section 2 - mec aerial work platforms...angle sensor fault: check the wiring to the sensor and then...

“4555SE” Service and Parts Manual August 2016Page 2-1

Section 2CONTROL SYSTEM

CONTENTS PAGE

Control Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Parameter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

“4555SE” Service and Parts ManualAugust 2016-2

CONTROL COMPONENT LOCATIONS

CONTROL COMPONENT LOCATIONS

ART_5125

Platform Controls/PCU

Lift Cylinders

Lower ControlsBatteries

Motor Controller/ECU2

Hydraulic Pump& Motor

Hydraulic Tank

Functions Manifold

Hour Meter

ECU

Battery Tray

Controls Tray

BatteryCharger

BatteryCharger

Main Power Switch


FAULT CODES

FAULT CODES

Fault Codes, when present, appear on the LED Indicator at the Upper Controls station.

ART_5126

LED Indicator

Upper Controls

Error Code Description Action

01 System Initialization Fault Disables All Motion

02 System Communication Fault Disables All Motion

03 Invalid Option Setting Fault Disables All Motion

12 Chassis Up/Down Switch ON at Power-up Fault

Disable Chassis Control

18 Pothole Guard Fault Disable Lifting and Driving

31 Pressure Sensor Fault Disables All Motion

32 Angle Sensor Fault Disables All Motion

34 Reserved

42 Platform Left Turn Switch ON at Power-up Message

Diagnostic Message Only

43 Platform Right Turn Switch ON at Power-up Message


46 Platform Joystick Enable Switch ON at Power-up Fault

Disable Platform Control

47 Platform Joystick Not In Neutral at Power-up Message


“4555SE” Service and Parts ManualAugust 2016Page 2-4

FAULT CODES

52 Drive Forward Coil Fault Disable Lifting and Driving

53 Drive Reverse Coil Fault Disable Lifting and Driving

54 Lift Up Coil Fault Disable Lifting and Driving

55 Lift Down Coil Fault Disable Lifting and Driving

56 Right Turn Coil Fault Disable Lifting and Driving

57 Left Turn Coil Fault Disable Lifting and Driving

58 General Brake Coil Fault Disable Lifting and Driving

59 Parallel Coil Fault Disable Lifting and Driving

61 Motor Controller Current Sensor Fault Controller Dependent

62 Motor Controller Hardware Failsafe Fault Controller Dependent

63 Motor Controller Motor Output Fault Controller Dependent

64 Motor Controller SRO Fault Controller Dependent

65 Motor Controller Throttle Fault Controller Dependent

66 Motor Controller Emergency Reverse Fault Controller Dependent

67 Motor Controller HPD Fault Controller Dependent

68 Low Voltage Fault Disable All Motion

69 High Neutral Current Fault Disable All Motion

70 Steering Input Out of Range Disable All Motion

71 Motor Controller Main Contactor Fault Disable Lifting and Driving

72 Motor Controller Over Voltage Fault Controller Dependent

73 Motor Controller Thermal Cutback Fault Controller Dependent

74 Motor Controller Motor Fault Controller Dependent

75 Motor Controller Pump Motor Fault Controller Dependent

76 Motor Controller Left Drive Motor Fault Controller Dependent

77 Motor Controller Right Drive Motor Fault Controller Dependent

78 Pump Motor Short Fault Disable Lifting and Driving

79 Left Drive Motor Short Fault Disable Lifting and Driving

80 Over 80% Load Warning Warning Only

81 Right Drive Motor Short Fault Disable Lifting and Driving

82 Right Brake Coil Fault Disable Lifting and Driving

83 Left Brake Coil Fault Disable Lifting and Driving



Error Code Description Action


TROUBLESHOOTING TABLE


Error Code

Troubleshooting

01 System Initialization Fault: ECU may be malfunctioning. Contact MEC Customer Service.

02 System Communication Fault: Check communications cable connections and other wiring. If that does not resolve the problem, contact MEC Customer Service.

03 Invalid Option setting Fault: Set appropriate option for this lift.

12 Chassis Toggle Switch ON at Power-up Fault: Check the wires to the Toggle Switch or look for a stuck Toggle Switch.

18 Pothole Guard Fault: Check that the pothole guards are extended. Check the pothole limit switches. Check wires to the switches. Check the down limit switch and connections.

31 Pressure Sensor Fault: Check the wiring to the sensor and then the sensor itself. Also check to make sure that the correct option is properly selected (or not) for load sensing.

32 Angle Sensor Fault: Check the wiring to the sensor and then the sensor itself. Also check to make sure that the correct option is properly selected (or not) for load sensing

42 Platform Left Turn Switch ON at Power-up Message: Ensure that nothing is holding the Joystick Toggle Switches down. If OK, contact MEC Customer Service.

43 Platform Right Turn Switch ON at power-up Message: Ensure that nothing is holding the Joystick Toggle Switches down. If OK, contact MEC Customer Service.

46 Platform Joystick Enable Switch ON at power-up Fault: Ensure that nothing is holding the Enable switch closed. Also check the neutral zone parameters. If OK, contact MEC Customer Service.

47Platform Joystick Not In Neutral At Power-up Message: Make sure that the Joystick is in the neutral (upright) position. Check the neutral zone parameter setting in Scissor Programmer. If it's OK, contact MEC Customer Service.

52 Drive Forward Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.

53 Drive Reverse Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.

54 Lift Up Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.

55 Lift Down Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.

56 Right Turn Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.

57 Left Turn Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.

58 General Brake Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.

59 Parallel Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.



61Motor Controller Current Sensor Fault: Drive or Lift Motor may be overheating. Let the lift cool down. If that does not help, cycle power to reset the Motor controller. If the problem persists, check the wiring and if OK, contact MEC Customer Service.

62 Motor Controller Hardware Failsafe Fault: Cycle power. If that does not resolve the issue check for noise sources. If still needed, contact MEC Customer Service.

63 Motor Controller Motor Output fault: Check wiring first then cycle power. Contact MEC Customer Service.

64 Motor Controller SRO Fault: Look at motor enable delay with the Scissor Programmer, it may be too short. