Clark ESX 12-25 Forklift Shop Manual

SM-718
ESX 12-25
Service Manual
657028
September 2007
Technical
Publications
Lexington, KY 40510
www.Clarkmhc.com
GROUP 12, BATTERY
GROUP 12
BATTERY
Battery Service . . . . . . . . . . . . . . . . . . . . .Section 1
SM-718, August ‘07 Battery • Group 12

GROUP 12, BATTERY
Group 12 • Battery SM-718, August ‘07

GROUP 12, BATTERY
Section 1
Battery Service
Contents
Section 1
Battery Service
Battery Handling..................................................2
Battery Removal ...................................................4
Battery Maintenance ..........................................4
Maximum Battery Life ................................... 4
Battery Vents..................................................... 5
Battery Cleaning.............................................. 5
Battery Charging ............................................. 5
Battery Electrolyte .......................................... 5
Clean Battery Compartment....................... 5
Replacement Batteries .................................. 6
Battery Installation ......................................... 6
Keeping Battery Records .............................. 6
Battery Tests ..........................................................7
Specific Gravity Test ....................................... 7
Load Test ............................................................ 7
Connector and Static Chain Installation .....8
Static Chain: ..................................................... 8
Batterry: ............................................................. 8
SM-718, August ‘07 Battery Service • 12-1-1

GROUP 12, BATTERY
Battery Handling
Caution
Remove all jewelry (watch, rings, bracelets, etc.)
before working on electrical systems. Severe
burns can result from contact with electrical cir-
cuits.
Warning
Battery service must be done by trained person-
nel. Battery acid can cause severe burns and in-
jury. Do not smoke or have open flames around
batteries.
Danger
Warning Explosive gas is always present around batteries,

Electric truck batteries are heavy and awkward especially when they are being charged.
to handle. On charge, they give off hydrogen and
oxygen which, in certain concentrations, are ex- • No smoking allowed in the charging area.
plosive. Electric truck batteries are also costly, so • Battery electrolyte must never be checked with
before you remove, service, or install a truck bat- an open flame.
tery, consult BATTERY MANUFACTURER for more • Open flame, sparks, or electric arcs must never
recommendations and instructions on handling be allowed in the battery charging area.
and charging batteries. Carefully read and follow • The battery contains corrosive sulfuric acid
recommendations and instructions. which can cause injury. If acid contacts your
eyes or skin, flush immediately with water and
Change or service batteries only in an area designated get medical assistance.
for this purpose. Refer to page 4 for additional infor-
mation.
• Be sure this area has provisions to flush and

neutralize acid spillage.
• Be certain the area has proper ventilation to
ventilate fumes from charging batteries.
• Check to see that there is fire protection. Fire
extinguishers should be properly maintained
and located in designated areas.
12-1-2 • Battery Service SM-718, August ‘07

GROUP 12, BATTERY
Persons maintaining batteries must wear protective

clothing such as:
• Face and head shields

• Long shirt sleeves
• Gauntlet gloves
• Rubber apron
Be sure the battery service area is equipped with ma-

terial handling equipment designed for the purpose
of removing and replacing batteries, such as a con- Danger
veyer or overhead hoist equipped with safety hooks. Never lay tools or other metal objects on a bat-
tery. Metal objects contacting battery terminals
IMPORTANT will cause short circuits. The shorted circuits
To prevent side forces from damaging the bat- could ignite battery fumes and cause the battery
tery, the distance between the lifting hooks (of to explode.
the spreader bar) must be adjusted to the same
dimension as measured between the battery lift-
ing eyes. Make sure the lifting hooks are the cor-
rect size to fit the lifting eyes of the battery.
• When using an overhead hoist, be sure to use

an insulated spreader bar or similar lifting
device.
• Be sure the hoist is equipped with a chain
container to accumulate excess lifting chain.
When this is not possible, be sure the battery
is covered with a nonconductive material, such
as plywood, as shown below.
• If the battery does not have a cover of its own,
cover it with a non-conductive material such as
plywood.

GROUP 12, BATTERY
Battery Removal Battery Maintenance

1. Move truck to the designated battery service Note
area. To obtain maximum performance and battery
life, follow the instructions supplied by your bat-
CAUTION tery vendor.
SAFE PARKING. Before working on truck:
Industrial batteries are used to supply the electrical
• Park truck on a hard, level and solid surface, power to operate an electric industrial truck. Their
such as a concrete floor with no gaps or voltage depends on the number of individual cells
breaks. they contain. There are approximately two volts for
• Put upright in vertical position and fully each cell in the commonly used lead-acid type bat-
lower the forks or attachment. tery. Batteries normally range from 6 volts to 72 volts.
• Put all controls in neutral. Turn key switch Their capacity varies depending on the application.
OFF and remove key. Only use batteries that comply with factory specifica-
• Apply the park brake and block the wheels. tions as to size and capacity.
•
2. Turn key switch OFF and disconnect battery.
Maximum Battery Life
• Do not add acid to a battery. Only qualified
battery representatives should determine if
this is necessary.
• When lifting a battery, use a lifting device de-
signed for this purpose.
• Check the electrolyte level after placing a bat-
tery on charge. The electrolyte level in a bat-
tery should be slightly below the lower lip of
the filling hole vent. Do not overfill. Overfilling
causes loss of electrolyte.
• Keep the battery clean, dry and in good condi-
tion.
3. Lift and latch seat deck to access battery. • Keep metal objects and tools away from the
top of the battery. Short circuits will cause bat-
4. If the battery to be handled is uncovered, cover tery damage andcould ignite battery fumes,
battery with a non-conductive material (plywood, causing the battery to explode.
heavy cardboard, etc.) prior to removal from truck. • Maintain good battery cable connections.
• Check power cables and wiring for damage
IMPORTANT that can cause premature drainage of the bat-
Do not wash battery in truck. tery.
• Do not overcharge a battery.
• Do not undercharge a battery.
CAUTION • Follow the instructions provided by the
An overhead hoist of sufficient lifting capacity supplier(s) of the battery and battery charging
(refer to “Weights” in Group 40) should be used equipment.
to lift battery. The safety hooks of the insulated • Maintain accurate battery records. If battery
spreader bar should be attached to the lifting troubles occur, these records will help you and
eyes provided in the battery casing. your battery representative determine the
nature of the problem.
5. Be sure battery is covered. Attach lifting device.
Lift and remove battery.

GROUP 12, BATTERY
Battery Vents Battery Charging

• When Charging Batteries: The vent caps must Follow the instructions supplied by the battery char-
be kept in place to avoid electrolyte spray. Care ger vendor.
must be taken to assure that vent caps are
functioning. The vents must be open to allow Battery Electrolyte
the battery to breathe. The battery cover must
• Check with battery manufacturer’s documenta-
be removed/opened to dissipate heat and
tion before working on battery electrolyte.
explosive gas.
• Always use a carboy tilter or siphon when han-
• When Cleaning Batteries: The vent caps must
dling battery electrolyte.
be tightly in place.
• When mixing electrolyte, always pour acid into
water-NEVER pour water into acid. Pouring
water into acid will cause a dangerous chemi-
cal action or splash.
Clean Battery Compartment

• Using baking soda and water solution, clean
the walls and floor of the compartment. Rinse
with clear water.
• Blow off the compartment walls and floor with
an air hose. Allow to air-dry.
CAUTION
Wear eye protection and protective clothing
when cleaning or drying with compressed air.
Battery Cleaning Reduce air pressure to 207 kPa (30 psi). Debris
The easiest and most satisfactory method of cleaning removed with air pressure can cause injury.
a battery is to wash it with a low-pressure cold water
spray. The battery top can also be washed with a bak-
ing soda solution and rinsed with clear water.
IMPORTANT
• Remove battery from truck before washing.
• Vent caps must be free of obstruction and in
good condition.
• Battery top should be clean and free of cracks
or breaks.
• Battery terminals must be clean and solidly
mounted.
• Damaged batteries should be repaired or re-
placed. Consult your battery vendor.
• Check to be sure all vent caps are tight before
washing the battery.
• Fill a bucket with cold water. Add a box of bak-
ing soda to the bucket. Stir the solution until
dissolved. Keep this solution around the bat-
tery service area at all times.
• After washing battery, thoroughly rinse with
clear cold water.
GROUP 12, BATTERY
Replacement Batteries • Load Voltage Tests should be performed and

recorded indicating the condition of a battery
CAUTION while it is performing work.
Use a battery properly sized to the dimensions • Actual Operating Hours of the Battery. Record
of the battery compartment. Batteries too small the actual time the battery is in use before put-
can shift and cause damage to the truck or injury ting it on charger.
to the operator or bystanders. Only use batteries • Charging Time. Keep an accurate record of
that comply with factory recommendations as to the actual time the battery is on charger. After
size and capacity. each charge, check to see if the battery is fully
charged. Test the battery before placing it back
Battery Installation into service. Record these results.
• Visually Inspect for loose terminal connections
If the battery is uncovered, cover the battery with a or posts, a cracked case, damaged cell covers
nonconductive material (i.e., plywood, heavy card- (vent caps), or excessive corrosion. This data
board, etc.) prior to installation. should be noted to help determine work envi-
ronment and possible trouble areas.
• Using an overhead hoist and insulated spread-
er bar, lift battery into battery compartment.
• Install battery retainer, if applicable.
• Remove non-conductive material from battery.
• Connect battery to truck.
Keeping Battery Records

Records should be maintained to get the best service
out of your battery and truck.
These records should contain:
• Test Date. Each test should be dated for future

reference and comparison.
• Specific Gravity and Temperature Readings.
Each battery cell should be checked and re-
corded before and after charging. The specific
gravity reading of the electrolyte, calculated
using a multiplier to account for the ambient
temperature, should not be less than 1.260. If
below 1.250, the battery should be recharged
and tested.
• Variation Between Each Cell Tested. The varia-
tion in specific gravity reading between cells
should not be greater than 15 points (0.015). If
readings are greater, there are defective cells.
NOTE
The pilot cell should be changed occasionally to
distribute any electrolyte loss over the battery
when taking readings.

GROUP 12, BATTERY
Battery Tests Load Test
NOTE Put the main hydraulic system into tilt by-pass while
Use both tests described here. reading battery volts with a voltmeter.
Specific Gravity Test Battery needs recharge or repair if voltage drops be-
low 80% of the rated voltage of the battery.
Test at least six cells across battery with a tempera- Minimum acceptable readings:
turecorrected hydrometer (see chart). Battery is fully
charged when the reading falls in the 1.280 to 1.300 • 36 volt battery: 28.8 volts
range. If the difference between cells is more than • 48 volt battery: 38.4 volts
.015, battery needs maintenance.
SPECIFIC GRAVITY TEST

SPECIFIC GRAVITY STATE OF CHANGE
1.260~1.300 100% CHARGED
1.230~1.250 75% CHARGED
1.200~1.220 50% CHARGED
1.170~1.190 25% CHARGED
1.140~1.160 VERY WEAK
1.110~1.130 DISCHARGED
The battery specific gravity is an indication of the bat-

tery’s state of charge. You can determine the specific
gravity of the electrolyte solution in a battery with an
hydrometer. If the state of charge is low, the hydrom-
eter will read low. If the state of charge is high, the
hydrometer will read high.
For, example a reading from:
• 1.260 to 1.300 indicates a fully-charged battery.

• 1.200 to 1.220 indicates a battery is in a dis-
charged condition and cannot give satisfactory
service.

GROUP 12, BATTERY
Connector and Static Chain Installation
NOTE Batterry:
See Group 13 for cable and wiring routing and con- Connectors must be clean, securely mounted, tight-
nection illustrations. fitting, and show no cracking.
Static Chain:
Chain must make good contact with the floor to en-
sure proper grounding of the truck. Replace or adjust
chain as follows:
• New Chain: Fasten at third link.

• Worn Chain: Fasten at first link.

WIRING, SWITCHES AND SENSORS
GROUP 13
Schematics and Electric Circuit Diagrams . . . .Section 1

General Electrical Service Tips . . . . . . . . . . .Section 2
Control Handle . . . . . . . . . . . . . . . . . . . . .Section 4
Switches and Sensors. . . . . . . . . . . . . . . . .Section 5
Display Gauge . . . . . . . . . . . . . . . . . . . . .Section 6
SM-718, August ‘07 Wiring, Switches and Sensors • Group 13

Group 13 Wiring, Switches and Sensors SM-718, August ‘07

GROUP 13, WIRING, SWITCHES AND SENSORS
Section 1
Schematics and Electric Circuit Diagrams
Standard Truck . . . . . . . . . . . . . . . . . . . IN-25197_G

Accessories . . . . . . . . . . . . . . . . . . . . . IN-25200_E
SM-718, August ‘07 Schematics and Electrical Circuit Diagrams • 13-1-1

13-1-2 • Schematics and Electrical Circuit Diagrams SM-718, August ‘07






NOTES:

Section 2
General Electrical Service Tips
Contents
General Electrical Service Tips ........................1
Checking Power Cables ....................................2
Torquing Fasteners..............................................2
Connecting and Mounting Components ...2
General Electrical Service Tips 2. Disable the truck:

• Turn the key switch to OFF.
CAUTION • Remove key.
Always wear safety glasses. • Make sure battery is disconnected.
3. Discharging Controller Capacitors

It is necessary to discharge the capacitors before
you work on the controller.
NOTE: Make sure that the battery has first

been disconnected at the battery
Remove all jewelry before receptacle.
working on truck. Battery Positive
Battery Negative
1. Move truck to service area:
• Park truck on a flat level surface.
• Fully lower upright.
• Tilt forks forward until fork tips touch the
floor.
SERVICE AREA
To discharge the capacitors connect a 200 ohm

10 watt resistor between the positive and nega-
tive input post of the controller for 10 seconds.
13-2-2
SM-718, August ‘07 General Electrical Service Tips • 13-2-1

Checking Power Cables Torquing Fasteners

Every cable and wiring harness on this truck is man- Improperly torqued fasteners can cause damage.
ufactured to an exact specification. A shorter cable
or harness will not fit. If either a harness or cable is Pivoted
Scale Handle
routed improperly, it will not fit. Subsequently, elec-
trical shorts and damaged components may result Socket
if the replacement part is the wrong one, or if it is
routed incorrectly.
Head Force or Pull

Pointer
Typical Torque Wrench
Use an appropriate wrench and tighten all fasteners

to the torque specified in the following inspection
procedures.
Cuts
Connecting and Mounting

Components
Power cables having small cuts Tape markers are used to correctly position each
may be repaired with electrical wire harness and electrical cable on the truck. When
tape.
correctly installed, the tape marker will be hidden
by the mounting clamp (guide). Be sure to follow
the instructions, where noted in this manual, when
Repairable Damage installing a wire harness or electrical cables. If you
do not, possible shorts and equipment damage
Cables having damage as shown in illustration be-
may result.
low should be removed immediately and replaced
with new. Be certain the replacement cable is the
exact same length, size and has the proper connec-
tor. Make absolutely certain the cable end is prop-
erly crimped and its connection properly torqued
upon installation.
Damaged Casing Tape Marker
Break Clamp
(and/or Guide)
Broken Wires
Markers on Wire Harnesses and Power Cables
Cable Unfit for Further Service
13-2-2 • General Electrical Service Tips SM-718, August ‘07

Multiple cable and wire connections must be con- There is a moisture-resistant seal at each wireend
nected as illustrated or electrical shorts and control of the connector and between the plug and socket.
damage may result. Check seals for damage that would make them un-
fit for furtherservice (cuts, etc.). Make certain the
end seals are seated flush with the end of the con-
nector housing. Make certain the plug and socket
Terminal Barrels latchtightly to each other.
Must Face Opposite
Each Other Firmly push plug into socket until
latch "clicks" locking the two components
Assemble together.
Back to Front
Buss Bar
Latch t
Barrel o cke
Barrel S
End seals g
must be firmly Plu
seated within Seal(s)
the assembly
housing.
Connector Plugs and Receptacles are permanently
labeled with the proper PL (Plug) and SO (Socket/ Seals and Latch
Receptacle) number for easy identification. Match
the plug number with the appropriate receptacle Retainer plates snap into place to secure the pins
number before making a connection. If you do not, and their sockets.
electrical shorts and possible damage to the equip-
ment may result. i.e., Plug #PL-6 plugs into pin sock- Check the plates and seal for damage and secure
et #SO-6, etc. mounting.
Retainer Plates
Pin Lock (Arrows must point in direction shown.) Rubber Seal
So
cke
t tch
La
g
SO-6 Socket Plu
Pin Retainer Plates e)
Retainer Plates
PL-6 Plug Pin(s)
Example of Pin Lock Plug and Socket
SM-718, August ‘07 General Electrical Service Tips • 13-2-3

NOTES:
13-2-4 • General Electrical Service Tips SM-718, August ‘07

Section 4
Wiring and Cables
Contents
The following illustrations depict wiring and cable
routing and connections for standard trucks and
main accessory harness.
Main Harness .............................. SI-14197_D

High-Low Switch .........................SI-14185_D
Cables ............................................. SI-14198_B
Electrical Components ............. SI-14195_A
Rear Accessory Harness ........... SI-14218_C
Main Accessory Harness .......... SI-14188_C
Optional 12 Volt Converter...... SI-14235_A
Optional Headlights...................SI-14219_D
SM-718, August ‘07 Wiring and Cables • 13-3-1

13-3-2 • Wiring and Cables SM-718, August ‘07






Fan
Traction
13-3-8 • Wiring and Cables

Unit
Control
Pump Panel
Panel
Horn
Fuse
Panel
Valve
Controller
Tiller
Card Solid
State
Relay
SM-718, August ‘07






Converter
12 Volt


NOTES:

Section 4
Control Handle
Contents
Control Handle .....................................................1
Description ........................................................ 1
Program and Acquire..................................... 1
Tiller Card................................................................3
Description ........................................................ 3
The traction and pump control have adjustments

to independently control the creep, deadband, and
Control Handle slope of each of the joysticks. See group 19 for de-
Description tails.
The multifunctional control handle allows the oper- Internal springs return the joysticks
ator to perform multiple functions simultaneously. back to neutral. The spring force of
The ESX truck can travel, lift or lower, and perform
one other hydraulic function (tilt or aux) at the same
the lift/lower axis is slightly stron-
time. The software prevents the operator from lift- ger than the forward/reverse axis.
ing and forward tilting at the same time. Travel and The base of the joystick, the thumb
lift/lower are controlled by the base of the control operated mini joystick, and the push
handle. Tilt and aux functions are controlled using
the mini thumb operated joystick.
buttons can be replaced, but not
serviced individually.
Both the base and mini joystick have redundant hall
effect sensors that do not have mechanical contacts The control handle bracket can be rotated on the
and are not adjustable. Each axis of the base and top battery plate to accommodate different opera-
mini joysticks sweep a 0-5V signal as the control tors. But this can only be done by a mechanic by
handle is moved. The signal is approximately 2.5V loosening the 4 bolts securing the bracket to the
when the joysticks are in their neutral position. This top plate, rotating, and then retightening the bolts.
signal is read by the tiller card. The tiller card con-
verts the voltage signal into the canbus language Program and Acquire
and shares the signal will the traction, pump, and
valve controls.
CAUTION: Before any adjustments
There are no adjustments that can be made to the are done, safely jack up the truck,
sensors in the control handle. Only the maximum block the drive wheels off the floor,
travel positions and the neutral positions of each disconnect the battery, and dis-
joystick axis must be acquired via a handset or PC charge the capacitors as described
console. It is important that the maximum position in Group SA
is learned correctly. If the controls receive a signal
from the tiller card that is beyond the maximum ac- Use the following method to acquire the control
quired value, it will stop the function and send an handle with the handset for the travel direction:
“out of range” alarm. (Detailed handset operation instructions are in
Group 19.)
SM-718, August ‘07 Control Handle • 13-4-1

