NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING TMX NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING RUSS DAVIES (859) 422-6421 russdavies@clarkmhc.com NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05 TMX Overview Controls and Motors (Hardware) CAN_BUS (Communication) Wiring Diagram Troubleshooting Handset Pc Console (Software) Programming: Master/Slave Programming: Pump Main Hydraulic Valve NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

TMX AC MOTOR No Brushes Replace bearings after 10,000 hours Stator No Brushes Replace bearings after 10,000 hours DO NOT wash with high pressure hose as water can get trapped inside the motor. Use of low pressure, (garden) hose is allowable, but avoid directly spraying the end cap to stator interface. Sensor Bearing Rotor NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Reseal motor with RTV (P/N 1758629) after any repair MOTOR RESEALING Reseal motor with RTV (P/N 1758629) after any repair NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

A B C WS VS US WM VM UM Batt+ Batt- Control Master/Slave CAN_BUS Connections Handset/ Dash Port Inputs & Outputs A B C Left Side Slave Right Side Master WS VS US WM VM UM Batt+ Batt- NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

DUALAC2 Wiring Connections Control Wiring DUALAC2 Wiring Connections DUALAC2 Controller is software adjustable same control for 36V or 48V NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

AC2 Wiring Connections W V U Batt- Batt+ Pump Control D C E B F A AC2 Pump controllers are voltage dependent and NOT software adjustable. Separate controls for 36V or 48V W V U Batt- Batt+ NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

The controllers communicate using a CANBUS format MASTER = Connected to “3” = Right Drive Control = Node “3” SLAVE = Connected to “4” = Left Drive Control = Node “4” PUMP = Connected to “5” = PUMP Control = Node “5” NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

TMX Sequence of Operation WIRING TMX Sequence of Operation NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

TMX Misc Information Do Not spray wash the motors or controls (garden hose ok) Blow out the control fans at each PM Do Not hook accessories to the encoders or Potentiometers. NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Common Error Codes Two Hour Meters -01 Seat Switch DASH DISPLAY Common Error Codes -01 Seat Switch -66 Low Battery (Lift Lockout) -77 Maintenance Hours (Reset Maintenance Hours) -79 Incorrect Start (SRO) -217 Wrong Battery Pump -245 Wrong Battery Master -255 Park Brake On Two Hour Meters Internal hour meter (not programmable) (fault Codes) Hour meter when you turn the key off (reset programmable) NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Handset TMX Handset P/N 8033636 NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

START MENU DUAL AC2 Master Controller Clark Revision Level 280 AMPS Internal Hour Meter Reading 36 Volt NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

HANDSET TREE NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

TESTER MENUS NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Roll up or down to next input or output OR TESTER MODE Press Roll up Until you come the Forward Switch Press the Enter button Activate the Forward Switch Press Roll up Until you come the Tester Menu Roll up or down to next input or output OR Press the out button to return Main Menu Tester Press the Enter button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

*MAIN MENU* PARAMETER CHANGE MASTER PROGRAMMING *MAIN MENU* PARAMETER CHANGE NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

MASTER PROGRAMMING VACC *ADJUSTMENTS* Defaults SET BATTERY TYPE (36V/48V) 36 ADJUST BATTERY (V) ? Actual Battery Volts MAX STEER RIGHT (V) ? Acquired during Setup MAX STEER LEFT (V) ? Acquired during Setup SET STEER 0-POSITION (V) ? Acquired during Setup SET STEER RIGHT (90°) 90 (Do Not Change) SET STEER LEFT (90°) 90 (Do Not Change) THROTTLE 0 ZONE (%) 1% THROTTLE Y ZONE (%) 15% THROTTLE X ZONE (%) 18% ADJUSTMENT #04 (ºC) 130 Temp Fault is signaled MOTOR SHUTDOWN (ºC) 145 Temp Truck is Stopped ADJUSTMENT #01 (1-9) 4 Batt. Level Display ADJUSTMENT #02 (1-9) 4 Lift Interrupt ADJUSTMENT #03 (%) 20% Display Volt Reset VACC NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

MASTER PROGRAMMING *ADJUSTMENTS* (CONT’D) Defaults MAIN CONTACTOR VOLTAGE (V) 36V AUX OUTPUT VOLTAGE (V) (NOT USED) 36V MAINTENANCE DONE (ON/OFF) OFF MAINTENANCE (NONE / OPT#1 / OPT#2) None MAINTENANCE TIME (0-1000) 250 1 X 10,000 HOURS (0-6) 0 1 X 1,000 HOURS (0-9) 0 1 X 100 HOURS (0-9) 0 1 X 10 HOURS (0-9) 0 1 X 1 HOURS (0-9) 0 NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

SET MODEL Press the roll up and Param. Up buttons at the same time Press the Out button Press the Enter button to save OR Press Out button to exit (no save) Press the Enter button Press the Param. Up button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

MASTER Program VACC Press Enter Button Press Enter Button Press Out Button Put directional lever in forward position push accelerator all the way to the floor and release Press Rollup Button until you see Program VACC Menu Press the Enter button to save OR Press Out button to exit (no save) Put directional lever in reverse position push accelerator all the way to the floor and release Press Enter Button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

PROGRAM VACC NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Set Steer Pot “0” Position Press the Enter button to save OR Press Out button to exit (no save) Press the roll up and Param. Up buttons at the same time Adjust steer wheel to straight position Press Rollup until you come to the Adjustments Menu Press Enter Button Press Out Button Press Rollup until you come to Set “0” Steer Pos. Adjustment NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Set Max Steer Left Turn steer wheel all the way to the Left Press Rollup until you come to Max Steer Left Adjustment Press Out Button Press the Enter button to save OR Press Out button to exit (no save) Press Enter Button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Set Max Steer Right Press Rollup until you come to the Max Steer right Adjustment Press Out Button Press the Enter button to save OR Press Out button to exit (no save) Press Enter Button Turn steer wheel all the way to the Right NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Alarm Log Press Out Button Press Enter Button Press Enter Button Press Rollup Button until you see the Alarms Menu Press the Enter button to save OR Press Out button to exit (no save) Press Enter Button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Pc Console Software Troubleshooting using a laptop computer with the ZAPI Pc Console software and Pc Console adapter cable (8032294). Pc Console cable plugs into the 9 pin RS232 port (Com1) The other end plugs into the “B” plug on the DUALAC2 control The switch must be set to PC when used with the Pc Console software or set to Flash for the Winflash software NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Pc Console Main Start up Screen NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Com Port Setup Pc Consloe Select Com Port Setup from the Configuration Menu NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Com Port Setup Pc Console DUALAC2 (Master/Slave) Com port1 set to 9600 bps Select OK AC2 (Pump) Com port1 set to 1200 bps NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Connecting to the Controller Pc Console Connecting to the Controller Note: Control not connected Select the start button to connect to the controller NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Main Startup Screen Pc Console Connected to Master control Internal hour meter Any alarm that is present Control connected NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Function Menu Pc Console Select the parameter function NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Set Model Pc Console Select Set model button Select Receive Menu button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Changing Controllers on the CAN_BUS Pc Console Changing Controllers on the CAN_BUS Select the up arrow to change from node #3 (Master) to node #4 (Slave) NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Changing Controllers on the CAN_BUS Pc Console Changing Controllers on the CAN_BUS Select the store button Select the close button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Now connected to the Slave Control Pc Console Now connected to the Slave Control NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Function Menu Pc Console Select the parameter function NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Changing Controllers on the CAN_BUS Pc Console Changing Controllers on the CAN_BUS Select the up arrow to change from node #4 (Slave) to node #5 (Pump) NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Changing Controllers on the CAN_BUS Pc Console Changing Controllers on the CAN_BUS Select the store button Select the close button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Now Connected to the Pump Control Pc Console Now Connected to the Pump Control NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Checking Alarm Logbook (Fault Log) Pc Console Checking Alarm Logbook (Fault Log) Select the Alarm Logbook function NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Alarm Logbook Function Pc Console Alarm Logbook Function Up to (5) Alarms can be stored in the alarm logbook Note: each alarm shows The alarm name The number of times the alarm happened The temperature when the alarm happened The hour meter reading when the alarm first happened. To save a copy of the log select the print button Pedal Wire KO 02 26C 341 Input Mismatch 01 30C 349 NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Saving Alarms from the Logbook Pc Console Saving Alarms from the Logbook x Select the print to file button Select OK button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Saving Alarm Logbook Pc Console Enter a file name for the log file select where you want to save the log file Select the save button 2 1 NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Clearing the Alarm Log Pc Console Select the Clear button Select the OK button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

