ELECTRIC SCHEMATICS NOTES: (Unless otherwise specified). Switch S BASE/PLATFORM makes contact from the CENTER to the LEFT position when placed in BASE.. Switch S UP/DOWN makes contact from the CENTER to the LEFT position when the switch is held in the CONTACT position and automatically returns to the CENTER position when released.. Switch LS opens the N/C set of contacts and closes the N/O set of contacts when the platform reaches approximately feet.. Switch LS closes the N/C set of contacts when the Pothole Bars are down and locked in place. S S ART LS LS ART "5ES / ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-
D5 D8 D D D5 D ART8 J 8 D D0 R R R R TB 80 D D D D D D J Plug Pin Identification PIN # WIRE # SIGNAL FUNCTION 0 INPUT Drive Reverse INPUT Drive Forward OUTPUT Brake, Decel Valve signal 8 INPUT Steer Left 5 8 OUTPUT Steer signal to Sevcon 5 INPUT Down signal 0 OUTPUT Signal to Motion Alarm(s) (optional) 8 OUTPUT Sevcon & Hour Meter (motor function requested) 5 INPUT Battery Negative 0 INPUT Steer Right INPUT Lift Up INPUT Limit Switch (V = platform down) OUTPUT Enable, from lower Lift switch OUTPUT To Sevcon (for speed cutback) 5 5 8 0 ART ] Fuse ] Contactor ] Tilt Sensor ] Circuit (Diode) Board 5] MotorControl Unit ] Main Harness Connection ] Control Cable Connection 8] Motion Alarm (option) ] Lift/Lower Switch 0] Platform-Base Selector ] Emergency Stop Switch ] Battery Gauge ] Hour Meter 5] Battery Cutoff Switch "5ES / ES" Service & Parts Manual - ANSI Specifications March 008 Page -
SEVCON MOTOR SPEED CONTROLLER The Sevcon Motor Speed Controller (MC-) is a microprocessor designed with the express purpose of operating the D/C electric motor at varying speeds. The controller uses Pulse-Width Modulation (PWM) technology on the Ground side of the motor to control motor speed. Out of concern for operator safety and to prevent short-circuiting, the Controller monitors certain circuits for potential abnormalities. When the controller senses a problem it errs to the side of safety and stops all motor operation. The green LED will flash a code indicating the reason for the shutdown. Refer to the LED Diagnostics Definitions and Sevcon Motor Speed Controller - Connections on the following pages. Cable Connection Identification B+ Battery Positive Cable from 50 AMP Fuse B- Negative Battery Cable and GROUND wire (5) connection M Motor Ground (Pulse-Width Modulated [PWM] variable speed control) MC- Plug Pin Identification PIN # WIRE # FUNCTION B+ power input (power up) Lift, Drive or Steer functions input (functions requiring motor) 8 Steer Requested (adds additional motor speed for steer) Enable Switch signal input 5 Speed cut-back ( Volts = full speed, 0 Volts = creep speed) Motor Start Relay signal (GROUND signal to activate Motor Start Relay) Lift Valve B- (provides GROUND signal to Lift Valve) 8 none none Accelerator reference signal (. Volts to Potentiometer) 0 none none none none none none ART8 March 008 Page - "5ES / ES" Service & Parts Manual - ANSI Specifications
LED Diagnostics Definitions (Flash Codes) LED READING LED Steady On LED Off Flashes Flashes Flashes 5 Flashes DIAGNOSIS Controller is operational and detects no irregularities on monitored circuits. No power-up No power to pin # No ground to B- post LED failure or internal controller fault Procedure fault. Enable depressed at power up Enable depressed for more then 5 seconds without function request No signal on wire pin # when function requested No B- to diode board Failed diode/s Damaged wire harness Internal controller fault Motor circuit low. Set with unit at rest and is the result of the voltage at M- dropping to approximately volts or lower. Possible causes: Short to ground in the motor circuit between the motor contactor and the M- terminal Motor circuit high. Set with the unit at rest and is the result of the voltage at M- terminal rising above volts. Possible causes: Motor contactor points are welded shut Motor contactor circuit open. Set when a function is requested but no current can flow through the motor circuit to the M- terminal. Possible causes: Blown 00 amp fuse Malfunctioning motor contactor Worn motor brushes Incomplete circuit to the Sevcon pin # If the motor and contactor circuits are diagnosed as working properly: Sevcon internal fault continued "5ES / ES" Service & Parts Manual - ANSI Specifications March 008 Page -5
LED Diagnostics Definitions (continued) LED READING Flashes Flashes 8 Flashes Flashes DIAGNOSIS Accelerator fault. Set with unit at rest, a flash will result in an 80% cutback of motor speed. The Accelerator is the proportional control circuitry for the Sevcon. It works in conjunction with the potentiometer located in the upper control box, which is connected to the joystick handle through a gear arrangement. Measure voltage at terminals and 5 on the platform terminal strip or at the potentiometer plug connection. With the joystick handle in neutral,. volts should be measured on the accelerator circuit (wire #) Voltage proportionally decreases with the travel of the joystick, with 0 volts at full stroke With the joystick centered, voltages lower than. or higher than. will trigger a ( flash) code Battery voltage fault. This includes battery voltage below volts or above 5 volts as measured on pin # This code will disable all functions Thermal cutback. Sevcon internal temperatures above degrees F Will limit motor speed in comparison with over temperature Resets when cooled Battery voltage at or below 8 volts As measured on pin # This code will interrupt or prevent lift function but will allow drive and steer functions When lift is interrupted due to a flash, the electric motor will still run. March 008 Page - "5ES / ES" Service & Parts Manual - ANSI Specifications
Sevcon Motor Speed Controller - Connections The following two pages describe the connections to the Sevcon Motor Speed Controller with a brief description of their function and the voltage measurements under normal conditions. Important:Batteries must be fully charged before troubleshooting! A fully charged battery set on a V DC system will have a nominal voltage of 5. V DC FUNCTION VOLTAGE READING PIN WIRE (WIRE ON EARLY UNITS) Battery Positive Input Pin Wire Lift, Drive or Steer functions requested Switched 5% less than battery voltage Controller power-up and reference point for battery state-of-charge Green LED indicates controller power-up Power travels through the upper emergency-stop switch with upper controls selected -Flash code and -flash code indicate low voltage at this terminal Motorized function is requested 5%-8% less than battery voltage Controller begins the motor run sequence with this signal but still requires a signal on pin and a change on pin before the motor will operate Pin Wire 8 Steer Function Requested Pin Wire Enable signal input Pin 5 Wire Speed cut-back signal from limit switch or Lift circuit When steering is operated 5%-8% less than battery voltage Adds motor speed to compensate for addition of steer requirement during drive operation Provides a minimum motor speed for steer requirement when only steer is operated When joystick trigger pulled 5% less than battery voltage. Motor will not start without this input A signal here longer then 5 seconds without a signal on pin- or pin- will result in a -flash code failure Full speed: V DC Creep speed: 0 V DC. Speed cut-back is the elevated drive speed "5ES / ES" Service & Parts Manual - ANSI Specifications March 008 Page -
Sevcon Motor Speed Controller - Connections (continued) FUNCTION PIN WIRE Motor Start Relay ground signal PIN WIRE Ground signal to Lift solenoid valve PIN WIRE Accelerator reference signal to the potentiometer (upper control box) POST B+ Battery positive cable from 00 amp fuse POST B Battery positive cable from 00 amp fuse POST M- PWM controlled motor ground VOLTAGE READING Idle: V DC When function requested: 0 V DC This is how the Controller maintains control over the motor circuit Sevcon controls the Motor Start Relay function ground signal Will not operate the motor start relay when,, & flash codes occur 0 volts No ground presence until lift is requested By providing the ground signal, lift function can be prevented anytime battery voltage falls below 8 volts. This will result in a flash code From.5 V DC with joystick in the neutral to 0 V DC at full stroke Controller uses this circuit to monitor joystick input after pins & energize Controls motor speed in reference to the voltage on this circuit Voltages above.0 V DC or below.0 V DC will result in a flash code Full battery voltage No real diagnostic value Battery ground cable connection Ground path for motor operation All system ground wires (wire #s 5 & 5A) terminate here Best place to connect ground lead from multi-meter while troubleshooting Idle: V DC V DC During operation, between 5 V DC & V DC volts is reference voltage used by the controller to monitor motor circuit irregularities at idle 0 volts at idle = flash code Above 0 volts at idle = flash code No voltage change after Motor Start Relay signal = 5 flash code March 008 Page -8 "5ES / ES" Service & Parts Manual - ANSI Specifications
5ES, S/N 000500-000 ES, S/N 0000-0 ITEM DESCRIPTION FUNCTION LOCATION A Tilt Light, 8V Warn when Machine is Tilted Upper Control Box A Level Sensor Activates Tilt Light In Lower Control Box A5 Push-Button Switch Activates Horn On Upper Control Box A Horn, V - 8V (option) Activated by Operator Under Platform A Overload/Motion Alarm (option) Warn of Movement Outside Lower Control Box A8 Motion Light (option) Warn of Movement Front Left Corner of Machine A Hour Meter Record Machine Usage Time Lower Control Panel A Battery Indicator Show Battery Status Lower Control Panel B- -V Deep Cycle Battery Power for Motor And Control Circuit Inside Battery Compartment BD Battery Disconnect Switch Disconnect All Electrical Power Lower Control Box CB Circuit Breaker, 5AMP Manual Control Circuit Protection Lower Control Panel CH Battery Charger Recharges -VDC Battery Pack Machine Base, Rear CHRL Charger Relay Disconnect Electric when Charger ON Inside Charger D - D5 Circuit Board Diodes Directs Signal to Proper Location Inside Lower Control Box D Diode w/ring Terminals Suppression Diode Across Contactor Coil D8 Diode Optional Out of Level Alarm Main Harness ES Switch, Emergency Stop Shutdown All Moving Functions Lower Control Panel ES Switch, Emergency Stop Shutdown All Platform Functions Upper Control Box F Fuse, 00AMP Main Line Fuse Inside Lower Control Box LS Limit Switch, Double Pole Enable Drive and High Speed Right Rear Corner of Machine LS Limit Switch, Single Pole Drive Enable if Pothole Deployed On pothole Linkage M Motor, V, HP Turn the Hydraulic Pump Inside Pump Compartment MC -V Contactor Connects Battery (+) to Motor Inside Lower Control Box PWM Controller, DC 50AMP Changes the Motor Speed Inside Lower Control Box POT Potentiometer, 0K Ohms Senses Operator Input Upper Control Box R - R Circuit Board Resistors Inside Lower Control Box S Key Switch, N/O Contact Block Select Base or Platform Controls Lower Control Panel S Switch, Toggle Lift/Lower at Lower Controls Lower Control Panel S Switch, Push Button Enable Other Functions at Platform Upper Control Box Handle S Switch, Micro Right Turn Switch Upper Control Box Handle S5 Switch, Micro Left Turn Switch Upper Control Box Handle S Switch, Toggle Select LIFT or DRIVE Upper Control Box S Switch, Micro Reverse or Lift Switch Upper Control Box S8 Switch, Micro Forward or Down Switch Upper Control Box S Switch, Toggle Switch Upper Control Box SOL Coil, Turn Right Solenoid Activate Turn Right Valve (SV) Main Manifold SOL Coil, Turn Left Solenoid Activate Turn Left Valve (SV) Main Manifold SOL Coil, Decel Solenoid Activate Decel Valve (SV5) Main Manifold SOL Coil, Lift Solenoid Activate Lift Valve (SV) Main Manifold SO5- Coil, Torque Solenoid Activate Torque Valves (SV) (SV) Main Manifold SOL Coil, Reverse Solenoid Activate Reverse Valve (SV) Main Manifold SOL8 Coil, Forward Solenoid Activate Forward Valve (SV) Main Manifold SOL Coil, Brake Solenoid Activate Brake Valve (SV) Main Manifold SOL0 Coil, Down Solenoid Activate Down Valve (SV8) Main Manifold SOL Coil, Down Solenoid Activate Down Valve (SV) Lift Cylinder Manifold March 008 Page 5-0 "5ES / ES" Service & Parts Manual - ANSI Specifications
ELECTRIC SCHEMATIC 5ES 000500-000 ES 0000-0 Model: / Serial # Reference Art #: 8R SWITCH CONTACT POSITIONS N/C N/C HELD OPEN N/O N/O HELD CLOSED WIRE CONNECTOR LEGEND P TERMINAL # MALE PIN FEMALE SOCKET EMERGENCY STOP Publication Art #: ART05 ES ENABLE S MODE SELECT SWITCH S DRIVE LIFT A 0 8 RIGHT S S5 LEFT REV/LIFT S A 8 5 8 0 5 HORN A5 5 5 FWD/DOWN S8 TILT LIGHT A S ON OFF POT OPTIONAL QUICK DISCONNECT S N U R W T J C F H P A V K L LS (SLOW SPEED) UPPER TERMINAL STRIP 5 8 0 5(-) P P P P P 5 P P P 8 P P 0 P P P P P A HORN OPTION P P P P D8 P P 5 LS P P P 5 P P0 P0 LS S UP DOWN PLATFORM S OFF BASE EMERGENCY STOP ES 5 0 0 D 5 MC R D5 R D8 R R D D D D D D J- CIRCUIT BOARD D D5 D0 D D D 5 8 0 5(-) 0 0 5(-) LS 5(-) P 5 P P 0 P P 5 0 5(-) 0 5(-) P8- P8- P- P- P P P A ALARM A8 LIGHT A A MOTION WARNING LEVEL SENSOR HOUR METER CHRL 0A P P P5 CHARGER INTERLOCK 0 0 P P 5 P5 0B 5(-) A BATTERY GAUGE CIRCUIT CB BREAKER P N G 05 BD CHRL CH 5 AMP 00 AMP F B - B 8 5 8 0 J 5 PWM M B+ B MC M P P P P MAIN MANIFOLD P 8 SOL SV LIFT 8 SV STEER SOL SOL RIGHT LEFT P SOL SOL SOL8 REV FWD P 0 SV5 DECEL P 0 SV SOL5 SV BRAKE SOL SV DRIVE P P 5A SV8 SOL0 DOWN SOL SV J LIFT CYLINDER MANIFOLD 5A SOL SV DOWN "5ES / ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-
