Professional Documents
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CONTROLLER
T5Z AC [B476]; T7Z AC [B477];
C60Z AC [B478]; C80Z AC [B479]
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 1
Description ......................................................................................................................................................... 2
Electrical System ........................................................................................................................................... 2
AC Traction Motor..................................................................................................................................... 4
Controller................................................................................................................................................... 4
Service PC Connection .............................................................................................................................. 4
Parameters ......................................................................................................................................................... 4
General ........................................................................................................................................................... 4
Parameter Description....................................................................................................................................... 5
Parameters..................................................................................................................................................... 5
Extended Shift........................................................................................................................................... 5
Walk Speed (Both Directions) ................................................................................................................... 5
Hi Speed (FWD)......................................................................................................................................... 5
Hi Speed (REV).......................................................................................................................................... 5
Minimum Acceleration.............................................................................................................................. 6
Maximum Acceleration ............................................................................................................................. 6
Plugging ..................................................................................................................................................... 6
ADS-Neutral .............................................................................................................................................. 6
ADS-Throttle ............................................................................................................................................. 6
Pick Acceleration ....................................................................................................................................... 6
Pick Deceleration....................................................................................................................................... 6
Battery Full Voltage .................................................................................................................................. 6
Lift Interrupt ............................................................................................................................................. 6
Service Hour Reminder............................................................................................................................. 6
Troubleshooting.................................................................................................................................................. 7
General ........................................................................................................................................................... 7
Status Codes .................................................................................................................................................. 7
Dash Display ...................................................................................................................................................... 60
General ........................................................................................................................................................... 60
Startup ........................................................................................................................................................... 60
Status LED .................................................................................................................................................... 60
Performance Mode Indicator......................................................................................................................... 60
Hourmeter...................................................................................................................................................... 61
Battery Charge Indicator .............................................................................................................................. 61
Fault Log ........................................................................................................................................................ 61
Connector Pin-Outs............................................................................................................................................ 62
System Logic Diagram....................................................................................................................................... 63
T5Z AC [B476];
T7Z AC [B477];
C60Z AC [B478];
C80Z AC [B479]
General
This section describes the Iskra motor controller
and dash display used in C60Z AC, C80Z AC, T5Z AC,
and T7Z AC lift trucks. Procedures are outlined for
controller programming and troubleshooting.
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. DO NOT use a screwdriver
to discharge the traction motor controller.
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments,
and connecting or disconnecting a handset or
PC.
CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never
put power to the controller with any power
wire disconnected. Never short any controller
terminal or motor terminal to battery. Make
sure to use proper procedures when servicing
the controller.
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Description 2200 SRM 1352
Description
ELECTRICAL SYSTEM power steering motor. The controller uses CANbus
communication to interact with the dash display and
The Iskra AC motor controller controls the AC trac- the control handle. See Figure 2 or Figure 3.
tion motor and the DC pump motor. The controller
can also be used with the optional brushless DC
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2200 SRM 1352 Description
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Parameters 2200 SRM 1352
Parameters
GENERAL Parameters can be adjusted through the dash dis-
play. The factory default values listed in Table 1 are
A parameter is a measurement or a setting that de- the recommended settings for new units. These set-
fines a lift truck function. A specific function param- tings will give satisfactory performance for most ap-
eter works with other function parameters to control plications.
the operation of the lift truck.
WARNING
WARNING If any of the parameter values are changed, the
The parameter for each function has a value operators must be told the lift truck will oper-
range so the motor controller can be used on ate differently.
different models of lift trucks. This variation
is needed for lift trucks of different sized and NEVER adjust any of the following parameters
operation voltages. Adjustment of a function without using the procedures and settings
to the wrong number value for your lift truck given in this section.
model can cause the truck to operate differ-
ently than normal. This different operation of Function Parameter Descriptions in this section
the truck can cause an injury. contains descriptions for the different parameters.
These parameters can also be accessed using the
NOTE: Table 1 shows the factory default setting for ETACC PC software.
each parameter that is adjustable by the user.
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2200 SRM 1352 Parameter Description
Parameter Description
PARAMETERS Walk Speed (Both Directions)
This parameter sets the maximum truck speed for
WARNING forward and reverse directions when the truck is in
If any of the parameter values are changed, the Walk mode. Increasing the setting will increase
operators must be told the lift truck will oper- the truck speed. Decreasing the setting will decrease
ate differently. truck speed.