File is saved as a Text file ALARM LOG FILE File is saved as a Text file Wed Mar 30 17:24:47 2005 DA2M2BKC CK1.14 36 V 280 A VMN HIGH 1 143 h 25 C degree MOTOR SHUTDOWN 1 143 h 23 C degree VMN HIGH 1 143 h 27 C degree MOTOR SHUTDOWN 1 143 h 27 C degree NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Tester Mode Pc Console Select the Tester function NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Pc Console Tester Mode List of parameters that can be viewed in tester mode NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Pc Console Tester Mode In Tester mode up to (4) different parameters can be Monitored at once. Select the advanced button to setup the recording function of tester mode NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Pc Console Tester Mode Select how often you want to sample the selected parameters Select how many total samples you want to take of the selected parameters Select OK button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Pc Console Tester Mode Select Start record button to record parameter values to the log. NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Pc Console Tester Mode Select Stop record button to stop recording parameter values to the log. NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

PC Console Tester Mode Select Save record button to save your log to a file. NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Pc Console Log File TIME STEER ANGLE HANDBRAKE TEMPERATURE #2 TEMPERATURE -90 280 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 The Log file gets stored in a .CVS file which can be converted to a .XLS NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

TMX HYDRAULIC SYSTEM The TMX uses a Priority Valve to control both the power steering and the main hydraulic functions. The Priority Valve provides a constant oil flow to the power steering any time the pump is running. Any excess flow is diverted to the main hydraulic valve. The power steering always has priority over any other hydraulic function. NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

HYDRAULIC SCHEMATIC NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Adding hydraulic attachments that require a change to the aux flow. MAIN HYDRAULIC VALVE Adding hydraulic attachments that require a change to the aux flow. Adjust Pump control panel 2nd Speed Fine and, or 3rd Speed Fine to correct pump speed for required aux flow. Next you need to adjust the aux flow at the valve to the Correct flow for the attachment. NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Main Hydraulic System Flow Control Adjustments Remove the nut from main hydraulic valve tie bolt. Remove the stud from the valve. Turn the flow control adjuster fully counter clockwise to the stop. Do not tighten against stop, or you can damage the valve. Turn adjuster clockwise per flow control specification. Repeat steps 3 and 4 for each flow control change required. Reinstall the tie bolt stud in the valve. Torque the stud to 38-43 N.m (28-32 ft-lb). NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

Main Hydraulic System Flow control Adjustments: Adjustable from 2 to 38 L/min (1 to 10 gpm). Before adjusting, turn fully counter-clockwise to stop, each clockwise turn of the adjustment increases flow by 3L/min (.75 gpm). After Adjusting the flow control valve settings it will be necessary to also adjust the pump control panel parameters to coinside with the settings you have made. Auxiliary Flow Adjustments Flow Settings L/min (gpm) Clockwise Turns of Adjustment Screw 6.3 (1.7) 0.50 8.7 (2.3) 0.75 12.3 (3.2) 1.00 19.0 (5.0) 1.50 23.4 (6.2) 1.75 33.5 (8.8) 2.50 39.8 (10.5) 3.00 52.9 (14) 4.50 Pump Control Panel Settings (using the Handset) Parameters Auxiliary Flow Settings GPM 36V Hz 48V Hz 2nd Speed Fine and 3rd Speed Fine 2.5 20 33 5.5 43 51 7 55 65 10 79 93 NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

PUMP Program VACC Press the Enter button to save OR Press Out button to exit (no save) Press Enter Button Pull lift lever all the way down and release it Press Rollup Button until you see Program VACC Menu Press Out Button Press Enter Button NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

*MAIN MENU* PARAMETER CHANGE PUMP PROGRAMMING *MAIN MENU* PARAMETER CHANGE Parameters Program Level Units 1 2 3 4 5 6 7 8 9 Acceleration Delay SEC. 0.5 0.7 1.0 1.4 1.9 2.5 3.2 4.0 4.8 5.5 Deceleration Delay Maximum Speed Up Hz Adjustable in 1 Hz Increments, TMX 12-20 Default 125 Hz, TMX 25 Default 95 Hz. DO NOT exceed maximum speed. Speed may however be reduced as required. 1st Speed Fine (Tilt) 2nd Speed Fine (S/S) 3rd Speed Fine (Aux) Default 30 Hz Adjustable in 1 Hz Increments Maximum Current % IMAX 47 53 58 64 70 76 82 88 94 100 Auxiliary Time 0.2 0.4 0.8 1.5 2.0 3.0 5.0 DO NOT CHANGE NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

TESTER MENU NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

END Questions???? NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

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TMX NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05