5ES, S/N 00000 - Current ES, S/N 05000 - Current ITEM DESCRIPTION FUNCTION LOCATION A Tilt Light, 8V Warn when Machine is Tilted Upper Control Box A Level Sensor Activates Tilt Light Inside Lower Control Box A5 Push-Button Switch Activates Horn Upper Control Box A Horn, V - 8V (option) Activated by Operator Under Platform A Overload/Motion Alarm (option) Warn of Movement Outside Lower Control Box A8 Motion Light (option) Warn of Movement Front Left Corner of Machine A Hour Meter Record Machine Usage Time Lower Control Panel A Battery Indicator Show Battery Status Lower Control Panel B- -V Deep Cycle Battery Power for Motor And Control Circuit Inside Battery Compartment BD Battery Disconnect Switch Disconnect All Electrical Power Lower Control Box CB Circuit Breaker, 5AMP Manual Control Circuit Protection Lower Control Panel CH Battery Charger Recharges -VDC Battery Pack Machine Base, Rear CHRL Charger Relay Disconnect Electric when Charger ON Inside Charger MC -V Contactor Connects Battery (+) to Motor Inside Lower Control Box D - D5 Circuit Board Diodes Directs Signal to Proper Location Inside Lower Control Box R - R Circuit Board Resistors Inside Lower Control Box D Diode w/ring Terminals Suppression Diode Across Contactor Coil ES Switch, Emergency Stop Shutdown All Moving Functions Lower Control Panel ES Switch, Emergency Stop Shutdown All Platform Functions Upper Control Box F Fuse, 00AMP Main Line Fuse Inside Lower Control Box LS Limit Switch, Double Pole Enable Drive and High Speed Right Rear Corner of Machine LS Limit Switch, Single Pole Drive Enable if Pothole Deployed On pothole Linkage M Motor, V, HP Turn the Hydraulic Pump Pump Compartment PWM Controller, DC 50AMP Changes the Motor Speed Inside Lower Control Box POT Potentiometer, 0K Ohms Senses Operator Input Upper Control Box S Key Switch, N/O Contact Block Select Base or Platform Controls Lower Control Panel S Switch, Toggle Lift/Lower at Lower Controls Lower Control Panel S Switch, Push Button Enable Other Functions at Platform Upper Control Box Handle S Switch, Micro Right Turn Switch Upper Control Box Handle S5 Switch, Micro Left Turn Switch Upper Control Box Handle S Switch, Toggle Select LIFT or DRIVE Upper Control Box S Switch, Micro Reverse or Lift Switch Upper Control Box S8 Switch. Micro Forward or Down Switch Upper Control Box S Switch, Toggle Switch Upper Control Box SOL Coil, Turn Right Solenoid Activate Turn Right Valve (SV) Main Manifold SOL Coil, Turn Left Solenoid Activate Turn Left Valve (SV) Main Manifold SOL Coil, Decel/Brake Solenoid Activate Decel/Brake Valve (SV5) Main Manifold SOL Coil, Lift Solenoid Activate Lift Valve (SV) Main Manifold SOL5- Coil, Torque Solenoid Activate Torque Valves (SV5)(SV) Main Manifold SOL Coil, Reverse Solenoid Activate Reverse Valve (SV) Main Manifold SOL8 Coil, Forward Solenoid Activate Forward Valve (SV) Main Manifold SOL Coil, Down Solenoid Activate Down Valve (SV) Lift Cylinder March 008 Page 5- "5ES / ES" Service & Parts Manual - ANSI Specifications
ELECTRIC SCHEMATIC 5ES 00000 - ES 05000 - Model: / Serial # Reference Art #: 00 Publication Art #: ART0-R SWITCH CONTACT POSITIONS N/C N/C HELD OPEN N/O N/O HELD CLOSED WIRE CONNECTOR LEGEND P TERMINAL # MALE PIN FEMALE SOCKET EMERGENCY STOP ES ENABLE S RIGHT S A S5 LEFT HORN A5 5 8 A 0 5 5 MODE SELECT SWITCH S DRIVE LIFT 0 8 REV/LIFT S 5 8 FWD/DOWN S8 TILT LIGHT A S ON OFF POT LS (SLOW SPEED) S P CHRL P UP DOWN PLATFORM S OFF BASE EMERGENCY STOP HOUR METER A 0 5 CHARGER INTERLOCK OPTIONAL BATTERY GAUGE 0A 0 P5 ES A 5 CIRCUIT CB BREAKER 0 0 P5 05 BD 5 0 0 