• Disconnect the dash display harness from • Turn the key switch On.
the traction control panel. • Handset will go through startup and display
• Plug handset into plug “B” of the traction software version.
control. • Make sure you do not step on operator pedal
• Plug in the battery. during this procedure.
• Turn the key switch On. • Press both the “ROLL UP” and “PARAM SET
• Handset will go through startup and display UP” buttons (top outside buttons) simultane-
software version. ously.
• Make sure you do not step on operator pedal • Display will read “CONFIG MENU’ “SET MOD-
during this procedure. EL”
• Press both the “ROLL UP” and “PARAM SET • Press the “ROLL DOWN” button once
UP” buttons (top outside buttons) simultane- • Display will read “CONFIG MENU” “ADJUST-
ously. MENT”
• Display will read “CONFIG MENU’ “SET MOD- • Press “ENTER” button
EL” • Display will read “FULL FWD TILT”
• Press the “ROLL DOWN” button once • Press “ROLL UP” 7 times
• Display will read “CONFIG MENU” “ADJUST- • Display will read “MAX. POT LIFT”
MENT” • Press “ENTER” button
• Press “ENTER” button • Move and hold the control handle in the
• Display will read “MAX JOY FORWARD” maximum lift direction.
• Press “ENTER” button • Display should read approx. 0.5V. Press
• Move and hold the control handle in the “ROLL UP” while holding.
maximum forward direction. • Display will read “MAX. POT LOWER”
• Display should read approx. 4.5V. Press • Move and hold the control handle in the
“ROLL UP” while holding. maximum lower direction.
• Display will read “MAX JOY REVERSE” • Display should read approx. 4.5V. Press
• Move and hold the control handle in the “ROLL UP” while holding.
maximum reverse direction. • Display will read “NEUTRAL LIFT-LOW”
• Display should read approx. 0.5V. Press • Release the control handle to the neutral
“ROLL UP” while holding. position.
• Display will read “NEUTRAL FWD-REV” • Display should read approx. 2.5V. Press
• Release the control handle to the neutral “ROLL UP”.
position. • Display will read “MAX. JOY2 RIGHT”
• Display should read approx. 2.5V. • Move and hold the mini joystick in the maxi-
• Press “OUT” button and then “ENTER” button mum right direction.
to save the control handle positions. • Display should read approx. 4.5V. Press
• Press “OUT” button to return to main menu. “ROLL UP” while holding.
• Turn Key Off, unplug handset, and reconnect • Display will read “MAX. JOY2 LEFT”
dash display. • Move and hold the mini joystick in the maxi-
mum left direction.
Use the following method to acquire the control • Display should read approx. 0.5V. Press
handle with the handset for the travel direction: “ROLL UP” while holding.
NOTE: (Detailed handset operation instruc- • Display will read “NEUTRAL2 LT-RT”
tions are in Group 19.) • Release the mini joystick to the neutral posi-
tion.
• Disconnect PL-41 on the main harness from • Display should read approx. 2.5V. Press
the pump control panel. “ROLL UP”.
• Plug handset into plug “A” of the pump con- • Display will read “MAX. JOY2 UP”
trol. • Move and hold the mini joystick in the maxi-
• Plug in the battery. mum up direction.
13-4-2 • Control Handle SM-718, August ‘07

• Display should read approx. 4.5V. Press the tiller card is replaced, then the tilt sensor and
“ROLL UP” while holding. control handle must be acquired using the handset
• Display will read “MAX. JOY2 DOWN” or PC Console.
• Move and hold the mini joystick in the maxi-
mum down direction.
• Display should read approx. 0.5V. Press Tiller
“ROLL UP” while holding. Card
• Display will read “NEUTRAL2 UP-DOWN”
• Release the mini joystick to the neutral posi-
tion.
• Display should read approx. 2.5V.
• Press “OUT” button and then “ENTER” button
to save the control handle positions.
• Press “OUT” button return to main menu.
• Turn Key Off, unplug handset, and reconnect
main harness PL-41 plug.
Mini Joystick
Horn Switch
Function
Change Switch
Multifunction Control
Handle Base
Tiller Card
Description
The Tiller Card receives the 0-5V signals from the
control handle and converts them into the canbus
language to share with the traction, pump, and
valve controllers. The tiller card receives a 12V pow-
er supply from the valve controller and then sends a
5V power supply to the control handle sensors and
the tilt sensor. It not serviceable or adjustable. If
SM-718, August ‘07 Control Handle • 13-4-3

Notes:
13-4-4 • Control Handle SM-718, August ‘07

Section 5
Switches and Sensors
Contents
Operator Presence Switch ................................1
Description ........................................................ 1
Adjustment ....................................................... 1
Steer Angle Sensor ..............................................1
Description ........................................................ 1
Program and Acquiring ................................ 1
High/Low Switch .................................................2
Description ........................................................ 2
Tilt Sensor ...............................................................3
Description ........................................................ 3
Installing and Adjusting ............................... 3
Program and Acquiring ................................ 4
Horn..........................................................................6
Description ........................................................ 6
Fuses.........................................................................6
Description ........................................................ 6
Operator Presence Switch Steer Angle Sensor

Description Description
The foot operated pedal actuates an operator pres- The steer angle sensor is mounted on top the steer
ence switch. When the pedal is depressed, the actuator. This device helps the drive motor control
switch closes. A spring under the pedal returns it to an efficient speed differential between the two
the raised position. The ESX will not function (travel drive motors when the truck is cornering.
or hydraulic) unless the operator presence switch is
closed. When the OP switch is open, a fault code The steer angle sensor is a potentiometer that trans-
of AL001 will appear on the dash display. The trac- lates the angle of rotation of the steer angle into a
tion control will apply the parking brakes when the voltage level read by the traction control. When the
operator presence switch is opened (pedal raised). steer wheel is straight ahead (0° turn angle) the in-
The pump motor will continue to idle for 5 seconds put signal to the control should be at the mid point.
after the OP switch is opened to allow for steering. As the vehicle turns left, this input signal decreases.
As the vehicle turns right, the input signal increas-
Adjustment es.
Adjust the switch so that it “clicks” as soon as the
Program and Acquiring
pedal starts to depress. This will give the operator
the maximum amount of freeplay without applying
the parking brakes. Check the full depressed posi- CAUTION! Before any adjustments
tion (pedal horizontal) to ensure that the switch will are done, safely jack up the truck,
not be damaged due to overstroking the actuator. block the drive wheels off the floor,
(Illustration of OP switch and pedal) disconnect the battery, and dis-
charge the capacitors as described
in Group SA
Use the following method to adjust the steer angle
sensor with the handset:
SM-718, August ‘07 Switches and Sensors • 13-5-1

NOTE: Detailed handset operation instruc- • Press “ROLL UP” button (6) times
tions are in Group 19. • Display will read “MAX STEER RIGHT”
• Turn steer wheel all the way to the right and
• Disconnect the dash display harness from hold
the traction control panel • Press “ENTER” button
• Plug handset into plug “B” of the traction • Press “OUT button
control • Display will read “ARE YOU SURE”
• Plug in the battery • “YES=ENTER” “NO=OUT’’’
• Turn the key switch On • Press “ENTER” button (this stores the value to
• Handset will go through startup and display be used for steering max right)
software version • Display will read “CONFIG MENU ADJUST-
• Press both the “ROLL UP” and “PARAM MENT
SET UP” buttons (top outside buttons) • Press “OUT” button
simultaneously. • Display will show software version
• Display will read “CONFIG MENU’ “SET • Turn the key switch Off and remove the tes-
MODEL” ter cord from the control
• Press the roll down button once • Plug the dash display harness into the “B”
• Display will read “CONFIG MENU” plug of the control
ADJUSTMENT • Lower truck to the ground and test drive
• Press “ENTER” button truck
• Display will read “MAX JOY FORWARD”
• Press “ROLL UP” button (8) times Steer Sensor
• Display will read “SET STEER O-POS”
• Press “ENTER” button
• Adjust the steer wheel to where it appears to
be centered
• Press “OUT button
• Display will read “ARE YOU SURE”
“YES=ENTER” “NO=OUT”
• Press “ENTER” button (this stores the value to
be used for Steering 0 position)
• Display will read “CONFIG MENU”
ADJUSTMENT
• Display will read “ MAX JOY FORWARD “
• Press “ROLL UP” button (7) times High/Low Switch
• Display will read “MAX STEER LEFT” Description
• Turn steer wheel all the way lo the left and
hold The high/low (upright height limit) switch is mount-
• Press “ENTER” button ed underneath the top tie bar of the triple, quad,
• Press “OUT button and hilo uprights. The switch opens when the forks
• Display will read “ARE YOU SURE” leave free lift (high position) and closes while forks
• YES=ENTER” “NO=OUT” are within free lift (low position). The switch signal is
• Press “ENTER” button (this stores the value to read by the valve control and shared to the traction
be used for steering max left) and pump controls via the canbus network. The
• Display will read “CONFIG MENU” high/low signal is used by the controls to reduce
ADJUSTMENT the travel speed when forks are high, give faster tilt
• Press “ENTER” button speeds when forks are low, and give full tilt range
• Display will read “ MAX JOY FORWARD” when forks are low (See group 19 for details on the
13-5-2 • Switches and Sensors SM-718, August ‘07

performance enhancing package). Do not override level ground must be recorded for the full forward
or disable the high/low switch. tilt and full back tilt. These values are entered into
On the 110”, 122”, & 130” MFH standard uprights, the adjustment menu of the pump control. Back tilt
there is no high/low switch. angles are negative and forward tilt angles are posi-
tive. The voltage of the tilt sensor in the full back
and full forward position must be acquired using a
handset or PC console. The other tilt positions: Re-
stricted back tilt (forks high), Restricted forward tilt
(forks high), and vertical mast (forks level) are en-
See Detail “A” tered as angle values in degrees. (See Group 19 for
handset details and instructions).
Several alarms are related to tilt sensor failure or

malfunctions. Most of these alarms will disable the
tilt function until the fault is corrected (See Group
19, section 3 for the fault code list and troubleshoot-
ing guide).
Installing and Adjusting

Before any adjustments are done, safely jack up the
truck, block the drive wheels off the floor, discon-
nect the battery, and discharge the capacitors as
described in Group SA
Use the following method to install and adjust the

tilt sensor:
NOTE: Procedure can also be found in
Group 19, Section 3. Refer to hand-
Tilt Sensor set operation instructions in Group
Description 19.)
The tilt sensor is located under the left tilt cylinder.
Procedure to turn tilt sensor off for installation
It is a linear potentiometer that extends and retracts
• Disconnect PL-41 on the main harness from
as the tilt cylinder strokes. The tilt sensor receives
the pump control panel.
5V power from the tiller card. The 0-5V output of
• Plug handset into plug “A” of the pump con-
the sensor is read by the traction control and shared
trol.
to the pump and valve controls via the canbus net-
• Plug in the battery.
work. This signal is used by the controls to deter-
• Turn the key switch On.
mine the angle of the upright relative to vertical.
• Handset will go through startup and display
The tilt sensor is a vital component to the perfor-
software version.
mance enhancing package on the ESX that gives
• Make sure you do not step on operator pedal
the operator features like two-way fork leveling and
during this procedure.
full range of tilt when the forks are low even with
• Press both the “ROLL UP” and “PARAM SET
tall MFH uprights (See Group 19 for details on the
UP” buttons (top outside buttons) simultane-
performance enhancing package).
ously.
• Display will read “CONFIG MENU’ “SET MOD-
It is important that the correct full range of tilt is
EL”
set by using the rod ends on the tilt cylinders. Af-
• Press the “ROLL UP” button once
ter rod ends are adjusted correctly and tightened,
• Display will read “SET OPTIONS”
the actual angle of the upright with the truck on

• Press “ENTER” button Program and Acquiring

• Display will read “HOUR COUNTER”
• Press “ROLL DOWN” button once CAUTION! Before any adjustments
• Display will read “TILT SENSOR” are done, safely jack up the truck,
• Press “ENTER” button block the drive wheels off the floor,
• Press “PARAM SET DOWN” disconnect the battery, and dis-
• Display will read “TILT SENSOR OFF” charge the capacitors as described
• Press “OUT” button and then “ENTER” button in Group SA
to save
• Press “OUT” button to return to main menu Use the following method to acquire the tilt sensor
• Turn Key Off, unplug handset, and reconnect maximum forward and back tilt voltages with the
main harness PL-41 plug. handset:
(Detailed handset operation instructions are in
Procedure to Install tilt sensor Group 19.)
• Install clamp and tilt sensor cylinder bracket Procedure to acquire tilt sensor
to rear of tilt cylinder as shown • Disconnect PL-41 of main harness from the
• Adjust tilt sensor eyelets to a collapsed pump control panel
length of 190mm. Tighten eyebolt jam nuts. • Plug handset into plug “A” of the pump con-
• Pivot tilt cylinder up and install sensor on trol
rear bracket only, leaving sensor collapsed. • Plug in the battery
• Ensure sensor does not get damaged or • Turn the key switch On
crushed while installing rod end to the up- • Handset will go through startup and display
right. software version
• Adjust rod ends and tilt mount to correct tilt • Press both the “ROLL UP” and “PARAM SET
range. Refer to tilt angle chart for correct UP” buttons (top outside buttons) simultane-
values. ously.
• Make sure to remove all racking from tilt • Display will read “CONFIG MENU’ “SET MOD-
cylinders EL”
• Tighten rod end bolts. • Press the “ROLL DOWN” button once
• Using an inclinometer, record the full back • Display will read “CONFIG MENU” ADJUST-
and full forward tilt angles MENT
• Install the tilt sensor bracket onto the rod • Step on operator pedal and tilt the forks
end. forward until bypass.
• Manually extend the tilt sensor to match the • Release pedal and wait for pump motor to
full back and full forward tilt to check the stop idling.
sensor stroke. Make sure the sensor stroke • Press “ENTER” button
is not too short or too long. Adjust the rear • Display will read “FULL FWD TILT”
clamp if required. • Press “ENTER” button
• Install tilt sensor to rod end bracket • Display should read a voltage near 0.5V, but
• Sensor should be parallel with tilt cylinder cannot be less than 0.2V.
rod. Adjust rear clamp is required. • Press “OUT” button and then “ENTER” button
• Proceed to program and acquiring of tilt to save this voltage position.
sensor. • Step on operator pedal and tilt the forks
backward until bypass.
• Release pedal and wait for pump motor to
stop idling.
• Display will read “FULL FWD TILT”
• Press “ROLL UP” button once.
• Display will read “FULL BACK TILT”
• Press “ENTER” button amount will also be stamped on the data

• Display should read a voltage near 4.5V, but plate.
cannot be more than 4.8V. • Press “ROLL UP” button
• Press “OUT” button and then “ENTER” button • Display will read “VERTICAL MAST”
to save this voltage position. • Default is 0.0. Adjust this value to calibrate
the two-way fork leveling feature. This value
Procedure to tune tilt angles and turn sensor on can be adjusted to compensate for tire wear,
• With the Handset connected to the pump upright deflection, and other factors that will
control and the key on cause the horizontal geometry of the truck to
• Make sure you do not step on operator pedal change over time.
during this procedure. • Press “OUT” button and then “ENTER” button
• Press both the “ROLL UP” and “PARAM SET to save the changes.
UP” buttons (top outside buttons) simultane- • Press “ROLL UP” button.
ously. • Display will read “SET OPTIONS”
• Display will read “CONFIG MENU’ “SET MOD- • Press “ENTER” button
EL” • Display will read “HOUR COUNTER”
• Press “ROLL DOWN” button once • Press “ROLL UP” button
• Display will read “CONFIG MENU” ADJUST- • Display will read “TILT SENSOR”
MENT • Press “PARAM UP” button to change to ON
• Press ”ENTER” button • Press “OUT” button and then “ENTER” button
• Display will read “FULL FWD TILT” to save.
• Press “ROLL UP” button twice. • Press “OUT” button to return to main menu.
• Display will read “FULL FWD ANGLE” • Turn Key Off, unplug handset, and reconnect
• Default is 6.0deg main harness PL-41 plug.
• Use the “PARAM UP” or “PARAM DOWN” to • Test tilt for proper function, speed, and range
adjust the angle to match what was mea- with forks low
sured after rod end adjustments. Refer to • Test tilt for proper function, speed, and range
tilt angle chart for correct values. The angle with forks high
should be entered to the nearest tenth of a • Test fork leveling feature in both directions
degree.
• Press “ROLL UP” button
• Display will read “FULL BACK ANGLE”
• Default is -8.0deg
• Use the “PARAM UP” or “PARAM DOWN” to
adjust the angle to match what was mea-
sured after rod end adjustments. Refer to
tilt angle chart for correct values. The angle
should be entered to the nearest tenth of a
degree.
• Display will read “RESTRICTED FWD”
• Default is 1.5deg. Confirm that this value is
correct and check the tilt angle chart value. Tilt Sensor

• Display will read “RESTRICTED BACK”
• Default is -5.0deg. Confirm that this value is
correct and check the tilt angle chart value.
This value is different depending on the
MFH of the upright. The restricted back tilt

Horn
Description
The electronic horn is operated by the first push
button on the control handle. The horn is not di-
rectly wired to the push button. Instead the push
button signals are received by the tiller card and
communicated to the traction control via the can-
bus network. The aux output driver on the slave
control actuates the horn signal. Only the Clark
electric horn can used on the ESX. Other horns will
not work properly. (Refer to wiring diagrams for de-
tails). The horn will only function with the key in the
ON position and battery connected.
(Illustration of horn mounting)
Fuses
Description
The ESX electrical system is protected by 2 power
fuses and several control fuses. Both the traction
and pump control have a 350A power fuse. There
are 8 standard control fuses to protect the electri-
cal system and components. The key switch has a
15A fuse and each of the controls (traction, pump,
& valve) has a 7.5A fuse. The valve control also has
a 10A fuse for power to the electro hydraulic valve
coils. The controller cooling fans have a 10A fuse.
To protect the display gauge, the tiller card, control
handle, and tilt sensor there are two 1A fuses. Each
of the control fuses is located in a central fuse box
next to the control handle. (Refer to wiring diagram
for details). Optional fuses for headlights and back-
up alarms will also be located in the central fuse
box.

