1930SE Harness-Main Circuit. Battery. Drive Motor Pump Motor. DC Contactor. 350A Drive Controller. 250A Fuse. Model Type Voltage Capacity.

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Valentine Stanley
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1 930SE Harness-Main Circuit Electrical Appliance Protector Option 00-0VAC VDC A 70W Charger Power Switch Battery Battery Model Type Voltage Capacity T-60 6V 0Ah 0A Fuse DC Contactor 30A Drive Controller Drive Motor Drive Motor Pump Motor

2 930SE Harness-Control Circuit Platform Ccntrol Module ECU Pin NO. ID. Colour Place NO. ID. Colour Place NO. ID. Colour Place A / / / B B GN/YE CAN_H C C GN/RD CAN_L A / / / B B BN/ RD Key Switch C C RD Power 3A 3A BN/ YE Overload Indicator 3B 3B WH/ BK Ground 3C 3C GN/ RD Pressure Sensor A A RD Power B B WH/ VT Angle Sensor C C GN/ WH Drive Controller A A RD Power B B BN Brake Release Switch C C BN/YE Drive Controller 6A 6A VT/ YE Lift Up Valve 6B 6B BN/BU Lift Down Valve 6C 6C BN/GY Drive Controller 7A 7A-Z BN/ WH Drive Controller 7B 7B WH/ BU Steer Left Valve 7C 7C WH/ BU Steer Right Valve 8A 8A BN/ GN Hourmeter,Drive Controller 8B 8B BN/RD Horn 8C 8C WH/VT Drive Controller 9A 9A-Z BN/ BK Drive Controller 9B 9B WH/BK Buzzer 9C 9C BU/ RD Brake 0A 0A GN/BU Brake Drive Controller 0B 0B- WH/BU Pothole Switch,Drive Controller A B C 0C 0C GN/ VT Brake Drive Controller A / / / B B BU/ RD Lift Up Limit Switch C C GN/ VT Tilt Sensor Lift Down Limit Switch A A BN/ GY Down B B BN/ WH Up C C GN Brake Release Switch Drive Motor Brake (Left) Brake (Right) 9C BU/RD GND- BK 0C- GN/VT 0A- GN/BU 3 LOC7 SIBAS Pin NO. ID. Colour Place GND- BK Ground B GN/YE ECU 3 00B BU/RD LOC3-K 00A- GN/WH LOC3-J C GN/RD ECU Charging Protection CP RD CP RD Charger H 3 SIBAS Pin NO. Colour WH YE 3 RD GN BU S 3 SIBAS Pin NO. Colour WH YE 3 RD GN BU A J 3 SIBAS Pin NO. Colour WH BU 3 RD BK OG C GN A- WH B BU GND- BK 00 BN/ GN 00- BU/RD 00- RD/ BU 00-3 RD 00A BN/RD A A 3B B 3 B B Brake Release Switch Key Switch ECU 00A- BN/WH A BN/GY B BN/WH 6 Toggle Switch 00- BU/RD 00A-6 BU/RD E-STOP A B C B+ 00 RD Main Circuit B- B-A BK BF+ FUSE RD Drive Controller J Pin NO. ID. Colour Place NO. ID. Colour Place 0A-Z GN/BU ECU 0C-Z GN/VT ECU FUSE RD Fuse 6 6B-Z BN/ BU DC Contactor 3 / / / 7 / / / 7A-Z BN/ WH ECU 8 6C BN/ GY ECU J Drive Controller J Pin NO. ID. Colour Place NO. ID. Colour Place / / / 8 / / / J / / / 9 / / / 8 3 C BN/YE ECU 0 JMPR GN/YE / / / / / / 8C WH/VT ECU A-Z WH LOC3-G 6 0B-Z WH/BU ECU 3 / / / J3 7 / / / JMPR GN/YE 6 Drive Controller J3 Pin NO. ID. Colour Place NO. ID. Colour Place B+-Z- RD Power 6 8A-Z BN/ GN ECU / / / 7 / / / 3 / / / 8 / / / C GN/ WH ECU 9 9A-Z BN/ GY ECU / / / 0 / / / Drive Controller 0A Fuse Steer Right Valve Valves Steer Left Valve Lift Up Valve DC Contactor DC Contactor GND-0 BK 8A- BN/GN 9B WH/BK B+-A RD Hourmeter Buzzer GND- BK 7C WH/BU GND- BK 7B WH/BU GND-3 BK 6A VT/YE B+-Z RD 6B-Z BN/BU 8B BN/RD GND-6 BK Horn LOC3 LOC Delphi Pin NO. ID. Colour Place NO. ID. Colour Place A 00A- RD Power J B BU/ RD ECU B 00A-3 RD Power K 3C GN/RD ECU C 00A- RD Power L C- GN ECU D 00A- RD Power M 6B BN/BU ECU E 0B- WH/BU ECU N GND-7 BK Ground F 0B-3 GN/ BU ECU P GND-8 BK Ground G B WH/VT ECU R GND-9 BK Ground H C GN/VT ECU S GND- BK Ground A H Delphi Pin NO. ID. Colour Place NO. ID. Colour Place A B+ RD Fuse J 00A- GN/ WH Platform Ccntrol Module B B BN/ RD ECU K 00B BU/ RD Platform Ccntrol Module C CP RD Charging Protection L 3A BN/YE ECU D B BN/WH ECU M 3B WH/ BK ECU E A BN/GY ECU N B- BK Ground F 00A-6 RD Power P B BN ECU G A-Z WH Drive Controller R / / / H C- GN ECU S CP RD Charging Protection J A J LOCG A J S LOC Delphi Pin NO. ID. Colour Place NO. ID. Colour Place A / / / J B WH Lift Up Limit Switch B / RD Power of Angle Sensor and Pressure Sensor K / WH+GN Pressure Sensor C 00A- RD Power L C GN Lift Down Limit Switch D 00A- RD Power M / RD Lift Down Valve E 0B WH/ BU Pothole Switch N / BU Lift Down Valve F / / / P B BK Ground G / WH+GN Angle Sensor R / BK Ground of Angle Sensor and Pressure Sensor H C GN/VT Tilt Sensor S / / / H S H Delphi Pin NO. ID. Colour Place NO. ID. Colour Place A 00 RD Fuse J 00A-7 BU/RD B 00A BN/ RD Key Switch K 00- RD/ BU Relay C 00A-6 BU/ RD E-STOP L 3A BN Overload Indicator D B BN/ WH Toggle Switch M GND- BK Ground E A BN/ GY Toggle Switch N GND-3 BK Ground F 00A- YE Relay P B BU Brake Release Switch G A- WH Brake Release Switch R / / / H C GN Brake Release Switch S 00A-7 BU/RD S 00 RD 00-3 RD 00- YE 00- RD/ BU 00A- YE GND BK 3A BN GND- BK 00A- RD B- BK 0B- WH 00A- RD 0B- WH 00A-0 RD B WH 00A-3 RD C GN 00A- RD 00A- RD C GN/ VT B-3 BK RD BU RD WH+GN BK RD WH+GN BK A Fuse Relay Overload Indicator C A B NO. NC. Beacon 3 Pothole Switch NO. 3 Pothole Switch NO. Lift Up Limit Switch Lift Down Limit Switch 3 Tilt Sensor Lift Down Valve 3 Angle Sensor Pressure Sensor Option

3 AC00-0V INPUT CH- GN/YE (6) CH- BU (6) CH-3 BN (6) PE N CHARGER CH-8 GN/YE (6) PLATFORM CONTROL BOX JS JOYSTICK JOYSTICK DEADMAN CP RD(8) CH- BK () L KACH CH-7 BK (0) STEER LEFT STEER RIGHT LIFT ENABLE DRIVE ENABLE LOW SPEED CP RD(8) CH- WH () CH-6 RD (0) S HORN C SB GROUND E-STOP SA KEY SWITCH GB BATTERY 6VDC GB BATTERY 6VDC GB3 BATTERY 6VDC 00A-7 BU/RD(6) GB+ RD(/0) SB SA SB SB6 SB7 SB8 00A-6 BU/RD(6) B 00- BU/RD(6) 00-3 RD() 00 BN/GN(6) 00 RD() 00- RD/BU(6) 00A BN/RD(6) FU AB+ RD() DRIVE INDICATOR LOW SPEED INDICATOR 7A LIFT INDICATOR K 00- RD/ BU(6) GND BK() PCU LED F 00A- YE(6) 00- YE() 00B BU/RD(8) 00A- BN/WH(6) KA CAN_L CAN_H SB3 PLATFORM E-STOP J BUZZER B 3 00A- GN/WH(8) KEY SWITCH INPUT 00A- RD(0) 00A- RD(0) A BU (8) YE (8) GN (8) RD (8) WH (8) TILT SENSOR 00A- RD(8) TILT D C B 00A-6 RD(8) B+-Z RD(6) B+-Z- RD(8) 00A- RD(8) 00A- RD(8) 00A-3 RD(8) 00A- RD(8) B+-A RD(6) SA LIFT UP B BN/WH(6) D A BN/ GY(6) E LIFT DOWN B BUZZER PRESSURE SENSOR LS K ANGLE SENSOR ASA 00A- RD(0) HL B- BK(0) BEACON C GN/RD(6) B GN/YE(6) 00A- GN/WH(8) 3 G H GND- BK(6) 00B BU/RD(8) B BN/RD(8) A RD(6) A RD(6) C RD(6) B BN/WH(8) A BN/GY(8) 9B WH/BK(6) 3C GN/RD(8) B WH/VT(8) C GN/ VT(8) C B B A A C B A B9 C3 B C ECU LED B-3 BK(0) B BK(8) C8 C B0 A7 C6 C0 A0 A9 C A8 B A3 C B B8 A6 C7 B7 C9 B6 B3 GND- BK(6) GND-3 BK(6) 8C WH/ VT(8) C BN/YE(8) 0B- WH/BU(6) 7A-Z BN/WH(8) 6C BN/GY(8) 0C GN/ VT(6) 0A GN/BU(6) 9A-Z BN/BK(8) C GN/WH(8) 8A BN/GN(6) B BN(8) 3A BN/YE(8) C GN (8) B BU/ RD(8) 8B BN/RD(6) 6A VT/ YE(6) 7C WH/BU(6) 7B WH/BU(6) 9C BU/RD(6) 6B BN/BU (8) 3B WH/BK(8) M N 0 Electrical Schematic 0B- WH/ BU(8) 0B-3 WH/ BU(8) E F BRAKE RELEASE SWITCH SA3 C- GN (8) H C GN (6) A- WH(6) P B BU(6) GND- BK(6) HL L 3A BN(8) GND- BK(8) OVERLOAD INDICATOR LIFT DOWN LIMIT SWITCH C- GN (8) C GN(0) 00A-3 RD(0) SQ LIFT UP LIMIT SWITCH J B WH(0) 00- RD(0) SQ SQ SQ6 SQ7 SQ8 (Option) 8A- BN/GN(6) HM GND-0 BK(6) B HOURMETER HORN GND-6 BK(6) M YV YV3 YV LIFT UP VALVE STEER RIGHT VALVE STEER LEFT VALVE YV LIFT DOWN VALVE N S R P SQ3 0B- WH(0) 00A-0 RD(0) POTHOLE LIMIT SWITCH 0B- WH(0) SQ 00A- RD(0) POTHOLE LIMIT SWITCH GND-3 BK(6) GND- BK(6) GND- BK(6) GND-7 BK(8) GND- BK(8) GND-9 BK(8) GND-8 BK(8) B- BK(8) GND- BK(6) GND-3 BK(6) GND-6 BK(6) GND- BK(6) B-A BK() GND-0 BK(6) G 6B-Z BN/BU(8) FU3 FUSE RD(6) 0A 0C- GN/VT(6) 0A- GN/BU(6) YB LEFT BRAKE YB RIGHT BRAKE GND- BK(6) M3 JMPR GN/YE(8) 8C WH/ VT(8) C BN/YE(8) 0B-Z WH/ BU(8) A-Z WH(8) 7A-Z BN/WH(8) 6C BN/GY(8) 0C-Z GN/VT(8) 0A-Z GN/BU(8) 6B-Z BN/BU(8) FUSE RD(6) 9A-Z BN/BK(8) C GN/WH(8) 8A-Z BN/GN(8) B+-Z- RD(8) LEFT DRIVE MOTOR M RIGHT DRIVE MOTOR M V RD (/0) W BK (/0) W BK (/0) U RD (/0) P- BK (/0) HY. PUMP MOTOR BF+ RD (/0) V W U P- J J J3 B+ BF+ MC MOTOR CONTROL MODULE B- GB BATTERY 6VDC FU 0A GB- BK (/0) SB POWER SWITCH = POSITION AMP CONNECTOR LOC8B = POSITION AMP CONNECTOR LOCB = POSITION AMP CONNECTOR LOCA S S 6 =6 POSITION DELPHI CONNECTOR LOC =6 POSITION DELPHI CONNECTOR LOC3 = POSITION SIBAS CONNECTOR LOC7 GB+ RD(/0) GB- BK(/0) NOTE:ALL WIRES ARE 8AWG OR 0.8mm UNLESS NOTED OTHERWISE B+-Z RD(6) KM DC CONTACTOR BF+ RD(/0)