P P P P 5 5 AMP 00 AMP F OPTIONAL QUICK DISCONNECT P5 8 P5 P5 P5 5 D MC P5 P5 MC P P5 5 M S P P P P 5 P P A 8 R D5 R D8 R R D D D D D D D SV LIFT SOL D D5 D D0 D 5 8 P5 0 P5 P5 5 8 0 J 5 PWM M B+ B N U R W T J C F H P A V K L 5 8 0 5 P J- CIRCUIT BOARD P P P 8 P P 0 P P P P 0 P 8 P P 0 P 0 SOL SOL8 SV DRIVE P REV FWD SV 8 STEER SOL SOL RIGHT LEFT SOL5 SV SOL SV5 SV SOL BRAKE/DECEL 5A MAIN MANIFOLD 5( ) P P P P LIFT CYLINDER MANIFOLD 5A SOL SV DOWN A 5 0 5 P 0 P P 5 P P P P P 5 P P P 8 P P 0 P P P P 5A 5 0 5A 0 5A P WHT P P A HORN OPTION LS BLK RED 5 0A 0 5A A A A LS A A A8 LEVEL SENSOR MOTION ALARM OPTIONAL MOTION LIGHT PNG CHRL CH B B 5A P 5 "5ES / ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-
Component Locations ES Models: all Model: / Serial # Reference Art #: none REFER TO ELECTRIC SCHEMATIC Publication Art #: S LIFT/DRIVE A 0 5 8 0 5 ES E-STOP S S S5 F F8 POT A OVERLOAD/TILT S BLK 5 A5 BLK REMOVABLE CONTROL HARNESS 5 HORN BUTTON PIN # WIRE # S F W 5 R V A H 0 P U T J N C 8 K M (GND) L 5 V U W T X H J F A C S G E R B D P K N L M END VIEW OF REMOVABLE CONTROL HARNESS (OPTIONAL QUICK DISCONNECT) S S PWM D MC F D D5 R R A8 5 ES CB A BD A TERMINAL BLOCK ON UNDERSIDE OF PLATFORM DECK A March 008 Page 5- "5ES / ES" Service & Parts Manual - ANSI Specifications
Model: / Serial # Component Locations 5ES - ES: all Reference Art #: none Publication Art #: ART REFER TO ELECTRIC SCHEMATIC A Terminal Block LS CH A B B B B LS "5ES / ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-5
Model: / Serial # Component Locations ES Models: all Reference Art #: none Publication Art #: ART DOWN SOL0 STEER RIGHT SOL STEER LEFT SOL REFER TO ELECTRIC SCHEMATIC SOL DECEL LIFT SOL SOL5 SOL BRAKE SOL SOL SOL8 REVERSE DRIVE FORWARD MAIN MANIFOLD EARLY MODELS LIFT CYLINDER MAIN MANIFOLD STEER RIGHT STEER LEFT CURRENT MODELS SOL SOL SOL5 SOL SOL LIFT SOL DECEL SOL SOL SOL8 REVERSE DRIVE FORWARD March 008 Page 5- "5ES / ES" Service & Parts Manual - ANSI Specifications
Model: / Serial # Plug Pin Identicication ES Models : all Reference Art #: none Publication Art #: REFER TO ELECTRIC SCHEMATIC PWM J5 Pin Identification PIN # WIRE # FUNCTION B+ power input (power up) Lift, Drive or Steer functions requested (functions requiring motor) 8 Steer Requested (adds additional motor speed for steer) Enable signal input 5 Speed cut-back ( Volts = full speed, 0 Volts = creep speed) Motor Start Relay signal (GROUND signal to activate Motor Start Relay) Lift Valve B- (provides GROUND signal to Lift Valve) 8 none none Accelerator reference signal (. Volts to Potentiometer) 0 none none none none none none Terminal Identification J5 POST FUNCTION B+ Battery Positive Cable from 00 AMP Fuse B- Negative Battery Cable and GROUND wire (5) connection M Motor Ground (Pulse-Width Modulated [PWM] variable speed control) D5 D8 D D D5 D Circuit Board J 8 D D0 R R R R TB 80 D D D D D D J Plug Pin Identification PIN # WIRE # SIGNAL FUNCTION 0 INPUT Drive Reverse INPUT Drive Forward OUTPUT Brake, Decel Valve signal 8 INPUT Steer Left 5 8 OUTPUT Steer signal to Sevcon 5 INPUT Down signal 0 OUTPUT Signal to Motion Alarm(s) (optional) 8 OUTPUT Sevcon & Hour Meter (motor function requested) 5 INPUT Battery Negative 0 INPUT Steer Right INPUT Lift Up INPUT Limit Switch (V = platform down) OUTPUT Enable, from lower Lift switch OUTPUT To Sevcon (for speed cutback) "5ES / ES" Service & Parts Manual - ANSI Specifications March 008 Page 5-