled gauge to keep your body away from

the job.

the side.

14. Do not overload rims. Ask your rim manufacturer if

special operating conditions are required.

15. Do not seat rings by hitting with a hammer while the

tire is filled with air pressure. Do not hit a filled or

partially-filled tire/rim assembly with a hammer.

16. Double check to make sure all the components are

properly seated prior to filling tire with air.

17. Have the tire in a safety cage when filling with air.

18. When removing wheels, regardless or how hard or

firm the ground appears, put hardwood blocks under

the jack.

• If tires are low, do not add air. Have the tire and

wheel inspected by a person trained and autho-

19. Block the tire and wheel on the other side of the vehi-

rized to do tire and wheel maintenance. The tire

cle, before you place the jack in position. Place

may require removal and repair.

blocks under the truck frame as near as possible to

• Incorrect (low) tire pressure can reduce the sta-

the jack to prevent the truck from falling if the jack

bility of a lift truck and cause it to tip over.

should fail.

IMPORTANT

20. Remove the bead seat band slowly to prevent it from

Check wheels and tires for damage every

dropping off and crushing your toes. Support the

time you check tire pressure. Make repairs

band on your thigh and roll it slowly to the ground.

when needed. Dirt can get into cuts and cause

This will protect your back and feet.

damage to the tire cord and tread. Remove

21. Bead breakers and rams apply pressure to bead

debris from all cuts.

flanges. Keep your fingers away from the bead

flanges. Slant bead breaker about 10° to keep it

Check the condition of the drive and steer wheels and

firmly in place. If it slips off, it can fly with enough

tires. Remove objects that are imbedded in the tread.

force to kill. Always stand to one side when you

Inspect the tires for excessive wear, cuts and breaks.

apply hydraulic pressure.

General Tire Maintenance, Inspec-

tion, and Repair

1. Park the truck as described in “Safe Parking” and

check for correct tire inflation air pressure.

• Drive GEX20/25/30: 800 kPa (116psi)

• Steer GEX20/25/30: 1000 kPa (145 psi)

Check all wheel lug nuts or bolts to be sure none are

loose or missing. Have missing bolts replaced and

! CAUTION

loose bolts tightened to the correct torque before

Check tire pressure from a position facing

operating the truck.

the tread of the tire, not the side. Use a long-

• Torque pneumatic steer tires to 225-250 N⋅m (165-

185 ft⋅lb).

• Torque 1 piece black lug nuts for pneumatic drive

tires to 155-180 N⋅m (114-133 ft⋅lb).

22-2-2 • Pneumatic Wheels and Tires

SM 765, Nov ’06

Group 22, Wheels and Tires

Inspection and Minor Repair

2. Loosen the five lug nuts on the wheel.

Inspect pneumatic tires and wheels carefully for.

1. Low inflation pressure.

2. Damaged tires. Check tires for cuts and breaks.

3. Damaged wheels or loosening of the lock ring on

multi-piece rims.

Steering

Axle hub

Wheel

wedge

Lock

ring

4. Check for loose nuts or bolts not in position.

5. Check the nuts or bolts for damage.

6. Check the surface of the wheels for bent flanges.

7. Check all parts for rust or corrosion.

Drive

Axle hub

8. Mark the damaged areas with chalk so that the parts

can be removed from operation.

3. Use a portable jack of adequate capacity placed

9. Remove all parts that are damaged and install new

under the frame of truck to raise drive or steer wheels

parts in the same position.

off floor.

10. Replace parts with the correct sizes and types. See

4. Once tire is off the ground enough to rotate freely,

your parts manual.

remove the lug nuts and lift the wheel from the hub.

Use caution when lifting tire and wheel.

11. Include your truck serial number when ordering

replacement parts.

Drive and Steer Wheel Remounting

Wheel Dismounting and Remounting

IMPORTANT

See “Tire Installation” in this Section to

Refer to “Lifting, Jacking, and Blocking” in Group SA for

make sure the wheel and tire mounting orien-

information on jacking up or raising the truck for wheel

tation is correct. Check the information for

removal. Always start with the truck parked safely.

correct tire-to-wheel mounting and wheel-to-

hub mounting.