4 Code with Troubleshooting

5 0 0/ System initialization System communication Invalid option setting Chassis Up or Down Switch ON at power-up Pothole Guard Pressure Sensor Not Used ECU(Check the ECU).(Check the platform control).(check the wiring on platform control connector) 3.(Check the ECU).(Check the battery).(check the relay on ground control) (Reset the option code).(check the wiring on toggle switch).(check the toggle switch).(check the pothole board and switches).(check the speed switch ).(Check the pressure sensor and wiring, the normal range of voltage output is 0.-.8V).(Check the option code)

6 Angle Sensor Platform Left Turn Switch ON at power-up Message Platform Right Turn Switch ON at power-up Message Platform Joystick Enable Switch ON at power-up Faul Platform Joystick not in neutral at power-up Message Drive forward coil fault Drive reverse coil fault Not Used Not Used.(Check the angle sensor and wiring, the normal range of voltage output is.9-3.8v).(check the option code).(check the left steer button).(check the platform controller).(check the right steer button).(check the platform controller).(wait several seconds when turn on the lift).(check the joystick deadman switch).(check the joystick).(check the platform controller) (Check the forward solenoid and wiring) (Check the option code) (Check the backward solenoid and wiring) (Check the option code)

7 Lift Up Coil Lift Down Coil fault Right Turn Coil Left Turn Coil General Brake Coil Parallel coil fault Motor Controller Not Used (Check the lift solenoid and wiring) (Check the down solenoid and wiring) (Check the right steering solenoid and wiring) (Check the left steering solenoid and wiring).(check the brake module and wiring).(check brakes and wiring) 3.(Check the battery voltage) (Parallel Coil : Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.) (Replace the ZAPI controller(only for ZAPI large electric)

8 Motor Controller Current Sensor Motor Controller Hardware Failsafe Motor Controller Motor Output Motor Controller SRO.(Check the drive motor and wiring).(check the drive motor controller and wiring) (Remark: To make suer the drive motor is good before change the drive motor controller, or the motor controller will be damaged again) (Motor Controller Hardware Failsafe : Cycle power. If that does not resolve the issue check for noise sources. If still needed, try replacing the Motor Controller.).(Check the drive motor and wiring).(check the drive motor controller and wiring) (Remark: To make suer the drive motor is good before change the drive motor controller, or the motor controller will be damaged again) (Motor Controller SRO : Look at motor enable delay with the Dingli Scissor Programmer, it may be too short. Make sure other Motor Controller parameters are properly selected.)

9 Motor Controller Throttle Motor Controller Emergency Reverse Motor Controller HPD Low Voltage High Neutral Current (Motor Controller Throttle : Check wiring. Make sure the correct throttle type is selected in the Motor Controller.) (Motor Controller Emergency Reverse : Ensure that the Emergency Reverse Check parameter is off in the Motor Controller.) (Motor Controller HPD : Look at motor enable delay with the Dingli Scissor Programmer, it may be too short. Make sure other Motor Controller parameters are properly selected.) (Low Voltage : Check battery voltage and charge batteries if necessary. Check the battery connections and tighten or clean. Check the voltage to the ECU and PCU. ) (High Neutral Current: The MC is sensing current in the motors when there should note. This could occur anytime the MC thinks the brakes are on and the motors are still turning. This message sometimes comes just before other faults but should be ignored in those cases.)

10 Steer Input Out of Range Motor Controller Main Contactor Motor Controller Over Voltage Motor Controller Thermal Cutback (Steering Input Out of Range: There is an inappropriate voltage at the steering input of the ZAPI motor controller. The ZAPI may need to be trained for the three steering voltages (on Differential Steered machines). Or the steering voltage from the ECU was at some point outside of the range that was recorded during the training session. Retrain the ZAPI and/or check for fluctuating voltages due to lose wires, etc.).check the main contactor and wiring).(check the drive motor and wiring) 3.(Check the drive motor controller and wiring) (Remark: To make suer the drive motor is good before change the drive motor controller, or the motor controller will be damaged again) (Motor Controller Over Voltage. Check battery voltage and make sure the battery charger is not on. Then cycle power to the lift. If that does not resolve the issue, try replacing the Motor Controller.) (Motor Controller Thermal Cutback : Drive or Lift Motor may be overheating. Let the lift cool down. If that does not help cycle power to reset the Motor controller. If that doesn t resolve the issue, replace the Motor Controller.)

