Caterpillar CAT EC15K EC18K EC20K EC25K EC25KE EC30K Forklift Complete Workshop Service Repair Manual

Service Manual 99759-84120 GE SX Controls EC15K, EC18K, EC18KL A3EC1-10200-up A3EC1-20200-up A3EC1-30200-up A3EC1-40200-up EC20K, EC25K A3EC2-10200-up A3EC2-20200-up A3EC2-30200-up A3EC2-40200-up A3EC2-80200-up EC25KE, EC25KL, EC30K A3EC3-10200-up A3EC3-20200-up A3EC3-30200-up A3EC2-40200-up A3EC3-80200-up EC30KL A3EC4-40200-up

SAFETY PRECAUTIONS Cat ® Lift Trucks Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules and precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “CAUTION” or “WARNING” as shown below. Mitsubishi Caterpillar Forklift America Inc. (MCFA) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all- inclusive. If a tool, procedure, work method or operat- ing technique not specifically recommended by Mitsubishi Caterpillar Forklift America Inc. (MCFA) is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Cat lift truck dealers have the most current information available. WARNING ! The meaning of this “Safety Alert Symbol” is as follows: Attention! Become Alert! Y our Safety is involved . The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

TABLE OF CONTENTS 1. GENERAL INFORMATION & FEATURES Glossary ............................................................................................................................... 1-1 Motor Options ...................................................................................................................... 1-5 Nameplate and Serial Number Locations ............................................................................ 1-6 Features of the Control System........................................................................................... 1-7 Basics of Circuit Operation ................................................................................................. 1-8 Standard Display ..................................................................................................................1-17 Premium Display..................................................................................................................1-18 Premium Display Set up Modes .........................................................................................1-19 Vehicle Monitoring System ..................................................................................................1-20 Traction Control Logic Flow Chart .......................................................................................1-21 General Maintenance Instructions .......................................................................................1-22 General Trouble Shooting Instructions ................................................................................1-24 2. PROGRAMMING Handset .............................................................................................................................. 2-1 Operation ............................................................................................................................. 2-2 GE Sentry Set-up Procedures ............................................................................................. 2-2 Function Settings ................................................................................................................. 2-4 Controller Setup ...................................................................................................................2-15 Traction Controller Settings ................................................................................................2-16 Accelerator Setup ................................................................................................................2-23 Pump Controller Settings .....................................................................................................2-25 Memory Maps ......................................................................................................................2-30 Speedometer Setup .............................................................................................................2-34 3. CHECKS & REPAIRS General Information ............................................................................................................. 3-1 Fuses .................................................................................................................................. 3-2 Exploded View of Contactor ................................................................................................ 3-3 Contactor Repair . ................................................................................................................. 3-4 Truck Management Module ................................................................................................ 3-5 Thermal Transfer ................................................................................................................. 3-6 Traction Control ...................................................................................................................3-10 Trouble Shooting Tips (Motors) ..........................................................................................3-11 Unsatisfactory Brush Performance .....................................................................................3-12 Commutator Surfaces Conditions ........................................................................................3-18 4. SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM SX Control ........................................................................................................................... 4-1 Failures that Cause Reduced or No Motor Torque ............................................................. 4-2 Misoperation of Other Features .......................................................................................... 4-5

TABLE OF CONTENTS 5. WIRING Traction Bypass with Pump Contactor Schematic ............................................................... 5-1 Pump Contactor Schematic.................................................................................................. 5-3 Traction Bypass with Pump Contactor Schematic ............................................................... 5-5 Traction Bypass with Pump Control Schematic ................................................................... 5-7 Pump Control Schematic...................................................................................................... 5-9 Traction Motor Controller with Pump motor Controller and Bypass .....................................5-11 Voltage Checks.....................................................................................................................5-13 TMM7A (Truck Management Module) .................................................................................5-16 Pump Driver..........................................................................................................................5-18 Pump Time Delay ................................................................................................................5-19 6. DIAGNOSTIC STATUS CODES Basic Checks ....................................................................................................................... 6-1 Status Codes ........................................................................................................................ 6-2

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Caterpillar CAT EC15K EC18K EC20K EC25K EC25KE EC30K Forklift Complete Workshop Service Repair Manual

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