NEVER adjust any of the following parameters
without using the procedures and settings
Hi Speed (FWD)
given in this section. This parameter sets the maximum forward speed of
the lift truck when the truck is in Ride mode. In-
Parameters can be adjusted through the dash display
creasing the setting increases the speed. Decreasing
LCD. These parameters can also be accessed using
the setting will decrease the speed.
the ETACC PC software.
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Parameter Description 2200 SRM 1352
Minimum Acceleration Decreasing the value will decrease the rate of accel-
eration.
This parameter sets the minimum acceleration rate
of the lift truck when the truck is in traveling at the Pick Deceleration
lowest throttle. Increasing the setting increases the
minimum rate of acceleration. Decreasing the set- This parameter controls the rate of deceleration
ting will decrease the minimum rate of acceleration. when the coast control switch is released. Increas-
ing the value will increase the rate of deceleration.
Maximum Acceleration Decreasing the value will decrease the rate of decel-
eration. Setting the value at 1 will result in no effect
This parameter sets the maximum acceleration rate on the rate of deceleration; the truck will coast until
of the lift truck when the truck is traveling at max- it comes to a stop.
imum throttle. Increasing the setting increases the
maximum rate of acceleration. Decreasing the set- Battery Full Voltage
ting will decrease the maximum rate of acceleration.
This is the battery voltage in millivolts at which the
Plugging battery is considered fully charged. Increasing the
setting increases the voltage. Decreasing the setting
This parameter controls the maximum rate of decel- reduces the voltage.
eration when the speed control is fully moved to the
opposite direction from the direction of travel while Lift Interrupt
the truck is moving. Increasing this setting will in-
crease the rate of deceleration. Decreasing the set- This is the battery voltage in millivolts at which the
ting will reduce the rate of deceleration. battery is considered 80% discharged. Increasing the
setting increases the voltage. Decreasing the setting
ADS-Neutral reduces the voltage.
This parameter controls the rate of deceleration When the Service Hour Reminder is ON, the dash
when the speed control is partially reduced and the display will display a one-time message to the oper-
ADS-Throttle parameter is set above 1. Setting ator when the preset hourmeter reading has been
the value at 1 will result in no effect on the rate of reached. The lift truck will continue to operate
deceleration; the truck will coast until it reaches normally until the hourmeter reaches 20 hours past
the lower throttle speed. Increasing the value will the preset service interval. At this time the lift truck
increase the rate of deceleration. Decreasing the function speeds will be reduced until the Service
value will decrease the rate of deceleration. Hour Reminder has been reset. The lift truck should
be serviced and the parameter reset to the next
Pick Acceleration hourmeter reading when service is due.
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2200 SRM 1352 Troubleshooting
Troubleshooting
GENERAL Check resistance on the proper scale from frame to
power and controller terminals. Resistance of less
The controllers are sealed units with no serviceable than 20,000 ohms can cause misleading symptoms.
components. Troubleshooting is usually limited to Resistance of less than 1000 ohms indicates a short
accessing status codes and following the diagnostic and should be corrected immediately.
procedures listed in the status code charts.
The on-board diagnostic system employed on this lift
Use standard testing procedures to verify inputs and truck can assist in the troubleshooting process. Read
outputs when necessary. and be familiar with the instructions for accessing
and using the dash display diagnostic system.
CAUTION Prior to troubleshooting systems and components on
Never attempt to probe through the back of this lift truck, ensure the battery is the correct volt-
the connector plugs of the motor controller. age and is fully charged. Make sure the battery con-
The plugs are special sealed plugs. Probing nector contacts are clean of corrosions and the bat-
through the back of the plugs will destroy the tery polarity within the connector is correct. Inspect
seal and can cause a short circuit. If a circuit to ensure all fuses are correct and have not failed.
must be tested for voltage, check for voltage Ensure the key switch is in the ON position when
at an amp-type plug, a switch, or a component. making voltage checks or checking the operator of a
If a circuit is suspect, check the circuit for component.
continuity from the front (pin end) of the plug.