11 Motor Controller Motor Motor Controller Pump Motor Motor Controller Left Drive Motor Motor Controller Right Drive Motor Pump Motor Short Left Drive Motor Short 930SE Only (Motor Controller Motor : Check connections to the motors. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller.) (Motor Controller Pump Motor : Check connections to the Pump Motor. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller.) (Motor Controller Left Drive Motor : Check connections to the motors. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller.) ( Motor Controller Right Drive Motor : Check connections to the motors. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller.) (Pump Motor Short : Check connections to the pump motor. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller.).(Check the left drive motor and wiring).(check the ZAPI drive controller and wiring) (Remark: To make sure the drive motor is good before change ZAPI motor controller, or the drive motor will be damaged again)

12 Over 80% Load Warning Right Drive Motor Short Right Brake Coil 930SE Only 930SE Only (Over 80% Load Warning: Platform is getting close to its limit of weight. Consider not adding more load.).(check the right drive motor and wiring).(check the ZAPI drive controller and wiring) (Remark: To make sure the drive motor is good before change ZAPI motor controller, or the drive motor will be damaged again).(check the wring on right drive motor and brake).(check the wires to right drive motor) 3.(Check the ZAPI controller and wiring) (Remark: To make sure the drive motor is good before change ZAPI motor controller, or the drive motor will be damaged again).(check the right motor brake and wiring).(check the brake module and wiring)

13 Left Brake Coil Brake release switch open fault Raised brake release fault Brake release switch fault Drive Motor Field Open 930SE Only 930SE Only 930SE Only 930SE Only.(Check the wring on left drive motor and brake).(check the wires to right drive motor) 3.(Check the ZAPI controller and wiring) (Remark: To make sure the drive motor is good before change ZAPI motor controller, or the drive motor will be damaged again).(check the left motor brake and wiring).(check the brake module and wiring) (Brake release switch open fault(only in 0807 ZAPI) (Raised brake release fault(only in 0807 ZAPI) (Raised release switch open fault, only in 0807 ZAPI) (Check the Field wires on motors and ZAPI controller to see if it is open or shorted -Only for ZAPI large electric)

14 90 Over 90% Load Warning 9 Left Drive Motor Field Short 9 Right Drive Motor Field Short ) 99 Over 99% Load Warning OL Overloaded Platform LL Machine Tilted Beyond Safe Limits NOTE: The common faults are in bold (Over 90% Load Warning: Platform is getting close to its limit of weight. Consider not adding more load.) (Check the Field wires on motors and ZAPI controller to see if it is open or shorted -Only for ZAPI large electric) (Check the Field wires on motors and ZAPI controller to see if it is open or shorted -Only for ZAPI large electric) (Over 99% Load Warning: Platform has reached its limit of weight. Do not add more load.) (Overloaded Platform : Remove the excess load immediately.) (Machine Tilted Beyond Safe Limits : If the machine is tilted, find a way to make it level. If the machine is level, check the wiring to the tilt sensor and then the sensor itself.)

15 Failures that do not have a fault code associated: No. No drive, no alarm, the rest functions all good No steering, no alarm, the rest functions all good No lift, no alarm, the rest 3 functions all good No down, no alarm, the rest functions all good.(check the option code).(check the drive speed setting) 3.(Check the drive motor and wiring).(check the drive motor controller and wiring).(check the steering function valve).(check the steering overflow valve ) 3.(Check the steering speed setting).(check the steering cylinder) (Check if the hydraulic pump is working when lift).(check the lift function valve if working).(check the up switch and ECU is no working).(check the down function valve).(check the cylinder orifice)

16 No No function, no alarm 7A fuse blown on ground control Platform lowers uncommented approximately 6 after lift Platform lowers uncommented.(check the option code and speed setting).(check the joystick).(check the beacon and wiring).(check the tilt sensor and wiring) 3.(Check the platform controller).(check 7A fuse) (Check the relief valve on upper lift cylinder, increase the pressure by turning adjust screw clockwise ¼ turn) ( NOTE: Emergency down function will be affected by excessive increase ).(Check the down function valve).(check the emergency lowering cable)

17 No. 9 0 Will not lift rated capacity No power on machine.(check the lift relief valve by turning the adjuster screw clockwise ¼ turn).(check the seal on lift relief valve) 3.(Check the seal on lift function valve).(check the pump).(check the platform control and wiring).(check the charger relay wiring) 3.(Check three power switches and wiring).(check the key switch and wiring on ground control).(check and 7A and 0A/300A fuse) 6.(Check the relay and wiring on ground control)

18 No. 3 No drive when elevated Slow drive speed in stowed position No charging (Check the elevated drive speed setting) (Check down limit switch and wiring).(check the charger and wiring).(check the battery water, terminals and wiring) 3.(Check the batteries for bad cells)

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