Section 6
Display Gauge
(BDI) Battery State of Charge
The Battery indicator has 10 bars. Each bar rep-
resents 10% of battery charge. At 20% (2 bars) of
charge the display will show alarm code AL006 and
will blink. This indication means it is time to charge
or change the battery. At 10% (1 bar) the display
will show alarm code AL066 and continue to blink.
AL066 is lift lock out. Therefore the lift function is
disabled and the truck will only travel at half speed.
(88888 Display) Digital readout

The digital readout shows the hour meter or alarm
Description code is an alarm is present.
The dash display provides the operator an easily
understandable, visual feedback of the status of the (RED LED Light) Tilt Restriction Indicator
truck and its system components. The display re- The red led light is the tilt restriction indicator. This
ceives the truck information from the traction con- is a visual notification to the operator when the lift
trol via the canbus network. It is connected to the function will not work past the free lift (high/low
traction control in the “B” connector. The same con- switch). If the red led is on, it means that the tilt
nection used for the handset or PC console. angle of the upright is outside of the restricted tilt
12V supply from traction control. zone (tilt range when forks are high) and that lift will
(Each icon with description) not function in the fork high position. If the red led
(Hour Glass) Hour Meter indicator. is off, it means the tilt angle is within the restricted
When the hour glass is displayed the hours of the tilt zone and the lift will function normally.
truck is being displayed on the 5 digit display.
Startup Procedure
(Turtle) Speed limit indicator When the key switch is turned ON, the dash will dis-
This indicator will display when the traction control play “88888” for approximately 1 second. This indi-
limits the travel speed. This will occur when the cates to the operator or mechanic that the gauge is
forks are high, when curve cutback is enabled, and working properly and all leds are functioning. After
with the occurrence of certain alarms. one more second, either the hour glass symbol or
the wrench symbol should come on.
(Wrench) Maintenance indicator
This indicator displays if an alarm occurs or the If the hour glass symbol comes on, the digital read-
planned maintenance is due (AL077). The alarm out shows the truck operating hours. If the wrench
code will appear on the 5 digit display. The planned symbol comes on, an alarm code appears on the
maintenance alarm can only be removed by a digital readout. The alarm code may indicate an
trained mechanic. easily correctable “operator fault” or it may indicate
that you need to have the truck serviced. (Refer to
Group 19, section 3 for details of alarm code)
SM-718, August ‘07 Dash Display • 13-6-1

Notes:
13-6-2 • Dash Display SM-718, August ‘07

GROUP 16, ELECTRICAL MOTORS
GROUP 16
ELECTRICAL MOTORS
Motor Specifications And Descriptions . . . . Section 1

Drive Motor Overhaul. . . . . . . . . . . . . . . . .Section 2
Pump Motor Overhaul . . . . . . . . . . . . . . . Section 3
SM-718, August ‘07 Electrical Motors • Group 16

Group 16 • Electrical Motors SM-718, August ‘07

Section 1
Motor Specifications and Descriptions
Contents
Specifications ....................................................... 1
Drive Motors ..................................................... 1
Pump Motor ...................................................... 1
Description and Location .................................2
Drive motors ..................................................... 2
Lift/Steer pump motor ................................. 2
Specifications
Drive Motors Pump Motor
Frame Size: 200 mm (7.874 in) diameter Frame Size: 170 mm (6.693 in) diameter
Weight: 45kg (99 lb) Weight: 50kg (110 lb)
Internal Bearings: Sealed and lubricated with high Internal Bearings: Sealed and lubricated with high
temperature grease for the life of the bearing. The temperature grease for the life of the bearing. The
bearing at the back end of the motor is a special bearing at the back end of the motor is a special
encoder bearing (sensor) that needs to be replaced encoder bearing (sensor) that needs to be replaced
every 10,000 hours, or any time the bearings are re- every 10,000 hours, or any time the bearings are re-
moved from the motor rotor shaft. moved from the motor rotor shaft.
Terminal Nut Torque: 15 N.m (133 in-lb) Terminal Nut Torque: 15 N.m (133 in-lb)
Rotor outside Diameter: 124 mm (4.882 in) Rotor outside Diameter: 102.2 mm (4.023 in)
Rotor inside Diameter: 44 mm (1.732 in) Rotor inside Diameter: 30 mm (1.181 in)
Number of Slots: 48 Number of Slots: 28
Stator outside Diameter: 200 mm (7.874 in) Stator outside Diameter: 170 mm (6.693 in)
Stator inside Diameter: 125 mm (4.921 in) Stator inside Diameter: 103 mm (4.055 in)
Number of Slots: 36 Number of Slots: 36
Nominal Air Gap: 0.5 mm (.0196 in) Nominal Air Gap: 0.4 mm (.0157 in)
Nominal Battery Voltage: 36V / 48V Nominal Battery Voltage: 36V / 48V
Maximum Battery Voltage: 39.5V / 52.5V Maximum Battery Voltage: 39.5V / 52.5V
Nominal Speed: 945 RPM / 1335 RPM Nominal Speed: 1310 RPM
Stall Current: 275A Stall Current: 450A / 400A
Insulation: Class F Insulation: Class F
Winding: Star Winding: Delta
Encoder: 64 Pulses / Rev Encoder: 64 Pulses / Rev
SM-718, August ‘07 Motor Specifications and Descriptions • 16-1-1

Description and Location all times. This pump runs for steering any time the
truck is in gear, or anytime a hydraulic function is
The truck has three electric AC motors:
requested.
• Two identical traction motors
• One main hydraulic/power steering pump motor. The external connections are easily accessible from
Drive motors the top of the motor where they are protected from
external damage.
The two drive motors are three-phase AC motors
with class F insulation. These motors do not use
The pump motor also has a built-in thermistor which
brushes and the motors are totally enclosed, mini-
constantly monitors the winding temperature and
mizing the service requirements. Because the mo-
reports this information to the control (this sensor
tors do not use brushes and are enclosed, sealing
is not serviceable). Should it sense that the motor
them from outside contamination, there is no need
is approaching the temperature limit, the control
to blow out the inside of the motors during a PM.
will cutback motor current until the temperature
Each motor has two bearings; the drive end bear-
decreases. Since it is cutting back current and not
ing is a ball bearing and the bearing at the rear of
voltage, the top end speed will not be affected, un-
the motor is a special encoder bearing (sensor) for
less the loads are close to capacity.
motor feedback to the control. One motor drives
the left traction wheel, the other the right. The elec-
tronic control system varies the speeds to the two
motors independently to accommodate cornering.
The external connections are easily accessible from

the top of the motor where they are protected from
external damage.
Each drive motor also has a built-in thermistor which

constantly monitors the winding temperature and
reports this information to the control (this sensor
is not serviceable). Should it sense that the motor
is approaching the temperature limit, the control
will cutback motor current until the temperature
decreases. Since it is cutting back current and not
voltage, the top end speed will not be effected, un-
less on a grade.
Lift/Steer pump motor

The pump motor is a three-phase AC motor with
class F insulation with an external fan. It is also a
brushless motor and totally enclosed. The pump
motor does incorporate a fan at the rear of the mo-
tor that blows air across the outside of the motor
frame to help control the temperature. This fan does
need to be blown out at every PM to keep it clear of
any debris. This motor has two bearings; the drive
end bearing is a ball bearing and the bearing at the
rear of the motor is a special encoder bearing (sen-
sor) for motor feedback to the control. An electronic
control system controls the speed of the motor at
16-1-2 • Motor Specifications and Descriptions SM-718, August ‘07

Section 2
Drive Motor Overhaul
Contents
Inspection Procedure ....................................1
Motor Cleanliness ........................................1
Drive Motor Removal and Installation ........1
Ball Bearings................................................2
Encoder Bearing...........................................2
Replacing Encoder Bearing .........................2
To replace the encoder bearing: ............... 2
Motor Reassembly .......................................3
Inspection Procedure Group SA, Section 2 for procedures)

2. Remove the top cover and the front cover.
Before performing these service procedures:
3. Remove all electrical cables from the drive
• Park truck safely.
motor. Tag cable terminals to aid in reinstal-
• Fully lower the upright.
• Apply the park brake lation and position the cable out of the way.
• Turn the key switch OFF. 4. Disconnect the wire harness from
• Disconnect battery from truck receptacle. the parking brake assemblies.
• Discharge capacitors by connecting a 200 5. Use two capscrews, M6 x 1.0 x 30mm long
ohm 10 watt resistor between the positive threaded into the holes at the top of the
and negative input post of the controller for brake assembly to release the brakes.
10 seconds. NOTE
Use four M6 x 1.0 bolts that are exactly 30mm
Motor Cleanliness long to release the brakes. Longer bolts will
damage the brake and shorter bolts will not re-
Electric motors should be kept clean at all times lease the brake. These bolts must be removed
to prevent shorting, minimize wear, and optimize before truck is placed back into operation.
cooling.
• Wipe off all dust, dirt, oil, water, etc., from Use two M6 x 1.0 bolts that are exactly 30mm long to
outer surface of motor. release the brakes. Longer bolts will damage the brake
• Remove any debris from cooling fan air vents and shorter bolts will not release the brake. These bolts
must be removed before truck is placed back into
and around motor frame to prevent over- operation.
heating.
• Air-clean (blow off ) motors using clean, dry
(moisture-free) compressed air at 207 kPa (30
psi) maximum air pressure.
The presence of any oil on or near the motor could
indicate either bad bearings or leaking hydraulic
system. Determine cause and repair problem be-
fore extensive motor damage occurs.
Drive Motor Removal and

Installation
1. Park the truck and block accordinaly. (See
SM-718, August ‘07 Drive Motor Overhaul • 16-2-1

6. Remove the three brake mount- Ball Bearings

ing bolts watchin for the two spacer
Both ball bearings are maintenance free. If it be-
washers located at each mounting comes necessary to remove the bearings to repair
location between the bottom brake the motor, they should be replaced. In any case the
plate and the top of the motor. seals (shaft oil seal and O-ring) must be replaced.
7. Lift the brake assembly from the motor. In general bearings should be replaced at approxi-
8. Remove bolts holding motor to axle. mately 10,000 operating hours.
9. Raise the drive motor from the drive axle
and then lower motor onto floor using Encoder Bearing
a suitable chain hoist or come-a-long.
The encoder bearing is used to communicate the
10. Reinstall in reverse order. Use new O-
motor speed to the controller.
ring, coated with drive axle fluid.
11. Check and fill drive axle oil as
NOTE
described in Group 20.
The encoder bearing is very sensitive
to static electricity. If you are going to
NOTE be working on the encoder bearing you
When removing or installing cables to should have a ground strap on to insure
motor, hold the terminal’s lower nut that the encoder bearing does not get
with a wrench while turning the upper damaged.
fastening nut with another wrench.
Use two M6 x 1.0 bolts that are exactly 30mm Replacing Encoder Bearing
long to release the brakes. Center brake visually
Replace Plastic Cap with spline hub on motor.
after brake installation
Torque to 9-11 Mn
(83 - 94 lbf in)
6 washers used to space
brake off of motor
Coat spline shaft of motors with

Never Seize (CLARK # 1802307)
before installation
Coat O-Ring with Transmission

fluid prior to installation
In general the encoder bearing should be replaced

every time the motor is disassembled.
To replace the encoder bearing:

• Turn key OFF.
• Set park brake.
• Disconnect battery.
• Remove the drive motor (see page 1 of this
section).
• Remove motor thru bolts.
• The silicone sealing the cables into the end
frame will need to be loosened to allow
removal of the end frame.
16-2-2 • Drive Motor Overhaul SM-718, August ‘07

• Remove the non-drive end housing from coder bearing and press it on with a steady
motor. pressure. The lead from the bearing must
• Remove rotor from motor. located in the notch in the housing frame.
• Use a gear puller to remove encoder bearing
from the rotor. Notch for Lead
• Press new encoder bearing, do not use a
hammer, onto rotor at the inner ring with
a steady pressure. The inner ring of the
bearing must to be pressed against the shaft
shoulder.
• Install the rotor into the stator housing.

• Tie strap the encoder bearing lead to one
of the motor leads to prevent it from being
pulled and contacting the rotor.
• Install the drive end onto the motor mak-
ing sure that the terminal block mounting
bracket is aligned with the slots in both end
frames.
Terminal Block
Mounting Bracket
Motor Reassembly
NOTE Thermal Sensor Lead
The encoder bearing is very sensitive
to static electricity. If you are going to
be working on the encoder bearing you
should have a ground strap on to insure • Install the motor through bolts and tighten.
that the encoder bearing does not get • Fill the void around the drive motor leads
damaged. with Silicone # 1758629.
• Reinstall the motor into the truck.
• Insure that the encoder cables are installed
correctly and do not get pinched or touch
the rotor.
• Install the end housing carefully onto the en-
SM-718, August ‘07 Drive Motor Overhaul • 16-2-3
NOTES:
16-2-4 • Drive Motor Overhaul SM-718, August ‘07

GROUP 19, MOTOR CONTROLS
GROUP 19
MOTOR CONTROLS
Description . . . . . . . . . . . . . . . . . . . . . . Section 1
Programming & Adjustments Using
ZAPI Handset . . . . . . . . . . . . . . . . . . . . . .Section 2
CONTROL TROUBLESHOOTING . . . . . . . . . Section 3
ESX Factory Control Settings . . . . . . . . . . . Section 4
Sequence of Operation. . . . . . . . . . . . . . . .Section 5
SM-718, August ‘07 Motor Controls • Group 19

Group 19 • Motor Controls SM-718, August ‘07

Section 1
Description
The CLARK ESX uses a Dual AC controller to control both drive motors and a single AC controller to control
the single motor/pump combination which supplies flow to all hydraulic functions and steering.
Contents
Traction Control and Motors ...........................1 Protection Features.............................................5
Lift/Steer Control and Motor ...........................2 Reverse Battery Polarity:............................... 5
Electro Hydraulic Valve, Valve Control, Connection Errors: .......................................... 5
and Control Handle ............................................2 Thermal Protection: ....................................... 5
Control Handle .....................................................2 External Agents: .............................................. 5
Variable Tilt and Performance Enhancing Protection Against Uncontrolled
Package ...................................................................2 Movement: ........................................................ 5
Operational Features ..........................................3 Low Battery Charge:....................................... 5
Creep Speed ..................................................... 3 Protection against accidental startup: .... 6
Control acceleration....................................... 4 Capacitor Charge: ........................................... 6
Regenerative Braking .................................... 4 Discharging Controller Capacitors............ 6
Coast braking ................................................... 4 Communications with Dash Display: ..... 6
Speed Limit ....................................................... 4 Tilt Sensor: ......................................................... 6
Stop on Ramp .................................................. 4 High/Low Switch: ............................................ 6
Static Return to Off (SRO) ............................. 4 Analog control unit ........................................ 6
Thermal Protector ........................................... 4 Speed Feedback .............................................. 6
Standard Fault Codes .................................... 4 Self Checking / Automatic Apply
Stored Fault Codes ........................................ 5 Parking Brakes.................................................. 6
Hour Meter Readings.................................... 5 Steer Angle Transducer ................................. 7
Battery Discharge Indication (BDI) ........... 5 Steering Table................................................... 7
Two-Way Fork Leveling: ................................ 5
Handset .............................................................. 5
Traction Control and Motors given handle position the control will maintain a set
speed, as determined by control parameter settings.
The dual AC traction control consists of two motor
These settings are adjustable to meet your custom-
controls mounted to a single finned heat-sink plate
er’s needs. One feature that is new to the ESX is “re-
and enclosed by a single cover. The left portion of
lease braking”. This feature will apply a regenerative
the control is reference to as the “master” control
braking force every time the driver moves the con-
and operates the right drive motor. The right por-
trol handle towards neutral. The final travel speed
tion of the control is referred to as the “slave” con-
will be determined by the new handle position.
trol and operates the left drive motor. The control
The control receives motor speed feedback from
receives inputs from the control handle, steer tire
the motor encoders which allow for precise speed
position sensor (steer pot), foot operator presence
regulation. Every motor also has a built-in therm-
switch, motor encoders, motor thermistors, tilt sen-
istor which constantly monitors the winding tem-
sor, high/low switch, and key switch. The control is
perature and reports this information to the control.
able to proportionally reduce the speed of the in-
Should it sense that the motor is approaching the
side tire when the truck is in a turn, based on the
temperature limit, the control will cutback motor
steer angle input from the steer sensor. Once the
current until the temperature decreases. Since it is
steer angle exceeds a certain value, the inside wheel
cutting back current and not voltage, the top end
will start to reverse. The speed of the vehicle is con-
speed will not be effected, unless on a grade. Each
trolled by the position of the control handle. For a
SM-718, August ‘07 Description • 19-1-1

control also has built-in thermal protection that will or partial lift function is requested by operator. The
reduce output current should the control approach unloader coil is smaller than the other coils and is
the thermal limit. located on the bottom of the valve. Each coil has a
Lift/Steer Control and Motor specific plug connector (plugs are labeled) on the
main harness and must be connected correctly.
A single motor/pump combination is used for both
hydraulic functions and steering. The motor is con- Just like the travel system, all of the hydraulic func-
trolled by a dedicated controller. The control handle tions on the ESX will not work unless the operator
is equipped with hall effect sensors that measure pedal is depressed. This includes the lowering func-
the distance the handle is stroked and provides this tional. In the event of an electrical failure, the low-
input to the control. The control uses this informa- ering poppet is equipped with a manual lowering
tion to increase motor speed in proportion to the valve.:
distance stroked, providing only the desired flow Note: Refer to Group 30 for detailed
rate. Tilt and aux behave the same as the lift func- instructions.
tion so that the pump speed is proportional to the
driver input. The maximum speed of each aux func-
tion can be programmed independently so that Control Handle
only the required flow rate is produced, minimizing The multifunctional control handle allows the oper-
power losses. When the key is in the “ON” position ator to perform multiple functions simultaneously.
and the operator presence switch is closed (pedal The ESX truck can travel, lift or lower, and perform
depressed), the control will operate the motor at a one other hydraulic function (tilt or aux) at the same
fixed idle rpm (roughly 500 rpm). This provides ad- time. The software prevents the operator from lift-
equate flow for the steering function. If the control ing and forward tilting at the same time. Travel and
receives an input from the control handle to lift, lift/lower are controlled by the base of the control
tilt, or aux function, then it will ramp up the motor handle. Tilt and aux functions are controlled using
speed to match the desired input. Once the request the mini thumb operated joystick.
is removed the motor speed will return to the fixed
idle. As with the traction control and motors, the Both the base and mini joystick have redundant hall
lift/steer control and motor have thermistors for effect sensors that do not have mechanical con-
thermal protection and the motor has a built-in en- tacts and are not adjustable. Each axis of the base
coder for speed feedback. and mini joysticks sweep a 0-5V signal as the con-
trol handle is moved. This signal is read by the tiller
Electro Hydraulic Valve, Valve card. The tiller card converts the voltage signal into
the canbus language and shares the signal will the
Control, and Control Handle traction, pump, and valve controls.
The ESX is equipped with a fully proportional elec-
tro hydraulic valve and controller. The valve control- Variable Tilt and Performance
ler sends current to each coil on the valve to control
the individual functions of lift, lower, tilt, and aux. Enhancing Package
proportional to the control handle movement. The The ESX has a performance enhancing package that
main valve has a total of 7 20V coils. Two more coils allows the operator to have faster tilt speeds when
can be present if the truck is equipped with an aux2 the forks are low, more tilt range when the forks are
valve. The 6 coils on top of the main valve (lift, low- low, two-way fork leveling (vertical mast), and re-
er, tilt back, tilt forward, aux1 left, & aux1 right) are duced travel speeds when the forks are high. This
interchangeable to make troubleshooting easier. system uses a limit switch mounted in the upright
The EH main control valve has an unloader valve that sends a signal to the controls to determine
that allows the idle flow to return to the sump tank. when the forks are high versus low. On a triple or
The valve controller only closes the unloader valve quad upright, this switch actuates off of the inter
when full lift is requested. Otherwise the unloader rail of the upright (free lift). The system also uses a
valve is open (neutral state) when tilt, aux, lower, tilt sensor located underneath one of the tilt cylin-
19-1-2 • Description SM-718, August ‘07

ders. The tilt sensor provides a signal to the controls works by the operator pressing and holding the
providing the tilt position (angle of tilt forward and right button on the control handle and then tilting.
backward). With the button held, the forks will stop when they
are level. The fork leveling features works while
The tilt range when the forks are low will be 8 de- back tilting or while forward tilting. This feature can
grees back and 6 degrees forward on standard, hilo, be calibrated by a trained mechanic as tire wear, up-
and triple stage uprights. The quad low tilt range right deflection, and other items change the geom-
will be 5 degrees back and 6 degrees forward unless etry of the truck. Refer to section 2 on fork leveling
the truck is equipped with special options. The tilt adjustments.
range when forks are high (restricted tilt range) will
be limited depending on upright maximum fork The traction control uses the high/low switch input
height (MFH). There are 5 programmed positions to reduce the maximum travel speed when the forks
of the tilt range. FF=Full forward tilt, RF=Restricted are in the high position.
forward tilt, V=Vertical (forks level), RB=Restricted
back tilt, FB=Full back tilt. Refer to tilt charts in sec- Operational Features
tion 2 of this group for specific tilt ranges.
Creep Speed
The software does not allow lifting in the high fork Parameters THROTTLE X POINT and THROTTLE Y
position if the tilt is not within the restricted tilt POINT control how the truck reacts when you first
range. There is a red light on the dash display to push on the control handle. Increasing THROTTLE
aide the operator. If the red light is on, the lift will X POINT will give you more handle stroke with less
only work in the low position. The red light will turn speed at the beginning of the stroke. Increasing
off when the tilt is between the restricted forward THROTTLE Y POINT will give more speed with less
tilt position (RF) and restricted back tilt position handle stroke. There are separate throttle X & Y
(RB). Refer to the variable tilt chart below. points for travel, lift/lower, and mini thumb oper-
ated joystick. See Charts below.
V
SPEED (Hz)
RB RF
MAX SPEED
Forks High
Restricted
Range
FB FF
Full
Range THROTTLE
Y POINT
Forks Low
STOP SMOOTH
FREQUENCY
CREEP
CONTROL
ACC HANDLE
THROTTLE MAX
SMOOTH VOLTAGE
X JOY
NEUTRAL
THROTTLE POINT FORWARD
FWD-REV
0
ZONE
718067 DEADBAND
FWD-REV
The ESX has tilt speeds approximately 4.5GPM when

the forks are low and 2.0GPM when the forks are
high. These speeds should not be adjusted. Please
consult Clark if different tilt speeds are required.
The two-way fork leveling (vertical mast) feature

Control acceleration the traction control will use the release braking of
Parameter ACCELERATION DELAY allows the adjust- the motors to stop the truck and then automatically
ment of the time it takes to accelerate from a stop applies the parking brakes. This feature enables
to full speed. The time is adjustable from 1 second great control on both inclines and level surfaces.
to 5.5 seconds in half-second intervals. See param- The traction control releases the parking brakes
eter-programming chart later in this manual. when the operator moves the control handle for-
ward or reverse.
Raising the operator pedal (opening the operator
Regenerative Braking
presence switch) will cause the parking brakes to
Parameter INVERSION BRAKING controls the amount apply instantly. The electro magnetic brakes are for
of time that it takes to stop the vehicle when chang- parking and emergency stopping only. Misuse and
ing from one direction to the other. This feature abuse can lead to parking brake failure.
should not be adjusted.
Static Return to Off (SRO)
Plugging (Changing direction) is the preferred
method of stopping the ESX. Raising the operator This feature requires the operator to return the
pedal will apply the electro magnetic parking brakes. control handle to the neutral position anytime
Misuse of the parking brakes will cause excess wear they leave the vehicle and return. If the operator
and can lead to parking brake failure. The traction presence switch or key switch is opened, the con-
control stores fault code -36 every time the operator trol shuts down and can not be restarted (The dash
pedal is raised and the truck is traveling more than 2 display will show a -79 or -205 fault code) until the
mph. control handle is returned to neutral.
Coast braking Thermal Protector

Parameter RELEASE BRAKING allows for the adjust- Each controller has an internal thermal protector on
ment of the amount of time that it takes to stop the heat sink. The controllers will reduce the output
the vehicle when you return the control handle to current to 50% of the set current when the heat sink
neutral. The time is adjustable from 1 second to 5.5 temperature reaches 75°C. The dash will display
seconds in half-second intervals. See parameter- the following codes depending on which control-
programming chart later in this manual. ler is over temperature, (Master -61 code, Slave -140
code, and Pump -203 code).
Speed Limit
Each motor has an internal thermistor that is moni-
Parameters MAX SPEED FORWARD and MAX SPEED tored by the motor controls. The current will reduce
BACKWARD allow for the adjustment maximum to the motors when the controls since high motor
speed that the vehicle can travel in each direction. temperatures. The dash will display the following
The maximum speed is adjustable from 0 Hz to 106 codes depending on which motor is over tempera-
Hz in 1 Hz increments. 106 Hz is the maximum al- ture, (Traction -65 code and Pump -207 code).
lowable speed for the ESX12-25.
Standard Fault Codes
PARAMETERS SPEED EMPTY MPH
The controllers have over 140 fault codes to assist
MPH 1 2 3 4 5 6 7 7.3 the service technicians and operators in the trouble
MAX SPEED FWD HZ 15 29 44 59 73 87 102 106 shooting the vehicle. If mis-operation of the vehicle
MAX SPEED REV HZ 15 29 44 59 73 87 102 106 occurs, a fault code will be displayed on the Dash
Display of the vehicle, or by plugging the handset
Stop on Ramp into the one of the controllers and reading the fault
Since the ESX has electro magnetic parking brakes, code.
the stop on ramp feature should be left OFF. When With the fault code number, follow the procedures
the operator returns the control handle to neutral, outlined in Group 19, Section 3 ,”Fault Codes”, sec-
tion to determine the problem and a solution.
Stored Fault Codes Features and functions:

This feature records the last 5 fault codes in each A. Monitor existing fault codes for traction,
controller. The last 5 fault codes can be accessed pump, and valve controls.
through the alarm log using a handset, or a lap- B. Monitor hour meter readings on traction,
top computer with the PcConsole software and pump, and valve controls.
adapter cable. The faults are stored with the hour C. Monitor or adjust the control functions
meter reading when the fault first happened, the D. Use as a tester to monitor input and output
number of time the fault has happened, and the information.
temperature the first time the fault happened.
NOTE: The Handset instructions and Trou-
Hour Meter Readings
bleshooting can be found in Group
This feature will display the recorded hours of use 19, Section 2 of this manual.
of the traction control to the Dash Display when
the key is on and no alarms are present. This hour
meter reading can be changed in the case a con- Protection Features
troller would need to be replaced. Reverse Battery Polarity:
The MAIN CONTACTOR is there to protect the con-
Battery Discharge Indication (BDI)
troller against reverse battery polarity and for safety
Provides accurate battery state of charge informa- reasons.
tion to the vehicle operator, Features and Func-
tions: Connection Errors:
Displays 100 to 0 percent charge in 10% incre-
ments. Lift Circuit is disabled at 10% discharge. All inputs are protected against connection errors.
Two-Way Fork Leveling: Thermal Protection:

While holding the function change button (right If the controller temperature exceeds 75° C, the
joystick push button) the operator can level the maximum current is reduced in proportion to the
forks or attachment while tilting. The ESX will stop thermal increase. The temperature can never ex-
tilting when the forks are level (upright vertical) if ceed 100° C.
the right push button is held while tilting. The fork
leveling feature works from while back tilting or External Agents:
forward tilting in both the low and high fork posi- The controller is protected against dust and the
tions. This feature can be calibrated by a trained spray of liquid to the degree of protection meeting
mechanic as tire wear, upright deflection, and IP54.
other items change the geometry of the truck.
Refer to section 2 on fork leveling adjustments. Protection Against Uncontrolled
Movement:
Handset
The main contactor will not close if:
This is a multifunctional tool used with the AC • The power unit is not functioning
controls. The handset (Clark part #8033636) has • The controller is not functioning perfectly.
a display and a key board for data entry. To check
alarms and perform other handset functions with- Low Battery Charge:
out having to remove the top cover, use the hand-
set adapter cable (Clark part #8041365). There is a When the battery charge is at 20%, the dash display
handset connection just under the control handle will blink, telling the operator it is time to charge or
leather boot on the front side of the control han- change the battery.
dle bracket. When the battery charge is at 10%, -66 Code (Bat-
tery Low) will display on the dash, the maximum
current is reduced to half the maximum current pro-

grammed for both the traction and pump. The lift The controls monitor if the tilt sensor signal is pres-
function is disabled and the truck maximum speed ent. If the tilt sensor is not connected, the control
is reduced to 4.0mph. Tilt and aux functions will still does not see the signal, or there is a wiring failure,
work, but at half the maximum motor current. the alarm -178 (tilt sensor out) will display. This
alarm disables the tilt function.
Protection against accidental startup: For troubleshooting, hanging uprights, and acquir-
ing the tilt sensor, there is a tilt sensor on/off setting
A precise sequence of operations is necessary be-
in the set options menu of the pump control. When
fore the control will start (SRO). Startup cannot oc-
the tilt sensor is turned off the alarm code -197 will
cur if the sequence is not followed completely. (Re-
be displayed. The truck should never be placed into
quest for drive, must be made after closing the key
operation if the tilt sensor is turned off. Refer to sec-
switch).
tion 2 for details.
Capacitor Charge:
High/Low Switch:
The controllers can hold an electrical charge for sev-
The high/low switch is mounted in the rails of the
eral seconds, due to the power capacitor bank. A
triple and quad stage uprights to open when the
discharge resistance is built in the controller, which
inter rails begin to move. This defines the low fork
ensures capacitor discharge to a safe voltage in
position (switch closed) and the high fork position
about one minute, after the key is switched off. If
(switch open). Tilt range will be limited, tilt speeds
it is necessary to work on the controller before that
will be slower, and maximum travel speed is re-
time, discharge the capacitors as described below.
duced when the forks are in the high position. Lift
is disabled when the tilt is outside the restricted tilt
Discharging Controller Capacitors
range and the forks are in the high position.
It is necessary to discharge the capacitors before
you work on the controller. To discharge the capac- Analog control unit
itors, disconnect the battery at the battery recep-
Connection C25 (PTHERMR) and C24 (NTHERMR)
tacle, connect a 200 ohm 10 watt resistor between
are used for the right motor thermal sensor. Con-
the positive and negative input post of the control-
nection C35 (PTHERML) and C34 (NTHERML) are
ler for 10 seconds.
used for the Left motor thermal sensor. Sensors are
analog.
Communications with Dash Display:
The traction controller communicates by canbus Speed Feedback
to dash display. The dash shows Battery State of
The traction motors control is based upon the mo-
charge, fault code if a fault occurs, hour meter read-
tor speed feed back. The speed transducer is an in-
ing, when speed reductions are in affect, and a red
cremental encoder, with two phases shifted at 90 °.
light to indicate outside of restricted tilt range.
The encoder is supplied with +12V from the control
panel.
Tilt Sensor:
The tilt sensor unit consists of a potentiometer in 3 Self Checking / Automatic Apply Parking
wire configuration. The tilt sensor receives 5V pow- Brakes
er supply from the tiller card. The tilt sensor signal
is received by the traction control. The electro magnetic parking brakes automatically
apply when the control handle is returned to neu-
• CPOT (C21 traction control) is the signal tral and after the traction motors bring the truck
received by the traction control. to a stop. The parking brakes are released by the
• PPOT (JA9 tiller card) is the 5V supply from traction control when the operator moves the con-
the tiller card. trol handle to forward or reverse. When the park-
• NPOT (JA16 tiller card) is the negative supply ing brakes are applied the traction control moni-
from the tiller card. tors the encoder bearings in the traction control for

movement. If movement is detected when parking

brakes are applied, the dash will display code -248.
Only a trained mechanic can clear the code -248
successfully completing the EM Brake Test via the
handset or PC Console. See section 2 & 3 for de-
tailed descriptions of the test mode and alarm. See
Group 23 for details of the electro magnetic brakes.
Steer Angle Transducer

Angular position of steered wheels is transduced to
an electric information (voltage) by means of a po-
tentiometer, with following characteristics:
• Resistance in the 2Kohm to 20Kohm range;
• Rotation electric angle: at least 300 °
• Positive supply: 12V;
• Potentiometer is installed in a way that in the
zero position (straight wheels), pot output
voltage is in the middle of the electric range
corresponding to a full left-to-right transition
of steer wheels;
• The potentiometer is installed in a way that,
when the truck turns right, pot voltage
increases;
• Use “SET STEER MIN” and “SET STEER MAX”
functions of the handset to record the
extremes (minimum and maximum) of the
potentiometer range;
• Use “SET STEER 0-POS” function of the hand-
set to record the pot output when the steer
wheels are straight.
Steering Table
The relationship between the two motors speed
changes as a function of the steering angle.
The steering angle information comes from the
transducer (potentiometer). As the steer wheel is
turned, the inside motor will slow and than finally
reverse direction to help the truck turn sharply.

NOTES:

Section 2
Control Programming
Contents
Programming & Adjustments Using ZAPI
Handset ...................................................................1 VALVE CONTROL ............................................... 21
Adjustments via Handset ............................. 1 ESX Handset Layout - Valve .......................21
Description of Handset & Connections .. 2 SUBMENU “SET OPTIONS” ..........................22
ESX Handset Layout - Master ...................... 3 SUBMENU “ADJUSTMENTS”.......................22
Master Control - “Dualac2” ...............................4 SUBMENU “PARAMETERS”..........................22
SUBMENU “SET OPTIONS” ............................ 4 OTHER HANDSET FUNCTIONS ..................... 24
SUBMENU “ADJUSTMENTS”......................... 4 Save and Restore Function ........................24
SUBMENU “PARAMETERS”............................ 7 “SET BATTERY TYPE” PROCEDURE ...........24
TESTER MENU........................................................9
MASTER CONTROL.......................................... 9
Master Control - “Dualac2”........................... 9
Slave Control - “Dualac2”................................ 11
ESX Handset Layout - Slave .......................11
SUBMENU “ADJUSTMENTS”.......................11
TESTER MENU .................................................12
SLAVE CONTROL ............................................12
Slave Control - “Dualac2”............................12
PUMP CONTROL................................................ 13
ESX Handset Layout - Slave .......................13
SUBMENU “SET OPTIONS” ..........................14
SUBMENU “ADJUSTMENTS”.......................14
SUBMENU “PARAMETERS”..........................17
TESTER MENU .................................................18
Programming & Adjustments Using ZAPI Handset

Adjustments via Handset
Adjustments of parameters and changes to the controller’s configuration are made using the digital Hand-
set. The Handset can be connected to the “B” connector of the traction controller, the “A” connector of the
pump controller, or the “A” connector of the valve controller.
Start with the battery disconnected at the battery receptacle, key switch in the OFF position.
To connect to the traction control: Disconnect the dash display harness from the Master Control and con-
nect the handset cord into this “B” connector.
To connect to the pump control: Without having to remove the top cover, using the handset adapter cable
(8041365), raise the leather boot on the control handle and plug the handset adapter cable into SO-40.
With top cover removed, the handset can be plugged into the “A” connector on the pump control.
To connect to the valve control: Remove the rubber seal from connector “A” on valve control and connect
the handset.
SM-718, August ‘07 Control Programming • 19-2-1

Description of Handset & Connections As shown in this Example; the “M” in DA2M2BKC,
indicates that the Handset is now monitoring the
INVERTER B Master control. The slave control is represented
CONNECTOR
with a :”S”, the Pump control would be indicated
CONSOLE CONNECTOR
with a “P”, and the valve control would be indicat-
ed with MHYRIO.
The last 6 digits of the top line in the example

above indicate the current software revision
loaded into the Master control. The CK indicates
CLARK and the 1.05 is the software revision level.
The bottom line on the display indicates the Bat-

DISPLAY
tery Voltage and the current level that has been
set and the current internal hour meter reading
of the control.
At the bottom of the Handset there are 6 push but-

tons used to navigate to a different control (Mas-
ter, Slave, Pump, or Valve), or to navigate through
the control functions and to make changes to the
parameters.
BUTTONS
Digital Handsets used to communicate with the AC Con-

trollers must be fitted with EPROM CK ULTRA, minimum
“Release Number 3.05, CLARK part number of the Hand-
set is 8033636.
A flow chart of the Handset functions is shown
on the following page.
The Handset is used to make adjustments to the

parameters, used to view test functions within
the electrical system of the truck and to view the
alarms (fault codes) that are present or stored in
The Handset “Release Number” will be displayed on the the memory of the controls.
Handset display momentarily when the key switch is first NOTE: See Group 19, Section 7 for
turned ON. ESX Factory Control Settings
The Handset display will then show a screen similar to

the one shown below.
19-2-2 • Control Programming SM-718, August ‘07

ESX Handset Layout - Master
HEADING
Enter
Main Menu Set Model Connected to 3 (Master), 4 (Slave), 5 (Pump), 8 (Can Tiller),
9 (Valve), 16 (MDI Gauge)
Roll Up
Parameter Enter Acceleration Delay 0-9
Change Release Braking 0-9 Enter Hour Counter Running / Key On
Set Options
Inverse Braking 0-9 Battery Check ON /OFF
Brake Pedal Braking 0-9 Hydro Key On ON /OFF
Speed Limit Braking 0-9 Stop On Ramp ON/OFF
Brake Cutback 0-9 Aux Input #1 Option #1/ Option #2/ Exclosive Hydro
Curve Braking 0-9 Set Temperature Analog / Digital / None
Operator Pedal Braking 0-9 Roll Up Steer Table Option #1/ Option #2
Max Speed Forward Hz EM Brake Test ON /OFF
Max Speed Reverse Hz
Roll Up Cutback Speed1 Hz
Cutback Speed2 Hz Enter Max. Joy Forward V
Adjustments
Cutback Speed3 Hz Max. Joy Reverse V
Curve Cutback % Neutral FWD-REV V
Curve Cutback #1 % Deadband FWD-REV %
Frequency Creep Hz Set Battery Type 36 / 48
Maximun Current 0-9 Adjust Battery V
Auxiliary Time Sec Max Steer Right V
Park Speed Limit Hz Max Steer Left V
ACC Smoth Sec Set Steer 0-Pos V
Inv Smooth Sec Set Steer Right °
Stop Smooth Hz Set Steer Left °
Throttle 0 Zone %
Throttle X Zone %
Enter Hour Meter Truck Hrs Throttle Y Zone %
Tester
Motor Voltage % Adjustment #04 °C
Frequency Hz Motor Shutdown °C
Encoder Hz Adjustment #02 1-9
Slip Value Hz Adjustment #01 1-9
Current RMS A Adjustment #03 °C
Temperature °C Main Cont Volt V
Master Motor Temperature °C Main Cont Percent %
Slave Motor Temperature °C EM Brake Volt V
FWD/REV Request V EM Brake Percent %
Rack Height Volt V Maintenance Reset ON /OFF
Tilt Sensor Volt V Maintenance None / Option #1 / Option #2
Steer Angle ° Maintenance Time HRs
Int Wheel Cutb % 1 X 10,000 Hours 0-6
Forward Switch ON /OFF 1 X 1,000 Hours 0-9
Roll Up Reverse Switch ON /OFF 1 X 100 Hours 0-9
Enable Switch ON /OFF 1 X 10 Hours 0-9
Operator Pedal Switch ON /OFF 1 X 1 Hours 0-9
Cutback Switch #1 ON /OFF Disp Gear Ratio 0 - 100
Cutback Switch #2 ON /OFF
High/Low Switch ON /OFF
Brake Switch ON /OFF
Exclusive Hydro ON /OFF
Brake Pedal Pot %
Hand Brake ON /OFF
Voltage Booster %
Battery Voltage V
Battery Charge %
Save Parameter DO NOT USE
Roll Up
Restore
Parameter DO NOT USE
Roll Up
Enter
Alarms Code, H, N, °C
Roll Up
Program VACC Not Used on ESX

Roll Up
Motor Data Not Available

Master Control - “Dualac2”

SUBMENU “SET OPTIONS”
1. HOUR COUNTER
RUNNING (Default) The dash hour meter registers any motor running.
SEAT The dash hour meter registers when the “key” is closed and operator
is standing on the operator pedal.
2. BATTERY CHECK
ON (Default) The battery discharge level check is carried out; when the battery
level reaches 10%, a fault is signaled (AL066) and the maximum cur-
rent is reduced to half the programmed value.
OFF The battery discharge level is displayed, but no fault is signaled.
3. HYDRO ON Must be OFF.
4. STOP ON RAMP Must be OFF. ESX is equipped with electro magnetic parking brakes
that automatically apply.
5. AUX INPUT #1 Must be OPTION #2. Input C10 is input for a speed reduction switch,
active low (open switch)
6. SET TEMPERATURE Must be ANALOG.
7. STEER TABLE Must be OPTION #1.
8. EM BRAKE TEST
ON Test mode to check holding capability of electro magnetic parking
brakes
OFF (Default) Normal operational mode
NOTE: See Group 19, Section 4 for ESX Factory Control Settings
SUBMENU “ADJUSTMENTS”
1. MAX JOY FORWARD Records the voltage value of the control handle when holding in the maxi-
mum forward position. Value should be approx. 4.5V. (See Group 13, Sec-
tion 4 for acquiring procedure)
2. MAX JOY REVERSE Records the voltage value of the control handle when holding in the maxi-
mum reverse position. Value should be approx. 0.5V. (See Group 13, Sec-
3. NEUTRAL FWD/REV Records the voltage value of the control handle when in neutral. Value
should be approx. 2.5V. (See Group 13, Section 4 for acquiring procedure)
4. DEADBAND FWD/REV Percentage of deadband from neutral position of control handle. Default
is 14%.
5. SET BATTERY TYPE Selects nominal battery voltage, 36V (Default) or 48V. (See Set Battery Type
procedure at end of this section)
6. ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller.
7. MAX STEER RIGHT Records in the controller EEPROM the steer potentiometer output voltage
when the steering wheel is turned fully right (maximum of the steering po-
tentiometer range). Value should be approx. 4.5V. (See Group 13, Section
5 for acquiring procedure).
8. MAX STEER LEFT Records in the controller EEPROM the steer potentiometer output voltage
when the steering wheel is turned fully left (minimum of the steering po-
tentiometer range). Value should be approx. 0.5V. (See Group 13, Section
5 for acquiring procedure).
9. SET STEER 0 POS Records in the controller EEPROM the steer potentiometer output voltage
when the steering wheels are straight. Value should be approx. 2.5V. (See
Group 13, Section 5 for acquiring procedure).
10. SET STEER RIGHT Sets the max steering angle in the right direction. Value should always be
(DO NOT CHANGE) 82°.
11. SET STEER LEFT Sets the max steering angle in the left direction. Value should always be
(DO NOT CHANGE) 98°.
12. THROTTLE 0 ZONE This parameter is a percentage of control handle movement for creeping.
How long the traction speed stays at the frequency creep setting before
accelerating. Default is 1%.
13. THROTTLE X POINT This parameter changes the characteristics of the accelerator input curve.
Default is 18%.
14. THROTTLE Y POINT This parameter changes the characteristics of the accelerator input curve.
Default is 15%.
SPEED (Hz)
MAX SPEED
THROTTLE
Y POINT
STOP SMOOTH
FREQUENCY
CREEP
CONTROL
ACC HANDLE
THROTTLE MAX
SMOOTH VOLTAGE
X JOY
NEUTRAL
THROTTLE POINT FORWARD
FWD-REV
0
ZONE
DEADBAND
FWD-REV
NEUTRAL FWD-REV and MAX JOY FORWARD are values acquired in the ADJUSTMENTS MENU.
The control handle acquiring procedure programs the actual minimum and maximum input volt-
ages from the control handle.
NOTE: See Group 13, Section 4 for acquiring procedure.

15. ADJUSTMENT #04 Determines the motor temperature level at which the “Motor Tem-
(DO NOT CHANGE) perature” fault is signaled. The default temperature is 130°C. DO NOT
CHANGE.
16. MOTOR SHUTDOWN This parameter determines the motor temperature level at which the “Mo-
(DO NOT CHANGE) tor Shutdown” fault is signaled. The default temperature is 145°C. DO NOT
CHANGE.
17. ADJUSTMENT #02 Adjust the lower level of the battery discharge table. (Adjustment for In-
ternal Resistance Compensation of the battery - a setting lower than 5 will
discharge the battery deeper before lift lockout). Default is 4
18. ADJUSTMENT #01 Adjust the upper level of the battery discharge table. (BDI display - a setting
lower than 5 will show a higher battery charge display for a longer period).
Default is 4.
19. ADJUSTMENT #03 Adjusts percentage of battery change it takes to reset battery state of
charge on dash display. Default is 20%.
20. MAIN CONT. VOLT. Adjusts the line contactor coil voltage (PWM output C27). Default is 36V.
(DO NOT CHANGE) DO NOT CHANGE.
21. MAIN CONT. PERC. Adjusts the holding voltage of the line contactor after pull in. Default is
(DO NOT CHANGE) 60%. DO NOT CHANGE.
22. EM BRAKE VOLTAGE Adjusts the electro magnetic parking brake coils voltage (PWM output C28).
(DO NOT CHANGE) Default is 36V. DO NOT CHANGE.
23. EM BRAKE PERC. Adjusts the holding voltage of the electro magnetic parking brake coils af-
(DO NOT CHANGE) ter pull in. Default is 60%. DO NOT CHANGE.
24. MAINTENANCE RESET OFF is the default Setting. When a maintenance warning occurs, the me-
chanic can cancel the warning by changing this parameter to ON. When
the truck is turned on again this parameter becomes OFF.
25. MAINTENANCE
NONE (Default) When truck reaches maintenance time, if this parameter is set as NONE, the
controller does not give a maintenance warning and does not reduce per-
formance.
OPTION #1 When truck reaches maintenance time, if this parameter is set as OPTION
#1, the controller gives a maintenance warning and does not reduce per-
formance.
OPTION # 2 When truck reaches maintenance time, if this parameter is set as OPTION
#2, the controller gives a maintenance warning and reduces the
maximum speed to 20%.
26. MAINTENANCE TIME Sets the number running truck hours before setting the maintenance fault.
This is a count down timer, it must be reset after each PM. Default is 250.
27. 1x 10, 000 HOURS Sets the ten thousands units of the hour meter displayed on the dash dis-
play. This will not change the hour meter of the controller. Default is 0.
28. 1x 1, 000 HOURS Sets the thousands units of the hour meter displayed on the dash display.
This will not change the hour meter of the controller. Default is 0.
29. 1x 100 HOURS Sets the hundreds units of the hour meter displayed on the dash display.
This will not change the hour meter of the controller. Default is 0.
30. 1x 10 HOURS Sets the ten units of the hour meter displayed on the dash display. This will
not change the hour meter of the controller. Default is 0.

SUBMENU “PARAMETERS”
1. ACCELER. DELAY Determines the acceleration ramping rate. Default is level 4.
2. RELEASE BRAKING: Controls the deceleration ramp when the travel request (control handle) is
released. The higher the setting, the more aggressive the braking. Default is
level 5.
3. INVERS. BRAKING Controls the deceleration ramp when the direction is changed (FWD to REV
or REV to FWD) during travel. The higher the setting, the more aggressive the
braking. DO NOT ADJUST BELOW LEVEL 7.
4. BRK PED. BRAKING NOT USED ON ESX
5. SPEED LIMIT BRAKING Deceleration ramp when the control handle position is changed but not
completely released. Default is level 5.
6. BRAKE CUTBACK Determines the deceleration ramp when the speed reduction input be-
comes active and the motor slows down. Default is level 3.
7. CURVE BRAKING Determines the deceleration ramp of the speed reduction when turning.
Default is level 5.
8. OPER. PEDAL BRK Determines the deceleration ramp when the operator pedal switch is
opened (pedal raised). This braking mode assists the electro magnetic
brakes to stop the truck in an emergency. DO NOT ADJUST BELOW LEV-
EL 6.
9. MAX SPEED FWD Determines maximum speed in forward direction. Default is 106Hz.
10. MAX SPEED REV Determines maximum speed in reverse direction. Default is 106Hz.
11. CUTBACK SPEED1 Speed reduction when cutback switch1 is active. (Input C10). Default is
(NOT USED) 100%.
12. CUTBACK SPEED2 Speed reduction when cutback tilt sensor ko alarm (AL183) is present. De-
fault is 25%.
13. CUTBACK SPEED3 Speed reduction when high/low switch is open (forks high). Default is
35%.
14. CURVE CUTBACK Determines the maximum speed of the truck when the steer wheel is com-
pletely turned 90°. This is a percentage of the maximum travel speed. De-
fault is 25%. The truck will proportionally reduce speed from 100%- (CURVE
CUTBACK) as the steer wheel is turned from 8°-90°. The rate of deceleration
is controlled by CURVE BRAKING.
15. CURVE CUTBACK #1 This parameter reduces the travel speed more than curve cutback when
the steer wheel is at 20° if set lower than 100%. Default is 80%. The rate of
deceleration is controlled by CURVE BRAKING.
16. FREQUENCY CREEP Minimum speed when the forward or reverse position of the control handle
(DO NOT CHANGE) is at it’s minimum position. Default is 0.30Hz. DO NOT CHANGE.
17. MAXIMUM CURRENT Changes the maximum current of the controller. Default is level 9. DO NOT
(DO NOT CHANGE) CHANGE.
18. AUXILIARY TIME NOT USED ON ESX
19. PARK SPEED LIMIT Speed threshold for the alarm INCORRECT PARK (AL036). Default is 29Hz.
(DO NOT CHANGE) DO NOT CHANGE.

20. ACC SMOOTH ACC SMOOTH controls the acceleration rate, when the speed request is be-
tween 0 Hz and the frequency setting defined by STOP SMOOTH. When
the speed request is above the STOP SMOOTH value, then the parameter
ACCELERATION DELAY controls the acceleration rate. Adjusting this level
changes the time (in seconds) required to accelerate the truck. The lower
the acceleration level the more aggressive the acceleration is. Default is
2.5 sec.
21. INV SMOOTH INV SMOOTH is similar to ACC SMOOTH, but it controls the acceleration rate
after the truck is plugged to a complete stop and starts to accelerate in the
opposite direction. Default is 1.0 sec.
22. STOP SMOOTH Sets the frequency point where ACC SMOOTH stops and ACCELERATION
DELAY starts. Default is 20Hz.
NOTE: See Group 19, Section 7 for Clark factory recommended settings
PARAMETERS PROGRAM LEVEL

Unit 0 1 2 3 4 5 6 7 8 9
Acceleration Delay (*) Sec. 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5
Release Braking (**) Sec. 20 10 8 4 3.5 3 2.5 2 1.5 1
Inversion Braking (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
DO NOT ADJUST BELOW
LEVEL 7
Speed Limit Braking (**) Sec. 8.9 8.3 7.7 7.1 6.6 6 5.5 4.9 4.4 3.8
Curve Braking Sec. 5 3 1.5 1.2 1.1 1 0.9 0.8 0.7 0.6
Adjustment #1 % Normal % -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.6 2.8
Adjustment #2 % Normal % -2.8 -2.2 -1.7 -1.1 -.06 0 0.6 1.1 1.6 2.8
(*) The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp
calculated by the software; the real ramp could change as a function of motor con-
trol parameter setting and, obviously, a function of the load.
(**) The braking feature is base on deceleration ramps. The value shown in the table
is the time to decrease the speed from 100 Hz to 0 Hz. This is the ideal ramp calcu-
lated by the software; the real ramp could change as a function of motor control
parameter setting and, obviously, a function of the load.
PARAMETERS SPEED EMPTY MPH

MPH 1 2 3 4 5 6 7 7.3
MAX SPEED FORWARD HZ 15 29 44 59 73 87 102 106
MAX SPEED REVERSE HZ 15 29 44 59 73 87 102 106
Maximum speeds are adjustable from 0 Hz to 106 Hz in 1 Hz increments. Forward speed and reverse speeds
can be set independently.

TESTER MENU
Input or output signals can be measured in real time using the TESTER function of the handset. The handset
acts as a multimeter able to read voltage, current and temperature. The following is a list of measurements
for different configurations.
NOTE: Handset Tester: user can verify the state of the following parameters:
MASTER CONTROL
Truck Hour Meter (HRs) Slave Motor Temperature (°C) Cutback Switch1 (ON/
OFF)
Motor Voltage (%) FWD/REV Request (V) Cutback Switch2 (ON/
OFF)
Frequency (Hz) Tilt Sensor Volt (V) High/Low Switch (ON/
OFF)
Encoder (Hz) Steer Angle (°) Voltage Booster (%)
Slip Value (Hz) Internal Wheel Cutback (%) Battery Voltage (V)
Current RMS (A) Forward Switch (ON/OFF) Battery Charge (%)
Temperature (°C) Reverse Switch (ON/OFF)
Master Motor Temperature (°C) Operator Pedal Switch (ON/OFF)
Master Control - “Dualac2”
1. TRUCK HOUR METER Shows truck hour meter

2. MOTOR VOLTAGE This is the voltage supplied to the motor by the controller; it is expressed as
a percentage of full battery voltage.
3. FREQUENCY This is the frequency of the voltage and current supplied to the motor.
4. ENCODER This is the speed of the motor, expressed in the same unit of the frequency;
this information comes from the speed sensor.
5. SLIP VALUE This is the difference of speed between the rotating field and the shaft of
the motor, expressed in the same unit of the frequency.
6. CURRENT RMS Root Mean Square value of the motor current.
7. TEMPERATURE The controller temperature measured on the aluminum heat sink holding
the MOSFET devices.
8. M. MOTOR TEMP. This is the temperature of the right (master) motor.
9. S. MOTOR TEMP. This is the temperature of the left (slave) motor.
10. FWD/REV REQUEST The voltage of the control handles output for travel direction. The voltage
level is shown on the left-hand side of the Handset display and the value in
percentage is shown on the right-hand side.
11. RACK HEIGHT VOLT NOT USED ON ESX.
12. TILT SENSOR VOLT This is the voltage Tilt Angle Sensor output.
13. STEER ANGLE This is the steer angle read by the control from the steer pot output.

14. INT. WHEEL CUTB. This is an indication of the speed reduction applied to the inside wheel; in
other words, it shows the ratio of the two speeds.
15. FORWARD SWITCH The position of the Forward direction digital input FW.
ON /+BV = input active, switch closed.
OFF / GND = input non-active, switch open.
16. REVERSE SWITCH The position of the Reverse direction digital input BW.
17. ENABLE SWITCH: NOT USED ON ESX
18. OPER. PEDAL SW The position of the operator presence switch.
19. CUTBACK SWITCH #1 The position of the Speed Reduction microswitch. NOT USED ON ESX.
20. CUTBACK SWITCH #2 The position of Speed Reduction from pump controller.
21. HIGH/LOW SWITCH The position of high/low switch mounted to upright.
22. BRAKE SWITCH NOT USED ON ESX
23. EXCLUSIVE HYDRO NOT USED ON ESX
24. BRAKEPEDAL POT. NOT USED ON ESX
25. HAND BRAKE NOT USED ON ESX
26. VOLTAGE BOOSTER This is the booster voltage supplied to the motor in load condition. It is ex-
pressed in a percentage of the full voltage.
27. BATTERY VOLTAGE Level of the battery voltage measured at the input of the key switch.
28. BATTERY CHARGE The calculated percentage charge level of the battery.

Slave Control - “Dualac2”
ESX Handset Layout - Slave
HEADING
Enter
Roll Up
Parameter
Not Available
Change
Set Options No Available
Roll Up
Enter Motor Voltage % Roll Up

Tester
Frequency Hz Enter Set Battery Type 36 / 48
Adjustments
Encoder Hz Adjust Battery V
Slip Value Hz Horn Output Volt V
Current RMS A
Temperature °C
Roll Up Voltage Booster %
Battery Voltage V
Battery Current A
Operator Pedal Switch ON /OFF
Forw Switch ON /OFF
Back Switch ON /OFF
Enable Switch ON /OFF
Roll Up
Restore
Roll Up
Enter
Roll Up

Roll Up
1. SET BATTERY TYPE Selects nominal battery voltage. Default is 36V. (See Set Battery Type pro-
cedure at end of this section)
3. HORN OUTPUT VOLT This parameter adjusts the voltage of the horn output. Default is 36V.
NOTE: See Group 19, Section 7 for ESX Factory Control Settings

TESTER MENU
The most important input or output signals can be measured in real time using the TESTER function of the
handset. The handset acts as a multimeter able to read voltage, current and temperature. The following is
a list of measurements for different configurations.
Handset Tester: user can verify the state of the following parameters:
SLAVE CONTROL
Motor Voltage (%) Current RMS (A) Battery Current (A)
Frequency (Hz) Temperature (°C) Operator Pedal Switch
(ON/OFF)
Encoder (Hz) Voltage Booster (%) Forward Switch (ON/OFF)
Slip Value (Hz) Battery Voltage (V) Reverse Switch (ON/OFF)
Slave Control - “Dualac2”
the MOSFET devices.
7. VOLTAGE BOOSTER This is the booster voltage supplied to the motor in load condition. It is ex-
9. BATTERY CURRENT The calculated percentage charge level of the battery.
10. OPER. PEDAL SW. The position of the operator presence switch.
11. FORWARD SWITCH The position of the Forward direction digital input FW.
12. REVERSE SWITCH The position of the Reverse direction digital input BW.
13. ENABLE SWITCH NOT USED ON ESX

PUMP CONTROL
ESX Handset Layout - Slave
HEADING
Enter
Roll Up
Parameter Enter Lift Acceleration Delay 0-9
Change Lift Deceleration Delay 0-9 Enter Hour Counter Running / Key On
Set Options
Tilt Acceleration Delay 0-9 Set Temperature Analog / Digital / None
Tilt Deceleration Delay 0-9 Hydro Function Running / Exclusive Hydro
Aux1 Acceleration Delay 0-9 Thermal Protection ON /OFF
Aux1 Deceleration Delay 0-9 Roll Up Tilt Sensor ON /OFF
Aux2 Acceleration Delay 0-9
Aux2 Deceleration Delay 0-9
Max Speed Up Hz Enter Full Forward Tilt V
Adjustments
Roll Up Min Speed Up Hz Full Back Tilt V
AUX1 Speed Mast Low HZ Full FWD Angle °
AUX1 Speed Mast High % Full Back Angle °
AUX1 Valve Percentage % Restricted FWD Angle °
AUX2 Speed Mast Low HZ Restricted BACK Angle °
AUX2 Speed Mast High % Mast Vertical °
AUX2 Valve Percentage % Max. Pot Lift V
Tilt Speed Mast Low HZ Max. Pot Lower V
Tilt Speed Mast High % Neutral Lift-Lower V
Tilt Valve Percentage % Max.Joy2 Right V
Hydro Speed Fine Hz Max. Joy2 Left V
Idle Speed Hz Neutral2 Left-Right V
Idle Time 0-9 Max.Joy2 Up V
Maximum Current 0-9 Max.Joy2 Down V
Auxilary Time Sec Neutral2 Up-Down V
Deadband Lift-Lower %
Deadband Joy2 %
Enter Hour Meter Truck Hrs Set Battery Type 36 / 48
Tester
Motor Voltage % Adjust Battery V
Frequency Hz Throttle 0 Zone %
Encoder Hz Throttle X Zone %
Slip Value Hz Throttle Y Zone %
Current RMS A Throttle2 0 Zone %
Temperature °C Throttle2 X Zone %
Motor Temperature °C Throttle2 Y Zone %
Lift Switch ON /OFF Adjustment #04 °C
Lower Switch ON /OFF Motor Shutdown °C
Aux 1 Right Switch ON /OFF Imax Protection 1-9
Aux 1 Left Switch ON /OFF Adjustment #03 °C
Aux 2 Right Switch ON /OFF PWM on Main Contactor ON /OFF
Aux 2 Left Switch ON /OFF PWM on Aux Contactor ON /OFF
Roll Up Tilt FWD Switch ON /OFF MC Aux Coil Volt V
Tilt BACK Switch ON /OFF MC Aux Percentage %
VM Tilt FWD Switch ON /OFF Mast Speed Approach Hz
VM Tilt BACK Switch ON /OFF Mast Approach Range 0-9
Vert Mast Button ON /OFF Second Stage CB %
Horn Button ON /OFF Multifunction Add Open %
High / Low Switch ON /OFF
Hydro Speed Req ON /OFF
Lift / Lower Request V
Aux Request V
Tilt Request V
Tilt Sensor Voltage V
Cutback Switch ON /OFF
Voltage Booster %
Battery Voltage V
Battery Current A
Roll Up
Restore
Roll Up
Enter
Roll Up

Roll Up

See Group 19, Section 7 for ESX Factory Control Settings

1. HOUR COUNTER
RUNNING (Default) The meter registers pump motor time only.
KEY ON The meter registers when the “key” is closed
2. SET TEMPERATURE Must be ANALOG. DO NOT CHANGE.
(DO NOT CHANGE)
3. HYDRO FUNCTION Must be RUNNING. DO NOT CHANGE.
(DO NOT CHANGE)
4. THERM PROTECTION DO NOT CHANGE.
(DO NOT CHANGE)
5. TILT SENSOR
ON (Default) Must be turned ON during normal operation.
OFF Only used to acquire tilt sensor and set tilt angles by trained mechanic.
1. FULL FWD TILT Records the voltage value of the tilt sensor when tilt is in the full forward
position and forks low. Value should be approx. 0.3V & cannot be below
0.2V. (See Group 19, Section 3 for acquiring procedure)
2. FULL BACK TILT Records the voltage value of the tilt sensor when tilt is in the full backward
position and forks low. Value should be approx. 4.7V & cannot be above
4.8V. (See Group 19, Section 3 for acquiring procedure)
3. FULL FWD ANGLE Set the full forward angle when forks are in the low position. Default is 6.0°.
This angle should be measured to the nearest tenth of a degree using an
inclinometer placed on the outer rail of the upright. (Refer to upright tilt
chart)
4. FULL BACK ANGLE Set the full backward angle when forks are in the low position. Default is
-8.0°. This angle should be measured to the nearest tenth of a degree using
an inclinometer placed on the outer rail of the upright. (Refer to upright
tilt chart)
5. RESTRICTED FWD Set the restricted forward angle when forks are in the high position. De-
fault is 1.5°. (Refer to upright tilt chart)
6. RESTRICTED BACK Set the restricted backward angle when forks are in the high position. This
value will be different depending on the MFH of the upright. Default is
-5.0°. (Refer to upright tilt chart) The restricted back tilt amount will be
stamped on the data plate.
7. MAST VERTICAL Set the vertical angle of the upright. Adjust this value to calibrate the two-
way fork leveling feature. This value can be adjusted to compensate for tire
wear, upright deflection, and other factors that will cause the horizontal
geometry of the truck to change over time. Default is 0.0°.
8. MAX. POT LIFT Records the voltage value of the control handle when holding in the maxi-
mum lift position. Value should be approx. 0.5V. (See Group 13, Section 4
for acquiring procedure)