Many faults noted by lift truck systems are the result
Standard probes are too large to be inserted of loose wiring connections and/or broken or shorted
into the center of the female pins (sockets) of wiring within the lift truck. Begin the troubleshoot-
the special sealed plugs and can expand the ing process by carefully inspecting the wiring involv-
pins. Expanded pins will not provide good con- ing the device or devices noted by the on-board diag-
nections once the plug is reconnected. The con- nostics system.
nectors are shaped to allow the insertion of a
flat blade screwdriver into the connector. After STATUS CODES
inserting the screwdriver into the connector,
attach probes with alligator clips to the shank Make sure the parameter values are correct for your
of the screwdriver to obtain readings. An addi- lift truck to ensure the trouble is not just an incorrect
tional method would be to use a breakout kit. setting. See function settings to set the correct pa-
rameter values. If there is no status code display and
If the controller detects an issue, a status code is dis- the lift truck does not operate correctly, there may be
played on the display panel. a fault in the controller.
Once the status code number is obtained, follow the The status codes are numbers for malfunction or lift
procedures outlined in the status code charts of this truck operation that are not correct and that the con-
manual to determine the problem. troller can sense. The controller will indicate this
code number on the LCD screen of the display panel.
NOTE: Due to the interaction of the controller with
all lift truck functions, almost any status code or con- NOTE: There are identifiers to determine which de-
troller fault could be caused by an internal failure of vice generated the code:
the controller. After all other status code procedures Xy = XXXX (Co 23538)
have been followed and no problem is found, the con- Co = Controller
troller should be replaced as the last option to correct Ti = Control Module
the problem.
The controller senses the following types of malfunc-
Tools and test equipment required are: tion:
Clip Leads Input voltages that are too high or too low
Digital Multimeter (20,000 ohms per volt) Input voltages in the wrong sequence or
Basic Hand Tools Correct input voltages that occur at the wrong time
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Troubleshooting 2200 SRM 1352
NOTE: A status code indication does not always mean The Fault Message charts in this section have a more
that there is a malfunction. A temporary operation complete description of the status code, the circuit
condition can cause a status code display. that has generated the input for the status code, the
symptom, and the possible cause.
These code numbers are only indicators that may
help diagnose a possible malfunction. A short de-
scription of the different status codes is shown in Ta-
ble 2.
Code Description
9024 Controller failure of the traction motor power circuit
9088 Pump motor shorted
9089 Pump motor open
9090 Pump at relief
9091 Controller failure of the pump motor power circuit.
12816 Controller internal voltage over 36 volts
12819 Incorrect voltage battery connected
12832 Controller internal voltage less than 16 volts
12835 Incorrect voltage battery connected
16912 Controller power section is over temperature
16944 Controller is in thermal cutback - high controller temperature
16945 Controller internal temperature sensor failure
17168 Traction motor is over temperature
17169 Controller is in thermal cutback - high traction motor temperature
17170 Traction motor temperature sensor failure
20756 Key switch open
21024 Control module failure
21378 Controller cannot establish contact with control module
21533 Horn circuit is shorted to B+
21534 Horn circuit is open
21535 Horn circuit is shorted to B
21544 Horn switch is closed at startup
21552 Steer handle inputs incorrect at startup
21553 Hi Speed switch is closed at startup
21555 Lift or lower switch is closed at startup
21568 Main contactor circuit is open
21569 Main contactor circuit is shorted to B+
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2200 SRM 1352 Troubleshooting
Code Description
21570 Main contactor circuit is open
21571 Main contactor circuit is shorted to B
21588 Internal failure of the power steering unit
29445 Traction motor encoder failure
29448 Steer handle switch closed at startup
29456 Error in control module speed/direction sensor
29458 Steer handle sensor is out of limits
33056 Controller cannot establish communication with control module
33057 Controller cannot establish communication the power steering controller
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Troubleshooting 2200 SRM 1352
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Troubleshooting 2200 SRM 1352
DESCRIPTION SYMPTOM
Controller has lost communication Traction and hydraulic systems will not operate.
with the control module.
Probable Causes and Test Procedures
1. Ensure all wiring connections between the control module and the controller are tight and secure.
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2200 SRM 1352 Troubleshooting
DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the control module (cont).
Probable Causes and Test Procedures
2. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 40 ohms.
If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
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Troubleshooting 2200 SRM 1352
DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the control module (cont).
Probable Causes and Test Procedures
3. Check for continuity between pin #3 (X2)at the control module connector and pin #28 at the controller
connector.
a. Repair any broken wiring.