Drive and Steer Wheel Dismounting

1. Make sure the truck is parked on a flat, hard surface

1. Remove the valve core from the valve stem to be sure

and the jacking and blocking devices are secure to

all air is removed from the tire.

hold the truck in a safe position.

2. Inspect the removed lug nuts for damage to the

threads. Also inspect all hub studs for thread damage.

SM 765, Nov ’06

Pneumatic Wheels and Tires • 22-2-3

Group 22, Wheels and Tires

Replace any lug nuts or studs that have damaged

the rim and side ring. The lock ring can sepa-

threads. Make sure studs are secure in the axle hub.

rate from the rim with enough force to cause

injury or death.

Wheel Disassembly and Tire Removal

1. Remove valve core from the valve stem to be sure all

air is removed.

WARNING

3. Set the wheel on the hub and start the lug nuts on the

Before starting disassembly, remove the air

hub studs. Tighten the nuts only enough to seat the

from the tire. Failure to remove the air from

nuts into the beveled openings on the wheel and to

the tire can result in serious injury.

secure the wheel on the axle hub.

4. Use a crisscrossing nut tightening sequence to torque

2. Remove lock ring.

the nuts to a pre-final torque of 54-81 N⋅m (40-60

Lock Ring

ft⋅lb). Make sure all nuts seat into beveled spacer

holes correctly.

Wheel

Wedge

3. Remove wheel wedge.

4. Remove tire from wheel.

5. Begin the crisscrossing sequence again and tighten

the lug nuts to final torque.

• Torque drive wheel 1 piece lug nuts to 155-180

N⋅m (114-133 ft⋅lb).

• Torque steer wheel lug nuts to 225-250 N⋅m

(165-185 lb⋅ft).

6. Carefully lower the truck and remove the jack.

7. Check tire pressure for correct inflation pressure.

• Drive wheel pressure is

5. Remove the rubber inner tube protector (flap).

GEX20/25/30: 800 kPa (116psi)

• Steer wheel pressure is

GEX20/25/30: 1000 kPa (145 psi).

! WARNING

If tires are not fully inflated, see “Adding Air

Pressure To Mounted Wheel/Tire Assem-

blies” and follow the procedures for adding

air to the mounted tires.

Before you add air pressure to the tire, make

6. Repair tire and/or tube, as needed.

sure the lock ring is correctly positioned in

22-2-4 • Pneumatic Wheels and Tires

SM 765, Nov ’06

Group 22, Wheels and Tires

7. Check for cracks in the wheel.

12. Clean the tire bead seat area. Remove all rust and

rubber with a wire brush or wheel.

Cracks in the wheel are caused by :

• Deep rim tool marks.

13. Clean wedge and lock rings. Make sure the seating

• Overload on wheels.

surface and bead seat areas are clean.

• Too much air pressure in the tires.

• Using the wrong size tires.

8. Check for cracks in the lock ring.

9. Check for cracks between the stud holes in the wheel.

Cracks are caused by :

• Loose wheel nuts.

• Wheel not installed correctly.

• Wrong size or type of parts used.

• Too much torque on the wheel fasteners. If the

wheel mounting parts are too tight, the studs or

bolts can break, causing cracks in the wheel

14. Apply paint to the tire rim with a brush. Or, use an

between the stud holes.

aerosol can of metal primer.

• Too little torque on the wheel fasteners. If the

The parts must be clean and dry before you apply the

wheel mounting parts are too loose, damage to

paint. Make sure to apply paint to the outside or tire

parts and tire wear will result.

side of the rim. This is important because air is on the

metal surface of the tire side of the rim

10. Check wedge ring for wear or damage. Corrosion

buildup will cause wear and damage to the wheel

15. Apply lubricant on the tire side of the rim base. Do

wedge ring.

not use a lubricant that has water or solvent which

will cause damage to the rubber.

11. Clean the wheels. Remove rust and dirt.

NOTE

Clark dealers can supply the correct lubri-

cant, which contains a rust inhibitor.

SM 765, Nov ’06

Pneumatic Wheels and Tires • 22-2-5

Group 22, Wheels and Tires

5. Install the wheel wedge.

Tire Replacement and Wheel

Reassembly

1. Put the tube into the tire.

6. Put the side ring over the rim and install the lock ring

as shown.