9. MAX. POT LOWER Records the voltage value of the control handle when holding in the maxi-
mum lower position. Value should be approx. 4.5V. (See Group 13, Section
4 for acquiring procedure)
10. NEUTRAL LIFT-LOW Records the voltage value of the control handle when released and returns
to the neutral position. Value should be approx. 2.5V. (See Group 13, Sec-
11. MAX. JOY2 RIGHT Records the voltage value of the mini joystick when holding in the maxi-
mum right position. Value should be approx. 4.5V. (See Group 13, Section
12. MAX. JOY2 LEFT Records the voltage value of the mini joystick when holding in the maxi-
mum left position. Value should be approx. 0.5V. (See Group 13, Section 4
13. NEUTRAL LT-RT Records the voltage value of the mini joystick when released and returns to
the neutral position. Value should be approx. 2.5V. (See Group 13, Section
14. MAX. JOY2 UP Records the voltage value of the mini joystick when holding in the maxi-
mum up position. Value should be approx. 4.5V. (See Group 13, Section 4
15. MAX JOY2 DOWN Records the voltage value of the mini joystick when holding in the maxi-
mum down position. Value should be approx. 0.5V. (See Group 13, Section
16. NEUTRAL UP-DOWN Records the voltage value of the mini joystick when released and returns to
the neutral position. Value should be approx. 2.5V. (See Group 13, Section
17. DEADBAND LIF-LOW Percentage of deadband from neutral position of control handle. Default
is 14%.
18. DEADBAND JOY2 Percentage of deadband from neutral position of control handle. Default
is 14%.
19. SET BATTERY TYPE Selects nominal battery voltage. Default is 36V. (See Set Battery Type pro-
cedure at end of this section)
20. ADJUST BATTERY Fine adjustment of battery voltage measured by the controller.
21. THROTTLE 0 ZONE This parameter is a percentage of control handle lift/lower movement for
maintaining a slow pump motor rpm. How long the pump motor speed
stays at MIN SPEED LIFT setting before accelerating. Default is 3%.
22. THROTTLE X POINT This parameter changes the characteristics of the lift/lower input curve.
23. THROTTLE Y POINT This parameter changes the characteristics of the lift/lower input curve.
24. THROTTLE2 0 ZONE This parameter is a percentage of mini joystick movement for maintaining
a slow pump motor rpm. How long the pump motor speed stays at MIN
SPEED LIFT setting before accelerating. Default is 3%.

SPEED (Hz)
MAX SPEED LIFT
THROTTLE
Y POINT
MIN SPEED
LIFT
CONTROL
HANDLE
THROTTLE MAX VOLTAGE
X POT
NEUTRAL
THROTTLE POINT LIFT
LIFT-LOW
0
ZONE
DEADBAND
LIFT-LOW
NEUTRAL LIFT-LOW and MAX POT LIFT are values acquired in the ADJUSTMENTS MENU.
The control handle acquiring procedure programs the actual minimum and maximum input volt-
ages from the control handle.
NOTE: See Group 13, Section 4 for acquiring procedure.
25. THROT2 X POINT This parameter changes the characteristics of the mini joystick input
curve.
26. THROT2 Y POINT This parameter changes the characteristics of the mini joystick input
curve.
27. ADJUSTMENT #04 To set the temperature when the warning alarm (AL207) of motor overheat-
(DO NOT CHANGE) ing displays. The warning temperature is 130°C. DO NOT CHANGE.
28. MOTOR SHUTDOWN To set the motor temperature when the “Motor shutdown” alarm (AL171)
(DO NOT CHANGE) displays. The shutdown temperature is 145°C. DO NOT CHANGE.
29. IMAX PROTECTION The value to start the current reduction when the motor temperature
(DO NOT CHANGE) reaches adjustment #4 value. DO NOT CHANGE.
30. ADJUSTMENT #03 DO NOT CHANGE.
(DO NOT CHANGE)
31. PWM ON MAIN CONT. Selects between PWM or ON/OFF operation of line contactor. Default is
(DO NOT CHANGE) ON. DO NOT CHANGE.
32. PWM ON AUX. OUT. Selects between PWM or ON/OFF operation of aux output. Default is OFF.
NOT USED ON ESX.
33. MC AUX COIL VOLT Adjusts the line contactor coil voltage. Default is 36V. DO NOT CHANGE.
(DO NOT CHANGE)
34. MC AUX PERC. Adjusts the holding voltage of the line contactor after pull in. Default is
60%.
35. MAST SPEED APPR. Frequency that pump motor reduces to when upright tilt is within the MAST
APPR RANGE. Default is 25Hz.

36. MAST APPR. RANGE This is the range around the MAST VERTICAL, RESTRICTED FWD, and RE-
STRICTED BACK electronic tilt positions that the pump motor will reduce
speed to MAST SPEED APPR. This parameter allows the tilt speed to be
slower when approaching one of the electronic tilt stops so that the up-
right will stop tilting accurately. Default is level 5.
37. SECOND STAGE CB Default is 100%. DO NOT CHANGE.
(DO NOT CHANGE)
38. MULTIF. ADD OPEN Additional percentage that valves open during multifunctioning. Default
is 0.0%
1. LIFT ACC. DELAY Lift acceleration delay of pump motor. Default is level 0.
2. LIFT DEC. DELAY Lift deceleration delay of pump motor. Default is level 0.
3. TILT ACC. DELAY Tilt acceleration delay of pump motor. Default is level 0.
4. TILT DEC. DELAY Tilt deceleration delay of pump motor. Default is level 0.
5. AUX1 ACC. DELAY Aux1 acceleration delay of pump motor. Default is level 0.
6. AUX1 DEC. DELAY Aux1 deceleration delay of pump motor. Default is level 0.
7. AUX2 ACC. DELAY Aux2 acceleration delay of pump motor. Default is level 0.
8. AUX2 DEC. DELAY Aux2 deceleration delay of pump motor. Default is level 0.
9. MAX SPEED LIFT Determines the maximum lifting speed. Default is 110Hz. Maximum lift
speed for 36V ESX should not exceed 110Hz and maximum lift speed for
48V ESX should not exceed 125Hz.
10. MIN SPEED LIFT Determines the minimum lifting speed. Default is 16.5Hz.
11. AUX1 SPD MAST LO Determines the maximum aux1 speed when forks are in low position. De-
fault is 32Hz. (See Aux flow charts for adjustments)
12. AUX1 SPD MAST HI Determines the maximum aux1 speed when forks are in high position. This
is a percentage of the AUX1 SPD MAST LO value. Default is 80%. (See Aux
flow charts for adjustments)
13. AUX1 VALVE PERC. Determines the maximum aux1 valve opening (current) when forks are in
the high position. This is a percentage of the MAX EVP3 AUX A1 & MAX
EVP4 AUX A2 in the valve control. Default is 83.5%. (See Aux flow charts for
adjustments)
14. AUX2 SPD MAST LO Determines the maximum aux2 speed when forks are in low position. De-
fault is 51Hz. (See Aux flow charts for adjustments)
15. AUX2 SPD MAST HI Determines the maximum aux2 speed when forks are in high position. This
is a percentage of the AUX2 SPD MAST LO value. Default is 100%. (See Aux
flow charts for adjustments)
16. AUX2 VALVE PERC. Determines the maximum aux2 valve opening (current) when forks are in
the high position. This is a percentage of the MAX EVP7 AUX A3 & MAX
EVP8 AUX A4 in the valve control. Default is 100%. (See Aux flow charts for
adjustments)
17. TILT SPD MAST LO Determines the maximum tilt speed when forks are in low position. Default
is 44Hz. (See upright tilt charts). CONSULT CLARK BEFORE ADJUSTING.

18. TILT SPD MAST HI Determines the maximum tilt speed when forks are in high position. This is
a percentage of the TILT SPD MAST LO value. Default is 64.3%. (See upright
tilt charts). CONSULT CLARK BEFORE ADJUSTING.
19. TILT VALVE PERC. Determines the maximum tilt valve opening (current) when forks are in the
high position. This is a percentage of the MAX EVP5 TILT BK & MAX EVP6
TILT FW in the valve control. Default is 69%. (See upright tilt charts). CON-
SULT CLARK BEFORE ADJUSTING.
20. HYD SPEED FINE Sets the idle speed of the pump motor for steering. Default is 16Hz.
21. IDLE SPEED Default is 12Hz. NOT USED ON ESX
22. IDLE TIME Sets the amount of time that IDLE SPEED will run before stopping the pump
motor. Default is level 5. NOT USED ON ESX.
23. MAXIMUM CURRENT Maximum current of the controller (See Tables Below). Default is level 9.
24. AUXILIARY TIME Time delay when HYD SPEED FINE (idle for steering) request is switched off.
(DO NOT CHANGE) This is the delay after raising the operator pedal switch. Default is 4sec. DO
NOT CHANGE.
The following tables show the different value at which the parameters can be set.
PARAMETERS PROGRAM LEVEL

UNIT 0 1 2 3 4 5 6 7 8 9
Acceleration Delay Lift Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Deceleration Delay Lift Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Acceleration Delay Tilt Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Deceleration Delay Tilt Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Acceleration Delay Aux1 Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Deceleration Delay Aux1 Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Acceleration Delay Aux2 Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Deceleration Delay Aux2 Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Maximum Current % IMAX 47 23 58 64 70 76 82 88 94 100
(*) The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal
ramp calculated by the software; the real ramp could change as a function of motor
control parameter setting and, obviously, a function of the load.
(**) The braking feature is base on deceleration ramps. The value shown in the table
is the time to decrease the speed from 100 Hz to 0 Hz. This is the ideal ramp calcu-
lated by the software; the real ramp could change as a function of motor control
parameter setting and, obviously, a function of the load.
TESTER MENU

The most important input or output signals can be measured in real time using the TESTER function of the
handset. The handset acts as a multimeter able to read voltage, current and temperature. The following is
a list of measurements for different configurations.
Handset Tester: user can verify the state of the following parameters:
PUMP CONTROL
Hour Meter Truck (Hrs) Aux1 Right Switch (ON/OFF) High/Low Switch (ON/OFF)
Motor Voltage (%) Aux1 Left Switch (ON/OFF) Lift/Lower Request (V)
Frequency (Hz) Aux2 Right Switch (ON/OFF) Aux Request (V)
Encoder (Hz) Aux2 Left Switch (ON/OFF) Tilt Request (V)
Slip Value (Hz) Tilt Forward Switch (ON/OFF) Tilt Sensor Voltage (V)
Current RMS (A) Tilt Back Switch (ON/OFF) Voltage Booster (%)
Temperature (°C) VM Tilt Forward Switch (ON/OFF) Battery Voltage (V)
Motor Temperature (°C) VM Tilt Back Switch (ON/OFF) Battery Current (A)
Lift Switch (ON/OFF) Vertical Mast Button (ON/OFF)
Lower Switch (ON/OFF) Horn Button (ON/OFF)
1. HOUR METER TRUCK Shows truck hour meter.
the MOSFET devices.
8. MOTOR TEMPERATURE This is the temperature of the pump motor.
9. LIFT SWITCH The position of the lifting digital input.
10. LOWER SWITCH The position of the lowering digital input.
11. AUX1 RIGHT SW The position of the aux1 right digital input.
12. AUX1 LEFT SW The position of the aux1 left digital input.

13. AUX2 RIGHT SW The position of the aux2 right digital input.
14. AUX2 LEFT SW The position of the aux2 right digital input.
15. TILT FWD SWITCH The position of the aux2 right digital input.
16. TILT BACK SWITCH The position of the aux2 right digital input.
17. VM TILT FWD SW The position of the aux2 right digital input.
18. VM TILT BACK SW The position of the aux2 right digital input.
19. VERT MAST BUTTON The position of the vertical mast button digital input.
20. HORN BUTTON The position of the horn button digital input.
21. HIGH/LOW SWITCH The position of the high/low switch that is mounted to the upright.
22. HRYDRO SPEED REQ. NOT USED ON ESX
23. LIFT/LOWER REQ. The voltage of the control handles output for lift/lower direction. The volt-
age level is shown on the left-hand side of the Handset display and the
value in percentage is shown on the right-hand side.
24. AUX REQUEST The voltage of the mini joystick output for aux1 (left/right) direction. The
voltage level is shown on the left-hand side of the Handset display and the
25. TILT REQUEST The voltage of the mini joystick output for tilt (up/down) direction. The volt-
age level is shown on the left-hand side of the Handset display and the
26. TILT SENSOR VOLT The voltage of the tilt sensor output.
27. CUTBACK SWITCH NOT USED ON ESX

28. VOLTAGE BOOSTER This is the booster voltage supplied to the motor in load condition; It is ex-
30. BATTERY CURRENT This is the battery current, not measured but calculated.
VALVE CONTROL
ESX Handset Layout - Valve


1. SET BATTERY TYPE Selects nominal battery voltage. 36V (Default) or 48V. (See Set Battery Type
procedure at end of this section)
2. VALVE SUPPLY DIG Chooses voltage to be supplied to ON/OFF valve coils. NOT USED ON ESX
3. VALVE SUPPLY ANL (DO Chooses voltage to be supplied to proportional valve coils. Default is 36V.
NOT CHANGE) DO NOT CHANGE.
4. EVP TYPE UNLOAD (DO Chooses valve type ON/OFF or proportional. Default is Analog. DO NOT
NOT CHANGE) CHANGE.
5. EVP1 TYPE LOWER Chooses valve type ON/OFF or proportional. Default is Analog. DO NOT
6. EVP2 TYPE LIFT Chooses valve type ON/OFF or proportional. Default is Analog. DO NOT
7. EVP3 TYPE AUX A1 Chooses valve type ON/OFF or proportional. Default is Analog. DO NOT
9. EVP5 TYPE TB Chooses valve type ON/OFF or proportional. Default is Analog. DO NOT
10. EVP6 TYPE TF Chooses valve type ON/OFF or proportional. Default is Analog. DO NOT
13. VALVE CALIB MODE Normal operation is OFF. When turned ON, the valve calibration routine is
activated so that the valve coils can be fined tuned. See valve calibra-
tion routine for details.
After completing the valve calibration routine, the values for the min and max values will be different than
the default value. Make sure you understand these parameters and how they affect truck behavior before
making any changes or adjustments. Also refer to the Aux Flow Chart for valve opening to flow relation-
ship.
1. MIN EVP UNLOADER Minimum current applied to valve coil. Default is 14.9% (149mA). DO NOT
2. MAX EVP UNLOADER Maximum current applied to valve coil. Default is 48.2% (482mA). DO NOT
3. MIN EVP1 LOWER Minimum current applied to valve coil. Default is 25.0% (250mA).

4. MAX EVP1 LOWER Maximum current applied to valve coil. Default is 56.1% (561mA). Decreas-
ing this value will slow down the maximum lowering speed. Increasing this
value will increase maximum lowering speed. DO NOT increase the lower-
ing speeds more than 100fpm when fully loaded. Also, when fully loaded
and hydraulic oil warm, flow limiters (velocity fuses) at upright cylinders
must not trip or lowering speeds are too fast.
5. MIN EVP2 LIFT Minimum current applied to valve coil. Default is 27.0% (270mA).
6. MAX EVP2 LIFT Maximum current applied to valve coil. Default is 80.0% (800mA).
7. MIN EVP3 AUX A1 Minimum current applied to valve coil. Default is 29.4% (294mA).
8. MAX EVP3 AUX A1 Maximum current applied to valve coil. Default is 50.1% (501mA).
11. MIN EVP5 TILT BK Minimum current applied to valve coil. Default is 29.4% (294mA).
12. MAX EVP5 TILT BK Maximum current applied to valve coil. Default is 66.6% (666mA).
13. MIN EVP6 TILT FW Minimum current applied to valve coil. Default is 29.4% (294mA).
14. MAX EVP6 TILT FW Maximum current applied to valve coil. Default is 66.6% (666mA).
19. UNLD OPEN DELAY Delay to open the unloader valve. Default is 0.0. DO NOT CHANGE.
(DO NOT CHANGE)
20. UNLD CLOSE DELAY Delay to close the unloader valve. Default is 0.0. DO NOT CHANGE.
(DO NOT CHANGE)
21. LOWER OPEN DELAY Delay to open the lower valve. Default is 0.3.
22. LOWER CLOS DELAY Delay to close the lower valve. Default is 0.2. Lowering this value will cause
the lowering valve to close more abruptly, which can cause the truck to
bounce in a loaded condition.
23. LIFT OPEN DELAY Delay to open the lift valve. Default is 0.0.
24. LIFT CLOSE DELAY Delay to close the lift valve. Default is 0.3. Lowering this value will cause
the lift valve to close more abruptly.
25. A1 OPEN DELAY Delay to open the Aux A1 valve. Default is 0.0.
26. A1 CLOSE DELAY Delay to close the Aux A1 valve. Default is 0.0.
29. TB OPEN DELAY Delay to open the tilt back valve. Default is 0.0.
30. TB CLOSE DELAY Delay to close the tilt back valve. Default is 0.0.
31. TF OPEN DELAY Delay to open the tilt forward valve. Default is 0.0.
32. TF CLOSE DELAY Delay to close the tilt forward valve. Default is 0.0.
OTHER HANDSET FUNCTIONS
Save and Restore Function
NOTE: DO NOT USE THE SAVE OR RESTORE FUNCTIONS VIA THE HANDSET OR PC CON-
SOLE. USE OF THESE FUNCTIONS CAN CAUSE TRUCK MALFUNCTIONS.
“SET BATTERY TYPE” PROCEDURE

The “Set Battery Type” in the master, slave, pump, and valve controls is used to change a truck from 36V to
48V or vice-versa. In order, each of the controls must have their battery type changed. Start with the master
control and go into the adjustments menu and change the “Set Battery Type” to 48V and save. Then go to
the slave control and the pump control and do the same. Next go to the valve controls set options menu to
find the “Set Battery Type”. After changing each of the 4 controls and saving each one, you must acquire the
control handle, the steer pot, the tilt sensor, and calibrate the valve. (Refer to Group 13 for control handle
and steer pot. Refer to Group 19 for the tilt sensor and valve calibration).
The only difference between the 36V and 48V ESX truck is the pump. The 36V truck has a pump with higher
flow than the 48V truck. The contactors and brakes on both are 36V. After changing the “Set Battery Type”
the new defaults are automatically stored in each of the controls. (Refer to Group 19, Section 8 for factory
defaults if needed).

ESX Fault Codes
Fault Fault Name Fault Control Troubleshooting Action
Code Description Required
1 "NO SEAT No input from MASTER or Controller detects the operator pedal Repair operator
SWITCH" seat switch SLAVE switch is open during operation. pedal switch
wiring
Check operator pedal switch wiring
and connections Replace operator
pedal switch
Check for inoperative operative pedal
switch.
6 “20% BATT Warning: the MASTER This alarm is set when the battery
WARNING” battery has reaches 30% of charge (20% on MDI
reached 30% of Guage). The MDI will blink to warn
charge the operator that lift-lock will occur
shortly.
8 "WATCHDOG" Watchdog circuit MASTER It is a self-diagnosing test within the If alarm is
has been logic between Master and Slave persistent and
triggered micro controllers. CANBUS
communication is
This fault could also be caused by a working well,
CAN-BUS malfunction, which blinds replace the
Master -Slave communication. So , controller.
before replacing the controller, check
the Canbus
13 "EEPROM KO" Warning: MASTER Fault in the area of memory in which
EEprom fault the adjustment parameters are
controller will stored;
use default
parameters This fault does not inhibit truck
operation, but the controller will use
default parameters.
If fault persists when key is switched

OFF and ON again.
If the fault disappears, remember that

the parameters stored previously
have been cancelled and replaced by
the default values. Replace controller
17 "LOGIC FAILURE Failure in MASTER Fault in the hardware section of the
#3 overload logic board that manages the
protection hardware current protection. Replace controller
hardware circuit
18 "LOGIC FAILURE Failure in U,V,W MASTER Contactor not closing, check for
#2 voltage correct contactor voltage.
feedback circuit
Fault in the hardware section of the
logic board that manages the phase's
voltage feedback. Replace controller
ESX Fault Codes
19 "LOGIC FAILURE An over voltage MASTER This fault signals that the under If the alarm is
#1 or under voltage voltage / over voltage protection persistent, check
condition has interrupt has been triggered that the correct
been detected battery voltage is
A real under voltage / over voltage at being used.
the key input (C3) happened. Voltage
has been below 16V
A real over voltage on the +Battery Check for voltage

happened, voltage has been higher spikes caused by
than 63V. other devices
connected
Fault in the hardware section of the downstream of
logic board that manages the over the LC.
voltage protection.
Possible plugging in or unplugging of

battery or charger with the key switch
on.
Replace controller
ESX Fault Codes
30 "VMN LOW" Wrong voltage MASTER This test is carried out during initial
on motor power diagnosis and in standby. Possible
outputs; failure causes
in the power
section or in the A real under voltage / over voltage Check Voltage at
mosfet driver situation occurred. +BATT of the
circuit or in the controller.
motor Problem with motor connections or Should be within
the motor power circuit; check if the 3 5V of battery
phases are correctly connected; voltage.
check if there's chassis ground of the Check with
motor to truck frame. contactor open
and closed.
Diode Test: Place POS lead on
Battery NEG and check to all 3
phases. Place NEG lead on Battery
POS and check to all 3 phases.
unhook battery at controller and do a

diode check between Batt + and Batt
- (should read .3 to .5 volts)
Unhook motor cables from controller

and do a diode test between Batt+
and all three phases, U,V,W. Check
between Batt- and all three phases,
U,V,W (should read .3 to .5 volts).
Fault in the inverter power section..
Replace controller
31 "VMN HIGH" Wrong voltage MASTER This test is carried out during initial
outputs; failure causes:
in the power
section or in the Problem with motor connections or Check Voltage at
mosfet driver +BATT of the
the motor power circuit; check if the 3
circuit or in the phases are correctly connected; controller.
motor check if there's chassis ground of theShould be within
motor to truck frame. 5V of battery
voltage.
Unhook battery at controller and do a Check with
diode check between Batt + and Batt contactor open
- (should read .3 to .5 volts) and closed.
Possible high battery voltage to the

case of the battery.
Fault in the controller power section. Replace controller

ESX Fault Codes
32 “MOVE OUT OF X-axis signal is MASTER This alarm is set when the input value Acquire joystick
RANGE” greater than the for X-axis is greater of the acquired
acquired value value (“MAX JOY FORWARD” or Verify the joystick
“MAX JOY REVERSE”) plus a fixed output
offset. It is suggested to perform a
joystick acquisition and verify the
joystick output.
Check for 5V power to joystick from
tiller card.
Check 1Amp Fuse F-8.
33 “MOVE FUNCT. X-axis signals MASTER The controller will check the Check the joystick
KO” are not consistency of the 2 signal from the output, the wiring
complementary joystick (C2 and A10 on tiller card), if on C2 and A10
the two signals are not on tiller card, tiller
complementary the inverter will set card power, CAN
the alarm. bus line between
tiller card and
dual-ac2
Replace base of
joystick.
34 “AQUIRE JOY MASTER Controller still contains default Perform joystick
STICK” joystick values. Acquisition
35 “TILLER STUF Heart bit on MASTER This alarm is set on master when it Verify the CAN
KO” Tiller can didn’t see the heart bit change on bus
message didn’t tiller can message, at each message connection/error
change how (BIT6 of BYTE1 on ID 0x3A0). To frame
request recover from this alarm you need to
turn OFF, turn ON the truck. It is
suggested to verify the CAN bus
36 “INCORRECT Operator pedal MASTER This alarm is set when the operator Operator may be
PARK” switch opened pedal switch is opened when the abusing park
at high speed speed of the truck is greater than the brake
threshold defined by the “PARK
SPEED LIMIT” parameter
37 “CONTACTOR Line contactor MASTER Before driving the line contactor coil, Check contactor
CLOSED” power contact the controller checks if the line tips
closed at power contactor is stuck. The controller
up drives the bridge for a while, trying to
discharge the capacitor bank. If they
don’t discharge, the fault condition is
entered.
38 “CONTACTOR Line contactor MASTER The controller has driven the line The wires to the
OPEN” power contact contactor, but the contactor did not coil are open or a
does not pull in close. loose connection.
Open fuse or cut Formatted: Bullets and Numbering
cable.
The contact does
not pull in
properly
Check contactor
set voltage.
ESX Fault Codes
53 “STBY I HIGH” Wrong voltage MASTER The microprocessors verify if the Replace
in current feedback of current sensor device Controller
sensor feedback output is within the zero current
circuit window. Possible causes of the fault.
Current sensor failure.
Failure in the controller:

60 “CAPACITOR Power Capacitor MASTER When key is switched on, the Connnect a 200
CHARGE” Voltage does controller tries to charge the ohm, 5W resistor
not increase capacitors through a power resistor, across the
when the key is and check if the capacitor is charged contactor tips. If
turned ON; (1/2 battery volts) within a timeout. If alarm is cleared,
failure in power they do not charge, a fault is controllers
section, or in signaled; the line contactor does not charging circuit is
Logic PCB, or in close. damaged.
driver PCB, or in Replace the
the motor The charging resistor is open control.
The charging circuit has a failure
There is a problem in the power

section.
Possible Motor connection open.
Check voltage between B+ and B- to

see if capacitor charges slow.
61 “ HIGH Warning: Master MASTER Temperature of control is greater than
TEMPERATURE” or Slave or both 75°C. Maximum current reduced
temperature proportionally to the temperature
higher that 75 increase. At 100°C the maximum
degrees C current of both controls is reduced to
zero.
65 “MOTOR TC Warning: Right MASTER or Right or left or both drive motors
START” or left or both SLAVE analog temperature sensor is greater
motors than the temperature set in
temperature ADJUSTMENT #4 (130°C) in the
high (over Adj ADJUSTMENT submenu. Check
#4) temperature
When this fault occurs. Maximum shown on
current is reduced to half and handset in tester
maximum speed is reduced to 60Hz. mode
If it happens when the motor is cold,

check the wring. If all is ok,
Replace controller
66 “BATTERY LOW” Warning: MASTER When battery level reaches 20% or Charge the
Battery charge less or (10% on the dash display), the battery
level below 20% current level for the drive motors is
reduced to 50% of the programmed
level, the travel speed is reduced,
and the lift function is locked out.
ESX Fault Codes
71 “MOTOR Warning: Right MASTER This fault occurs when the right or left
SHUTDOWN” or left or both or both motor temperature switches
motors temp. are open (digital sensor), or if the
are very high analog sensor temperature overtakes
(over MOTOR the cut off level.
SHUTDOWN
param.) The cut off level is adjusted with the
MOTOR SHUTDOWN parameter
(145°C) in the ADJUSTMENT
submenu.
If this fault occurs, maximum current

is reduced to zero and the motor is
stopped.
If the shutdown occurs when the

motor is cold check the wiring. If
wiring is ok
Replace controller
72 “MOTOR Drive motor MASTER After 15 seconds the motor stalled
LOCKED” locked up with maximum current, controller
reduces maximum current to 50%.
Check in line contactor pulled in

74 “DRIVER Line contactor MASTER When the key is turned ON, the
SHORTED” coil driver is microprocessor checks that the line
shorted contactor coil driver is not shorted
If it is, this fault is signaled.
Check if there is an external short or

low impedance pull-down between
NLC (C26) and –Batt.
If no external causes can be found. Replace controller

75 “CONTACTOR Line contactor MASTER When the initial diagnosis is finished,
DRIVER” coil driver is the traction logic closes the line
open (not able contactor and checks the voltage
to drive the coil drain of the driver.
to the correct
voltage) If this is not low, the driver is unable
to close and the fault is signaled. Replace controller
ESX Fault Codes
76 “COIL SHORTED” Init: Line MASTER When the key is turned on, the
contactor coil microprocessor checks the line
driver protection contactor coil driver short circuit
circuit is protection hardware. If it does not
damaged or react in a correct way to the
Stby or running: microprocessor stimulus, the fault is
short on line signaled.
contactor
Alarm also When the fault occurs while the line
applies to EM contactor is closed this indicates a
brake coils short circuit across the line contactor
coil. Check if there is an external
short circuit and if the ohmic value
(105 Ohms) of the line contactor coil Replace
is correct. contactor coil
Check the EM brake diodes. Replace brake

diode.
Check the EM brake wiring.
Check the EM brake coils. Replace brake

coil.
77 “MAINTENANCE Displayed when MASTER This is just an indication that the
HOURS” the normal hour vehicle is due for its Periodic
meter exceeds Maintenance.
the maintenance
hours set for the
vehicle
79 “INCORRECT Warning: Wrong MASTER If SRO FUNCTION is active, every
START (SRO)” traction request time work is stopped the operator
sequence must put the truck in neutral.
This fault If forward or reverse is active when

indicates an key switch is turned on.
incorrect starting
sequence If forward or reverse closed without
operator pedal switch input.
If the fault persist after checking the

wiring and switch, Replace controller
80 “FORWARD + Warning: MASTER Processor is continuously checking
REVERSE” Forward and for a request for forward and reverse
reverse inputs at the same time.
are both active
Defective wiring.
Running micro switch failure.
Incorrect operation.
If defect persist Replace controller

ESX Fault Codes
81 “TH MOTOR Warning: MASTER The range of the motor temperature Check sensor
SENSOR KO” Motor Master analog sensor is always checked and wiring.
temperature a fault is signaled if it’s out of range Check sensor.
sensor is out of
range When this fault occurs. The maximum
current is reduced to half and
maximum speed is reduced to 60 Hz.
82 “ENCODER Motor speed MASTER This fault indicates that the frequency
ERROR” sensor supplied to the motor is greater than
(encoder) does 20 Hz, and the signal feedback from
not work the encoder has a jump higher than
properly 20 Hz in less than ten milliseconds.
This condition clearly shows a
malfunctioning of the encoder signal.
Check encoder wiring; if no fault is

found in the wiring it is necessary to
replace the encoder.
84 “STEER SENSOR Steering MASTER This fault indicates an out of range
KO” Potentiometer steering potentiometer signal.
signal out of
range The fault comes up under the
following two conditions:
The “set Steer 0 pos” (programmed

straight wheel pos) parameter is
wrong (lower than “set steer min) or
higher than “set steer max”)
Check voltage on wire #47, it should

be approx. 12 volts.
If not 12 volts unplug right and left

motor encoders and retest wire #47
again for 12 volts.
If 12 volts on wire # 47, determine

which encoder is shorted.
Check for damaged steer pot.
Check steer pot mounting to ensure

alignment of spring tip.
87 “WATCHDOG” Watchdog circuit SLAVE It is a self-diagnosing test within the If alarm is
has been logic between Master and Slave persistent,
triggered micro controllers. replace the
controller
This fault could also be caused by a
Canbus malfunction, which blinds
Master –Slave communication. So ,
before replacing the controller , check
the Canbus
ESX Fault Codes
92 “WATCHDOG” Watchdog circuit CANTILLER It is a self-diagnosing test within the If alarm is
has been logic persistent,
triggered replace the
controller
93 “CAN BUS KO” ANY Device is unable to read data from
the CANBUS, due to high traffic or
noise. Check CAN BUS wiring and
communincation between controllers.
Alarm will occur on other controllers

in truck when flashing new software
on one control since the CANBUS is
interrupted during flashing.
96 “LOGIC FAILURE Failure in SLAVE Fault in the hardware section of the
#3 overload controller that manages the hardware
protection hw current protection. Replace controller
circuit
97 “LOGIC FAILURE Failure in U,V,W SLAVE Contactor not closing, check for
#2 voltage correct contactor voltage.
feedback circuit
controller that manages the phase‘s
voltage feedback. Replace controller
98 “LOGIC FAILURE An over voltage SLAVE This fault signals that the under See Master
#1 or under voltage voltage / over voltage protection
condition has interrupts been triggered
been detected
A real under voltage / over voltage
situation happened.
Verify battery setting.

controller that manages the over
voltage protection. Replace logic
Card.

on.
99 “TH MOTOR Warning: SLAVE The range of the motor temperature
SENSOR KO” Motor Slave analog sensor is always checked and
temperature a fault is signaled if it’s out of range
sensor is out of
ESX Fault Codes
109 “VMN LOW” Wrong voltage SLAVE This test is carried out during initial
outputs; failure causes: See Master
in the power
section or in the Problem with motor connections or
mosfet driver the motor power circuit; check if the 3
circuit or in the phases are correctly connected;
motor check if there’s chassis ground of the
motor to truck frame.
unhook battery at controller and do a

– (should read .3 to .5 volts)

110 “VMN HIGH” Wrong voltage SLAVE This test is carried out during initial
in the power
Unhook battery at controller and do a


111 “FF VALVE” Problem on Flip- MHYRIO Flip-Flop circuit, that manage On/Off Verify the wiring
Flop circuit valve drivers short circuit protection connection for
ON/OFF valve.
does not reset in the correct way. It is
suggested to check the wiring for Replace the
ON/OFF valve. device
112 “WATCHDOG” Watchdog circuit MHYRIO It is a self-diagnosing test within theIf alarm is
has been logic persistent,
triggered replace the
If an alarm occurs replace the logic controller
113 “HIGH SIDE MHYRIO The high side driver that supplies the Check the Postive
DRIVER KO” valve coils positive is shorted or supply to valves.
open. If at battery volts
Check 10Amp Fuse F-5 in standby, or 0V
when command is
active then
control is
damaged.
114 “EVPG1 DRIVER Lift/Lower MHYRIO One of the GROUP1 valve drivers is Check valve coils.
KO” open (does not close when it is NEV connection
commanded by the microcontroller) should change
from +BATT to 0V
when activated.
ESX Fault Codes
115 “EVPG2 DRIVER Aux1 MHYRIO One of the GROUP2 valve drivers is Check valve coils.
from +BATT to 0V
when activated.
116 “EVPG3 DRIVER Tilt MHYRIO One of the GROUP3 valve drivers is Check valve coils.
from +BATT to 0V
when activated.
117 “EVPG4 DRIVER Aux2 MHYRIO One of the GROUP4 valve drivers is Check valve coils.
from +BATT to 0V
when activated.
118 “COIL SHORTED” MHYRIO ON/OFF valve drivers are protected Check for short
against coil short circuit; if a short is circuits to both
present across the coil, the flip flop connections of
circuit is set and an alarm is signaled. valves.
119 “EV DRIVER MHYRIO One of the on/off valve drivers is Replace control
SHORT” shorted: check external connection, if
connection is ok the driver is probably
damaged.
120 “UNDER MHYRIO This fault is signaled if an under Check voltage at
VOLTAGE” voltage condition is detected in the MYRHIO
MHYRIO power supply. keyswitch input.
Check 7.5Amp Fuse F-4
121 “CAN BUS KO” MHYRIO There is a problem related to the
CAN-BUS line
The error is signaled if the MHYRIO

controller does not receive any
message from the CAN-BUS line.
First of all, check the wiring. If the

wiring is ok replace the controller.
Alarm will occur on valve controller

when flashing new software on pump
control since the CANBUS is
interrupted during flashing.
122 “EVP DRIVER Unloader Valve MHYRIO The unloader valve drivers is open Check valve coil.
KO” (does not close when it is NEV connection
from +BATT to 0V
when activated.
123 “EV DRIVER KO” MHYRIO One of the ON/OFF valve drivers is Check valves.
open (does not close when it is NEV connection
commanded by the microcontroller). should change
from +BATT to 0V
when activated.
124 “EVPG1 DRIVER MHYRIO One of the GROUP1 valve drivers is Replace control
damaged.
ESX Fault Codes
damaged.
damaged.
damaged.
128 “EVP DRIVER MHYRIO The single proportional valve driver is Replace control
damaged.
129 “EEPROM KO” Warning: MHYRIO Fault in the area of memory in which Replace control
Eeprom fault the adjustment parameters are and/or reset
controller will stored; this fault does not inhibit truck defaults
use default operation, but the controller will use
parameters default parameters.
If defect persists when key is

switched OFF and ON again, replace
the control.
If the fault disappears, remember that

the parameters stored previously
have been cancelled and replaced by
the default values.
130 “WAITING FOR The device is MHYRIO The Mhyrio-CB is waiting for the
PEV” waiting the enable message from pump (send
enable message when pump contactor is close) that
from PUMP confirm the presence of Vbat on
Mhyrio-cb PEV input (B2).
Check for alarms on the PUMP
control.
Check connections to PEV on
MYRHIO
Pump contactor is open.
Check 10Amp Fuse F-5
131 “WRONG SET Battery voltage MHYRIO This fault indicates that actual battery
BATTERY” does not voltage is 20% higher or 20% lower
correspond to than “SET BATTERY” parameter
programmed setting. Replace battery
“SET with correct
BATTERY” battery.
ESX Fault Codes
132 “STBY I HIGH” Wrong voltage SLAVE The microprocessors verify if the
in current feedback of current sensor device
circuit window. Possible causes for the
fault.
Failure in the controller Replace controller
If the fault persist.

133 “LO SIDEDRIVER MHYRIO This alarm is set when the MHYRIO-
KO” CB input B2 PEV (Positive for
ElectroValve) is lower than half of
parameter "VALVE SUPPLY ANL".
Check 10Amp Fuse F-5

139 “CAPACITOR Power Capacitor SLAVE When key is switched on, the inverter See Master
CHARGE” Voltage does tries to charge the capacitors through
not increase a power resistor, and check if the
when the key is capacitor is charged (1/2 battery
turned ON; volts) within a timeout. If they do not
failure in power charge, an fault is signaled; the line
section, or in contactor does not close.
Logic PCB, or in
driver PCB, or in The charging resistor is open
the motor

section.