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2200 SRM 1352 Troubleshooting
DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the control module (cont).
Probable Causes and Test Procedures
4. Check for continuity between pin #4 (X2) at the control module connector and pin #27 at the controller
connector.
a. Repair any broken wiring.
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Troubleshooting 2200 SRM 1352
DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the control module (cont).
Probable Causes and Test Procedures
5. Check for continuity between pin #2 (X2) at the control module connector and pin #29 at the controller
connector.
a. Repair any broken wiring.
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2200 SRM 1352 Troubleshooting
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Troubleshooting 2200 SRM 1352
DESCRIPTION SYMPTOM
Controller has detected an open circuit Hydraulic system will not operate.
in the lower valve.
Probable Causes and Test Procedures
1. Disconnect the pump coil connector at the lift pump.
2. Measure the resistance across pins from the pump coil.
a. Resistance should be approximately 1 ohm.
Replace the coil.
3. Check for open circuit condition in wire #150 and wire #86 from the connector to pin #22 and pin #23 at
the controller.
a. Repair broken wiring or loose connections.
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2200 SRM 1352 Troubleshooting
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Troubleshooting 2200 SRM 1352
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2200 SRM 1352 Troubleshooting
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Dash Display 2200 SRM 1352
Dash Display
GENERAL When the lift truck is operating normally, the LED
will be solid green when the key is in the ON posi-
The dash display is a multifunction device. It con- tion.
tains a truck status LED and an LCD which dis- If there is a fault noted by the lift truck controller
plays the performance mode indicator and the bat- and the controller has prevented traction and hy-
tery charge indicator. The menu system can be ac- draulic functions, the LED will be solid red.
cessed through the dash display by starting the truck When the battery charge reaches 75% of full
in service mode and entering the proper password. charge, the horn will sound and the LED will
See Figure 4. alternately blink from red to green.
If the controller has noted a condition that require
the lift truck to operate at a reduced performance
level, the LED will blink red.
STARTUP
When the key is turned to the ON position and the
handle is in the full upright position, all segments
of the display will be illuminated and the horn will
beep twice. The LED will flash red, green, and then
go blank momentarily. Then the display will show
the truck mode setting and the hourmeter reading.
STATUS LED
The status LED is located in the top center of the dis-
play. When the key switch is in the ON position, the
LED is on. The LED can indicate in either red or
green depending on the information being communi-
cated.
When the lift truck key is in the OFF position, the Figure 5. Performance Mode Screen
LED will be OFF.
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2200 SRM 1352 Dash Display
HOURMETER
The hourmeter accumulates hours when the key is
in the ON position and main contactor is closed. The
hourmeter is capable of showing five digits and dis-
plays complete hours. See Figure 6. At truck startup,
the display will show the truck hours for 10 seconds
after the key has been turned to the ON position. The
hourmeter reading will be turned off if the control
handle is moved to the operating position any time
within the 10 second display period.
FAULT LOG
The Fault Log menu will list the truck system initiat-
ing the fault, the error code associated with the fault,
the hourmeter reading when the fault occurred, the
number of times the fault has been logged, and the
system temperature when the fault occurred. See
Figure 8. The Fault Log auto scrolls. The system
will retain the last ten faults noted.
Figure 6. Hourmeter
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Connector Pin-Outs 2200 SRM 1352
Connector Pin-Outs
Controller Connector (CPS 05)
Pin Wire Number Function
1 W10 - AC RED Battery Positive
2 W342 - A High Speed
3 W26 - A Aux. Lift Switch
4 W27 - A Aux. Lower Switch
5 W28 - A Control Module
6 W98 - AC Steer Handle Switch
7 - -
8 - -
9 - -
10 - -
11 W25 - A Aux. Horn Switch
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 W79 - M RED Main Contactor Coil
19 - -
20 W45 - H Horn
21 - -
22 W150 - A Pump Coil (+)
23 W86 - A Pump Coil ( )
24 - -
25 W386 - A Traction Motor Temp Sensor
26 - -
27 W901/H - WHT CAN Hi
28 W900/L - BLK CAN Lo
29 W102/BARE - GRN Traction Motor Temp Sensor
30 W250 - E Traction Motor Encoder
31 W577 - E Traction Motor Encoder
32 W578 - E Traction Motor Encoder
33 - -
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2200 SRM 1352 System Logic Diagram
CANbus
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NOTES
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