1. NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING
TMX
NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING
RUSS DAVIES
(859)
NATIONAL SERVICE MANAGER’S NEW PRODUCT INTRODUCTION MEETING “05

2. 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

3. 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
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4. Reseal motor with RTV (P/N 1758629) after any repair
MOTOR RESEALING
Reseal motor with RTV (P/N ) after any repair
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5. 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-
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6. DUALAC2 Wiring Connections
Control Wiring
DUALAC2 Wiring Connections
DUALAC2 Controller is software adjustable same control for 36V or 48V
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7. 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+
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8. 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”
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9. TMX Sequence of Operation
WIRING
TMX
Sequence of
Operation
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10. 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

11. 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)
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12. Handset TMX Handset P/N 8033636
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13. START MENU DUAL AC2 Master Controller Clark Revision Level 280 AMPS
Internal Hour Meter Reading
36 Volt
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14. HANDSET TREE
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15. TESTER MENUS
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16. 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
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17. *MAIN MENU* PARAMETER CHANGE
MASTER PROGRAMMING
*MAIN MENU* PARAMETER CHANGE
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18. 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
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19. 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

20. 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
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21. 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
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22. PROGRAM VACC
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23. 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
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24. 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
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25. 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
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26. 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
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27. Pc Console Software
Troubleshooting using a laptop computer with the ZAPI Pc Console software and Pc Console adapter cable ( ).
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
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28. Pc Console Main Start up Screen
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29. Com Port Setup Pc Consloe
Select Com Port Setup from the Configuration Menu
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30. Com Port Setup Pc Console
DUALAC2 (Master/Slave) Com port1 set to 9600 bps
Select OK
AC2 (Pump) Com port1 set to 1200 bps
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31. Connecting to the Controller
Pc Console
Connecting to the Controller
Note: Control not connected
Select the start button to connect to the controller
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32. Main Startup Screen Pc Console Connected to Master control
Internal hour meter
Any alarm that is present
Control connected
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33. Function Menu Pc Console Select the parameter function
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34. Set Model Pc Console Select Set model button
Select Receive Menu button
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35. 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

36. Changing Controllers on the CAN_BUS
Pc Console
Changing Controllers on the CAN_BUS
Select the store button
Select the close button
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37. Now connected to the Slave Control
Pc Console
Now connected to the Slave Control
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38. Function Menu Pc Console Select the parameter function
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39. 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

40. Changing Controllers on the CAN_BUS
Pc Console
Changing Controllers on the CAN_BUS
Select the store button
Select the close button
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41. Now Connected to the Pump Control
Pc Console
Now Connected to the Pump Control
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42. Checking Alarm Logbook (Fault Log)
Pc Console
Checking Alarm Logbook (Fault Log)
Select the Alarm Logbook function
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43. 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
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44. Saving Alarms from the Logbook
Pc Console
Saving Alarms from the Logbook x
Select the print to file button
Select OK button
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45. 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
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46. Clearing the Alarm Log Pc Console Select the Clear button
Select the OK button
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47. File is saved as a Text file
ALARM LOG FILE
File is saved as a Text file
Wed Mar 30 17:24:
DA2M2BKC CK1.14
36 V A
VMN HIGH h 25 C degree
MOTOR SHUTDOWN h 23 C degree
VMN HIGH h 27 C degree
MOTOR SHUTDOWN h 27 C degree
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48. Tester Mode Pc Console Select the Tester function
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49. Pc Console
Tester Mode
List of parameters that can be viewed in tester mode
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50. 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
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51. 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
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52. Pc Console
Tester Mode
Select Start record button to record parameter values to the log.
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53. Pc Console
Tester Mode
Select Stop record button to stop recording parameter values to the log.
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54. PC Console
Tester Mode
Select Save record button to save your log to a file.
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55. 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

56. 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.
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57. HYDRAULIC SCHEMATIC
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58. 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.
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59. 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 N.m (28-32 ft-lb).
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60. 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
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61. 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
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62. *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 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
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63. TESTER MENU
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64. END
Questions????
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65. xxxxx
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66. xxxxx
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67. TMX
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