140 “ HIGH Warning: Master SLAVE Temperature of control is greater than Allow unit to cool.
TEMPERATURE” or Slave or both 75°C. Maximum current reduced If alarm persists,
temperature proportionally to the temperature replace control
higher that 75 increase. At 100°C the maximum
zero.
148 “ENCODER Motor speed SLAVE This fault indicates that the frequency
ERROR” sensor supplied the motor is greater that 20
(encoder) does Hz, and the signal feedback from the
not work encoder has a jump higher than 20
properly Hz in less than ten milliseconds. This
condition clearly shows a

found in the wiring. Replace encoder
ESX Fault Codes
150 “WATCHDOG” Watchdog circuit PUMP It is a self-diagnosing test within the Replace control
has been logic between Master and Slave
triggered micro controllers. This fault could
also be caused by a CAN-BUS
malfunction, which blinds Master –
Slave communication. So , before
replacing the controller, check the
CAN-BUS
155 “EEPROM KO” Warning: PUMP Fault in the area of memory in which Replace control
Eeprom fault the adjustment parameters are and/or restore
controller will stored; this fault does not inhibit truck defaults.
use default operation, but the controller will use
parameters default parameters.
If defect persists when key is

switched OFF and ON again, replace
the control. If the fault disappears,
remember that the parameters stored
previously have been cancelled and
replaced by the default values.
160 “LOGIC FAILURE Failure in U,V,W PUMP Fault in the hardware section of the
#2 voltage controller that manages the phase ‘s
feedback circuit voltage feedback.
Replace controller
Check line contactor.
161 “LOGIC FAILURE An over voltage PUMP This fault signals that the under
#1 or under voltage voltage / over voltage protection Check the battery
condition has interrupt has been triggered. Two voltage.
been detected possible reasons:
Check the LC tips
A real under voltage / over voltage for good contact.
situation happened.
Check for other
Verify battery setting. devices shorted
on the keyswitch
Fault in the hardware section of the line.
voltage protection. Replace logic
Card.

on. Replace controller
ESX Fault Codes
171 “MOTOR Warning: PUMP This fault occurs when the pump Replace control
SHUTDOWN” Pump motor motor temperature switches are open
temp. are very (digital sensor), or if the analog
high (over sensor temperature overtakes the cut
MOTOR off level.
SHUTDOWN
param.) The cut off level is adjusted with the
MOTOR SHUTDOWN parameter
(145°C) in the ADJUSTMENT
submenu.
If this fault occurs, maximum current

is reduced to 130 amps needed for
steering.
If the shutdown occurs when the

motor is cold check the wiring. If
wiring is ok replace controller.
172 “VMN LOW” Wrong voltage PUMP This test is carried out during initial
outputs; failure causes
in the power
section or in the A real under voltage / over voltage
mosfet driver situation occurred.
circuit or in the
motor Problem with motor connections or
the motor power circuit; check if the 3
phases are correctly connected;
check if there’s chassis ground of the
Diode Test: Place POS lead on

Battery NEG and check to all 3
phases. Place NEG lead on Battery
POS and check to all 3 phases.

Unhook motor cables from controller

and do a diode test between Batt+
and all three phases, U,V,W. Check
between Batt- and all three phases,
U,V,W (should read .3 to .5 volts).
Fault in the inverter power section.

Replace controller
voltage protection.
Check line contactor.

ESX Fault Codes
173 “VMN HIGH” Wrong voltage PUMP This test is carried out during initial
in the power

Possible high battery voltage to the

case of the battery.

174 “TH MOTOR Warning: PUMP The range of the motor temperature
SENSOR KO” Motor Pump analog sensor is always checked and
temperature a fault is signaled if it’s out of range
sensor is out of
178 “TILT SENSOR TILT Sensor PUMP Tilt Sensor voltage greater than or
OUT” Voltage greater less than learned tilt sensor voltage.
than or less than
learned voltage. Check tilt sensor mounting.
Relearn tilt sensor.
If tilt sensor voltage still not correct

replace tilt sensor.
179 “OUT RESTRIC. Red LED on PUMP Upright is tilted outside of the
RNG” MDI gauge restricted tilt zone.
180 “CONTACTOR Line contactor PUMP Before driving the line contactor coil,
CLOSED” power contact the controller checks if the line
closed at power contactor is stuck. The controller
up drives the bridge for a while, trying to
discharge the capacitor bank. If they
don’t discharge, the fault condition is
entered. It is suggested to check the
contactor contact, see if it is
mechanically stuck.
ESX Fault Codes
181 “CONTACTOR Line contactor PUMP The controller has driven the line
OPEN” power contact contactor, but the contactor did not
does not pull in close.
The wires to the coil are open or a

loose connection.
Open fuse or cut cable.
The contact does not pull in properly
Check contactor coil is of correct

voltage.
182 “MOTOR Pump motor PUMP After 15 seconds the motor stalled
LOCKED” locked up with maximum current, controller
reduces maximum current to 50%.
Check if pump contactor pulled in.
Possible bad encoder bearing.

183 “TILT SENSOR Tilt sensor PUMP If the option “TILT SENSOR” is set to
KO” signal did not ON and the tilt request is greater than
change during a fixed threshold (75%), the PUMP
tilt function will verify that the tilt is moving
(checking the voltage change of the
tilt sensor). It is suggested to verify
the tilt sensor wiring and the tilt
maximum speed parameter.
Alarm may occur while traveling and
holding tilt in bypass for more than 3
seconds.
Check tilt sensor mounting.
184 “MHYRIO IN PUMP Indicate the valve controller is in
ALARM” alarm condition. Connect to it to
diagnose.
185 “TILT WARNING” PUMP Alarm occurs when tilt is outside of
the restricted tilt zone (RED LED light
ON) and the high/low switch is open,
which disables the lift. Operator must
tilt the upright back into the restricted
range in order to continue lifting.
186 “AQUIRE JOY PUMP Joystick values remain at default Acquire joystick.
STICK” values
187 “LIFT OUT OF Lift signal is PUMP This alarm is set when the lift joystick Acquire joystick.
RANGE” greater than the signal is greater than the acquired Verify joystick
acquired value value “MAX POT LIFT” or “MAX POT output
LOWER” plus a fixed offset.
Check for 5V power to joystick from
tiller card.
Check 1Amp Fuse F-8.
188 “TILT OUT OF Tilt signal is PUMP This alarm is set when the tilt joystick Acquire joystick.
RANGE” greater than the signal is greater than the acquired Verify joystick
acquired value value “MAX JOY2 UP” or “MAX JOY2 output
DOWN” plus a fixed offset.
ESX Fault Codes
189 “AUX OUT OF Aux signal is PUMP This alarm is set when the aux Acquire joystick.
RANGE” greater than the joystick signal is greater than the Verify joystick
acquired value acquired value “MAX JOY2 RIGHT” output
or “MAX JOY2 LEFT” plus a fixed
offset.
190 “AQUIRE TILT PUMP Tilt sensor values remain at default Acquire tilt sensor
SENSOR” values
191 “LIFT FUNCTION Lift signals from PUMP The controller will check the
KO” joystick are not consistency of the 2 signal from the
complementary joystick (A11 and A13 on cantiller
card), if the two signal are not
complementary the inverter will set
the alarm. It is suggested to check
the joystick output, the wiring on A11
and A13 on tiller card, tiller card
power, CAN bus line between tiller
card and dual-ac2
192 “TILT FUNCTION Tilt signals from PUMP The controller will check the
complementary joystick (E1 and E8 on pump), if the
two signal are not complementary the
inverter will set the alarm. It is
suggested to check the joystick
output, the wiring on E1 and E8 on
pump
193 “AUX FUNCTION Aux signals from PUMP The controller will check the
complementary joystick (C7 and C8 on cantiller card),
if the two signal are not
complementary the inverter will set
the alarm. It is suggested to check
the joystick output, the wiring on C7
and C8 on tiller card, tiller card
power, CAN bus line between tiller
card and dual-ac2
194 “I = 0 EVER” PUMP Indicate no current is sensed during a Replace control
command.
Probable damaged control.

195 “STBY I HIGH” Wrong voltage PUMP The microprocessors verify if the Replace control
in current feedback of current sensor device
circuit window. Possible causes of the fault;
Failure in the logic card: first replace

the logic card; if the fault persist,
replace the power unit.
196 “THERMIC Warning: Pump PUMP The range of the temperature sensor
SENSOR KO” temperature is always checked and a warning is
sensor is out of signaled if it is out of range. This fault
range will reduce the maximum current
output of the controller to 50%.
ESX Fault Codes
197 “TILT SENSOR Tilt sensor PUMP This alarm is set if the option “TILT
OFF” disabled SENSOR” is set to OFF
Truck will have reduced travel speed
Setting this to OFF is for
troubleshooting and mechanics only.
Setting should always be ON when in
normal operation.
198 SWITCH LIFT Optional Lift PUMP If optional lift limit switch is installed
STOP Interrupt switch for a specified lift height, this alarm
is open will occur when switch is opened and
lifting will be interrupted.
This is a different (optional) switch
than the high/low switch mounted
under the top tie bar.
199 ADJUST TILT Tilt angles PUMP FF< RF <= V < RB <= FB. The Program correct
ANGLES saved in angles programmed in the tilt angles
adjustments ADJUSTMENT menu must satisfy the
menu do not above equation.
agree with FF = Full Forward Tilt
software RF = Restricted Forward Tilt
equation VM = Vertical (Forks Level)
RB = Restricted Back Tilt
FB = Full Back Tilt
200 “TILLER STUF. Information on PUMP This alarm is set on pump when it Verify the CAN
KO” CAN TILLER didn’t see the heart bit change on bus
message didn’t tiller can message, at each message connection/error
change how (BIT6 of BYTE1 on ID 0x3A0). To frame
request recover from this alarm you need to
turn OFF, turn ON the truck. It is
suggested to verify the CAN bus
201 “ENCODER Motor speed PUMP This fault indicates that the frequency
ERROR” sensor supplied the motor is greater that 20
(encoder) does Hz, and the signal feedback from the
not work encoder has a jump higher than 20
properly Hz in less than ten milliseconds. This
condition clearly shows a
found in the wiring.
May occur when high/low switch Replace encoder
opens during full lift speed due to tilt
being outside the restricted range.
ESX Fault Codes
202 “CAP CHARGE” Power Capacitor PUMP When key is switched on, the inverter See Master
Voltage does tries to charge the capacitors through
not increase a power resistor, and check if the
when the key is capacitor is charged (1/2 battery
turned ON; volts) within a timeout. If they do not
failure in power charge, a fault is signaled; the line
section, or in contactor does not close.
Logic PCB, or in
driver PCB, or in The charging resistor is open
the motor

section.

203 “ HIGH Warning: Pump PUMP Temperature of control is greater than Allow control to
TEMPERATURE” Controller 75°C. Maximum current reduced cool. If unit
temperature proportionally to the temperature persists replace
higher that 75 increase. At 100°C the maximum control.
zero.
205 “INCORRECT Warning: Wrong PUMP If SRO FUNCTION is active, every
START” pump request time work is stopped the operator
sequence must put the truck in neutral.
If any hydraulic function (lift, lower,

tilt, aux1, or aux2) is active when key
switch is turned on.
If any hydraulic function (lift, lower,

tilt, aux1, or aux2) forward or reverse
closed without operator pedal switch
input.
Replace controller
If the fault persist after checking the
wiring and switch, This fault indicates
an incorrect starting sequence.
Formatted: Bullets and Numbering
ESX Fault Codes
207 “MOTOR TC Warning: Pump PUMP Pump motor analog temperature
START” motors sensor is greater than the
temperature temperature set in ADJUSTMENT #4 Check
high (130°C) in the ADJUSTMET temperature
submenu. shown on
handset in tester
When this fault occurs, current goes mode
down to IMX PROTECTION value
and motor rpm begins to decrease.
Motor current and speed decrease
linearly as the temperature increases
until MOTORSHUTDOWN is
reached.
If it happens when the motor is cold,

check the wring. If all is ok,
Replace controller
208 “BATTERY LOW “ Warning: PUMP When battery level reaches 20% (10
Battery charge % on MDI gauge) or less, the current Charge Battery
level below 20% level for the drive motors is reduced
to 50% of the programmed level
209 “DRIVER Line contactor PUMP When the key is turned on, the
SHORTED” coil driver is microprocessor checks that the line
shorted contactor coil driver is not shorted; If
it is, this fault is signaled. Check if
there is an external short or low
impedance pull-down between NLC
(C26) and Batt- If no external causes
can be found. Replace controller
210 “CONTACTOR Line contactor PUMP When the initial diagnosis is finished,
DRIVER” coil driver is the controller closes the line contactor
open (not able and checks the voltage drain of the
to drive the coil driver. If this is not low, the driver is
to the correct unable to close and the fault is
voltage) signaled. Replace controller
211 “COIL SHORTED” Init: Line PUMP When the key is turned on, the
contactor and microprocessor checks that the line
EB coil driver contactor coil driver short circuit
protection circuit protection hardware If it does not
is damaged or react in a correct way to the micro
Stby or running: processor stimulus, the fault is
short on line signaled. When the fault that occurs
contactor or EB while the line contactor is closed this
coil indicates a short circuit across the
line contactor coil. Check if there is
an external short circuit and if the
ohmic value (105 Ohms) of the line
contactor coil is correct
212 “COIL Brake coil open PUMP Check for open wiring to the brake Repair wiring
INTERUPTED” coil
217 “WRONG SET Battery voltage PUMP This fault indicates that actual battery
programmed setting. Replace battery
“SET with correct
ESX Fault Codes
BATTERY” battery.
218 “SAFETY” Input F5 is not PUMP Check that the jumper is in place
connected to between F5 and F11. See wiring
Batt- Diagram.
222 “NO CAN MSG” Pump has lost PUMP This Fault is present in combi Replace control
Can Systems (traction + Pump). The
communication pump has detected a fault and has
with Master informed the traction controller
through the can-bus line. The pump
is waiting for the traction ok. The fault
must be looked for in the traction
controller or can-bus circuit.
Check CAN BUS wiring
232 “MASTER KO” Slave micro SLAVE Slave and Master microprocessor Replace control
processor perform a crosscheck in order to
detects Master verify functionality. There are two
processor conditions under which the slave
malfunctioning enters this fault condition:
The SLAVE microprocessor receives

an incoherent Can message from the
MASTER microprocessor.
The SLAVE microprocessor

compares the inputs status and the
related MASTER operations and finds
they are not coherent. In both cases,
the SLAVE brings the controller to a
safe status opening the power bridge
and the line contactor.
233 “NO CAN MSG 3” Slave has lost SLAVE Slave (node #4) signals that it has Replace control
Can lost communication with the Master
communication (node #3) This fault could be
with Pump determined to be a problem in the
truck CAN-BUS line or be an internal
problem in the controller logic card.
First check the CAN_BUS
connection.
235 “THERMIC Warning: Slave SLAVE The range of the temperature sensor
ESX Fault Codes
236 “INPUT Slave micro SLAVE Safety related inputs (Fwd direction, Check CANBUS
MISMATCH” processor has Rev direction, accelerator Enable, wiring.
detected a Seat switch) are inputs to both micro
mismatch processors by independent hardware Replace control
between inputs circuit. The two microprocessors read
status and the these inputs and compare by
input status exchanging related status on the
transmitted Via Canbus. If the SLAVE
Canbus by microprocessor finds a mismatch
master micro between its inputs and MASTER
processor inputs, it brings the controller to a
safe status opening the power bridge
and the line contactor.
243 “NO CAN MSG 5” Master has lost MASTER Master (node #3) signals that it has Replace control
Can lost communication with the Pump
with Pump determined to be a problem in the
connections.
Check 2 pin jumper B1 to B2 on
PUMP is missing
245 “WRONG SET Battery voltage MASTER This fault indicates that actual battery
programmed setting. Replace battery with correct
“SET battery.
BATTERY”
246 “SLAVE KO” Master micro MASTER Slave and Master microprocessor Replace control
processor perform a crosscheck in order to
detects Slave verify functionality. If the MASTER
micro processor detects SLAVE microprocessor
Malfunctioning malfunctioning, it brings the controller
to a safe status opening the power
bridge and line contactor.
247 “NO CAN MSG 4” Master has lost MASTER Master (node #3) signals that it has Replace control
Can lost communication with the Slave
with Slave determined to be a problem in the
connections.
248 “EM BRAKE MASTER Electromagnetic brakes are worn out Check EM brakes
OPEN” or damaged. Software detected
unintentional movement of traction
motors.
Check wiring.
ESX Fault Codes
Check brake coils
To clear this alarm, a successful EM
brake test must be performed in the
SET OPTIONS menu of the
MASTER.
249 “THERMIC Warning: Master MASTER The range of the temperature sensor
250 “ MHYRIO CAN Master has lost MASTER Check CANBUS connections. Replace control
KO” Can
communication
with Mhyrio
253 "AUX OUTPUT EB coil driver MASTER The microprocessor checks the driver
KO" shorted or open of the electromechanical brake coil. If
the status of the driver output does
not correspond to the signal coming
from the microprocessor, the fault is
signaled. It is suggested to check for
an external short or a low impedance
pull-down between NAUX (C31) and
–Batt.
Check EM brake diodes. Replace controller
Check wiring.
16A06 “CAN BUS KO” MDI CAN MDI-CAN does not communicate with Replace control
the CAN-BUS system, display
functions are off. The problem is that
the MDI-CAN does not receive
commands from the MASTER.
The reason could be in the MDI-CAN

itself (CAN-BUS driver damaged or
Microprocessor input port damaged)
or in the CAN-BUS wires or in the
MASTER electronic (CAN-BUS driver
damaged or pre CAN-BUS I/O port
damaged).
Blank "DASH DISPLAY" Dash Display MASTER Check 5 volt power supply for dash
blank display. If no 5 volts
Check wiring and connector at control Replace dash

and display. If not wiring or display
connections
Technical
Publications
700 Enterprise Dr.
Lexington, KY 40510
Printed in USA www.Clarkmhc.com

Clark ESX 12-25 Forklift Shop Manual

Uploaded by

Copyright:

Available Formats

Clark ESX 12-25 Forklift Shop Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Clark ESX 12-25 Forklift Shop Manual

Uploaded by

Copyright:

Available Formats

SM-718

Battery Service . . . . . . . . . . . . . . . . . . . . .Section 1

SM-718, August ‘07 Battery • Group 12

Group 12 • Battery SM-718, August ‘07

SM-718, August ‘07 Battery Service • 12-1-1

Warning Explosive gas is always present around batteries,

• Be sure this area has provisions to flush and

12-1-2 • Battery Service SM-718, August ‘07

Persons maintaining batteries must wear protective

• Face and head shields

Be sure the battery service area is equipped with ma-

• When using an overhead hoist, be sure to use

SM-718, August ‘07 Battery Service • 12-1-3

Battery Removal Battery Maintenance

12-1-4 • Battery Service SM-718, August ‘07

Battery Vents Battery Charging

Clean Battery Compartment

Replacement Batteries • Load Voltage Tests should be performed and

Keeping Battery Records

These records should contain:

• Test Date. Each test should be dated for future

12-1-6 • Battery Service SM-718, August ‘07

Battery Tests Load Test

SPECIFIC GRAVITY TEST

The battery specific gravity is an indication of the bat-

For, example a reading from:

• 1.260 to 1.300 indicates a fully-charged battery.

SM-718, August ‘07 Battery Service • 12-1-7

Connector and Static Chain Installation

• New Chain: Fasten at third link.

12-1-8 • Battery Service SM-718, August ‘07

Schematics and Electric Circuit Diagrams . . . .Section 1

SM-718, August ‘07 Wiring, Switches and Sensors • Group 13

Group 13 Wiring, Switches and Sensors SM-718, August ‘07

Standard Truck . . . . . . . . . . . . . . . . . . . IN-25197_G

SM-718, August ‘07 Schematics and Electrical Circuit Diagrams • 13-1-1

13-1-2 • Schematics and Electrical Circuit Diagrams SM-718, August ‘07

SM-718, August ‘07 Schematics and Electrical Circuit Diagrams • 13-1-3

13-1-4 • Schematics and Electrical Circuit Diagrams SM-718, August ‘07

SM-718, August ‘07 Schematics and Electrical Circuit Diagrams • 13-1-5

13-1-6 • Schematics and Electrical Circuit Diagrams SM-718, August ‘07

SM-718, August ‘07 Schematics and Electrical Circuit Diagrams • 13-1-7

13-1-8 • Schematics and Electrical Circuit Diagrams SM-718, August ‘07

General Electrical Service Tips 2. Disable the truck:

3. Discharging Controller Capacitors

NOTE: Make sure that the battery has first

To discharge the capacitors connect a 200 ohm

SM-718, August ‘07 General Electrical Service Tips • 13-2-1

Checking Power Cables Torquing Fasteners

Head Force or Pull

Use an appropriate wrench and tighten all fasteners

Connecting and Mounting

Damaged Casing Tape Marker

13-2-2 • General Electrical Service Tips SM-718, August ‘07

Pin Retainer Plates e)

PL-6 Plug Pin(s)

Example of Pin Lock Plug and Socket

SM-718, August ‘07 General Electrical Service Tips • 13-2-3

13-2-4 • General Electrical Service Tips SM-718, August ‘07

Main Harness .............................. SI-14197_D