IMPORTANT

Install washer 22.123 on tube over valve stem

before flap is installed, when specified. See

sketch. Refer to Service Parts List.

Wheel

Washer

Tube

7. Connect air chuck and turn the tire over with the

2. Put the rubber tube protector(flap) over the tube.

valve stem down. Put 21 kPa (3 psi) of air into the

tire.

3. Install the tire onto the wheel rim, against the bead

seat area.

8. Turn wheel to the other side. Check to make sure

lock ring is in correct location.

4. Put the wheel wedge over the rim.

22-2-6 • Pneumatic Wheels and Tires

SM 765, Nov ’06

Group 22, Wheels and Tires

Filling Tires with Air

Turn the regulator valve counterclockwise (CCW)

until you can feel no resistance from the regulator.

Follow these procedures when putting air into tires. All

This will adjust the regulator presssure to a low pres-

wheel and tire assemblies must be filled in a safety cage.

sure near zero.

The hose must have an adapter that can be connected to

the valve stem.

1. Attach an air hose to valve stem.

2. Open the control valve which will let compressed air

into the tire.

3. At intervals, close the control valve and check the

pressure in the tire by reading the gauge. Do not put

too much presssure into the tire.

4. Continue to fill the tire to the correct air pressure

reading of

Slowly turn the cylinder valve counterclockwise

Drive tire GEX20/25/30: 800 kPa (116 psi).

(CCW) to open position.

Steer tire GEX20/25/30: 1000 kPa (145 psi)

IMPORTANT

Put equal pressure in both tires of a dual

assembly. Do not put air into a tire that is flat

without first inspecting it and the wheel for

damage.

Filling Tires with Nitrogen

If your air supply does not have enough pressure to fill the

tire, you can use a pressurized cylinder of commercial

The tank gauge will now show tank pressure.

nitrogen gas to get the correct tire pressure. With the tire

in a safety cage, connect the nitrogen cylinder to the valve

stem with the use of an air chuck.

! WARNING

Use nitrogen only. Do not use oxygen or any

other gas to fill tires. Make sure all items of

equipment used (nitrogen cylinder, regulator,

gauges, hoses) are UL approved and in good

condition. Use the correct regulator and hose

Turn the regulator valve clockwise (CW) until the

for the pressures that are necessary.

regulator gauge reads the correct tire pressure. Fill

the tire with nitrogen.

1. Be sure tank valve is closed to connect hose to valve

stem. Tank vlave is closed by turning handle on top

of tank clockwise to a stop.

22-2-8 • Pneumatic Wheels and Tires

SM 765, Nov ’06

Group 22, Wheels and Tires

6. Turn the tank valve clockwise (CW) and close the

Checking and Adjusting Tire Pressure

valve.

WARNING

Before you add air pressure to the tire, make

sure the lock ring is correctly positioned in

the rim and wheel wedge. The lock ring can

separate from the rim with enough force to

cause injury or death.

7. Disconnect the air chuck from the valve stem.

1. Attach a clip-on air chuck to valve stem. Stand by the

side of the wheel and put the correct air pressure in

the tire.

8. Turn the regulator valve counterclockwise (CCW) to

the off position.

2. If your air supply does not have enough pressure to

fill the tire, you can use a nitrogen cylinder to get the

correct pressure.

9. Use a tire pressure gauge to check the tire pressure. If

necessary, put more air into the tire. Do this as many

times as necessary to reach the correct tire pressure.

3. Put a clip-on type air chuck on the nitrogen cylinder

! CAUTION

hose and attach it to the valve stem. Follow the pro-

cedures described previously for adjustment of the

Use a long-handled gauge so that your hand

nitrogen cylinder valves.

does not go inside the cage, or in front of any

component of a multi-piece wheel.

WARNING

Use nitrogne only. Do not use oxygen or any

other gas to fill tires.

SM 765, Nov ’06

Pneumatic Wheels and Tires • 22-2-9

Clark GEX20-30 (RATED CAPACITY : 2000~3000kg). SERVICE MANUAL (2006) - page 2