TMX

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TMX
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INTRODUCTION MEETING RUSS DAVIES (859)
422-6421 russdavies_at_clarkmhc.com
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TMX Overview

• Controls and Motors (Hardware)
• CAN_BUS (Communication)
• Wiring Diagram
• Troubleshooting
• Handset
• Pc Console (Software)
• Programming Master/Slave
• Programming Pump
• Main Hydraulic Valve

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TMX AC MOTOR
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.

Rotor
Sensor Bearing
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MOTOR RESEALING

• Reseal motor with RTV (P/N 1758629) after any
  repair

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Control Master/Slave
CAN_BUS Connections
Handset/ Dash Port
Inputs Outputs
A
B
C
Right Side Master
Left Side Slave
UM
VM
WM
US
VS
WS
Batt
Batt-
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Control Wiring
DUALAC2 Wiring Connections
DUALAC2 Controller is software adjustable same
control for 36V or 48V
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Pump Control
AC2 Wiring Connections
D
C
E
B
F
A

• AC2 Pump controllers are voltage dependent and
  NOT software adjustable.
• Separate controls for 36V or 48V

W
U
V
Batt-
Batt
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CANBUS

• 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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WIRING
TMX Sequence of Operation
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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.

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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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Handset
TMX Handset P/N 8033636
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START MENU
DUAL AC2
Master Controller
Clark Revision Level
280 AMPS
Internal Hour Meter Reading
36 Volt
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HANDSET TREE
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TESTER MENUS
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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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MASTER PROGRAMMING
MAIN MENU PARAMETER CHANGE
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MASTER PROGRAMMING

• 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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MASTER PROGRAMMING

• ADJUSTMENTS (CONTD)
• Defaults
• MAIN CONTACTOR VOLTAGE (V) 36V
• AUX OUTPUT VOLTAGE (V) (NOT USED) 36V
• MAINTENANCE DONE (ON/OFF) OFF
• MAINTENANCE (NONE / OPT1 / OPT2) 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

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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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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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PROGRAM VACC
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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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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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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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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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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

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Pc Console
Pc Console Main Start up Screen
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Pc Consloe
Com Port Setup
Select Com Port Setup from the Configuration Menu
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Pc Console
Com Port Setup
DUALAC2 (Master/Slave) Com port1 set to 9600
bps Select OK AC2 (Pump) Com port1 set to 1200
bps
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Pc Console
Connecting to the Controller
Note Control not connected Select the start
button to connect to the controller
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Pc Console
Main Startup Screen

• Connected to Master control
• Internal hour meter
• Any alarm that is present
• Control connected

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Pc Console
Function Menu
Select the parameter function
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Pc Console
Set Model

• Select Set model button
• Select Receive Menu button

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Pc Console
Changing Controllers on the CAN_BUS
Select the up arrow to change from node 3
(Master) to node 4 (Slave)
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Pc Console
Changing Controllers on the CAN_BUS

• Select the store button
• Select the close button

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Pc Console
Now connected to the Slave Control
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Pc Console
Function Menu
Select the parameter function
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Pc Console
Changing Controllers on the CAN_BUS
Select the up arrow to change from node 4
(Slave) to node 5 (Pump)
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Pc Console
Changing Controllers on the CAN_BUS

• Select the store button
• Select the close button

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Pc Console
Now Connected to the Pump Control
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Pc Console
Checking Alarm Logbook (Fault Log)
Select the Alarm Logbook function
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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

02
26C
341
Pedal Wire KO
Input Mismatch
01
30C
349
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Pc Console
Saving Alarms from the Logbook
x
Select the print to file button Select OK button
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Pc Console
Saving Alarm Logbook

1. Enter a file name for the log file
2. select where you want to save the log file
3. Select the save button

2
1
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Pc Console
Clearing the Alarm Log

• Select the Clear button
• Select the OK button

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ALARM LOG FILE
File is saved as a Text file
Wed Mar 30 172447 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 VMN HIGH 1 143 h 25 C
degree
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Pc Console
Tester Mode
Select the Tester function
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Pc Console
Tester Mode
List of parameters that can be viewed in tester
mode
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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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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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Pc Console
Tester Mode
Select Start record button to record parameter
values to the log.
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Pc Console
Tester Mode
Select Stop record button to stop recording
parameter values to the log.
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PC Console
Tester Mode
Select Save record button to save your log to a
file.
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Pc Console
Log File
TIME STEER ANGLE HANDBRAKE TEMPERATURE 2 TEMPERATURE
0 -90 0 280 23
1 -90 0 280 23
2 -90 0 280 23
3 -90 0 280 23
4 -90 0 280 23
5 -90 0 280 23
6 -90 0 280 23
7 -90 0 280 23
8 -90 0 280 23
9 -90 0 280 23
10 -90 0 280 23
11 -90 0 280 23
12 -90 0 280 23
13 -90 0 280 23
14 -90 0 280 23
15 -90 0 280 23

• The Log file gets stored in a .CVS file which can
  be converted to a .XLS

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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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HYDRAULIC SCHEMATIC
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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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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).

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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 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) Pump Control Panel Settings (using the Handset) Pump Control Panel Settings (using the Handset) Pump Control Panel Settings (using the Handset)
Parameters Auxiliary Flow Settings Auxiliary Flow Settings Auxiliary Flow Settings
Parameters GPM 36V Hz 48V Hz
2nd Speed Fine and 3rd Speed Fine 2.5 20 33
2nd Speed Fine and 3rd Speed Fine 5.5 43 51
2nd Speed Fine and 3rd Speed Fine 7 55 65
2nd Speed Fine and 3rd Speed Fine 10 79 93
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PUMP Program VACC
Press the Enter button to save
OR Press Out button to exit (no save)
Pull lift lever all the way down and release it
Press Enter Button
Press Rollup Button until you see Program VACC
Menu
Press Out Button
Press Enter Button
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PUMP PROGRAMMING
MAIN MENU PARAMETER CHANGE
Parameters Program Level Program Level Program Level Program Level Program Level Program Level Program Level Program Level Program Level Program Level Program Level
Parameters Units 0 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 SEC. 0.5 0.7 1.0 1.4 1.9 2.5 3.2 4.0 4.8 5.5
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. 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. 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. 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. 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. 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. 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. 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. 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. 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) Hz Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments Default 30 Hz Default 30 Hz Adjustable in 1 Hz Increments
Maximum Current IMAX 47 53 58 64 70 76 82 88 94 100
Auxiliary Time SEC. 0 0.2 0.4 0.8 1.0 1.5 2.0 3.0 4.0 5.0
DO NOT CHANGE
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TESTER MENU
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END

• Questions????

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xxxxx
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xxxxx
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TMX
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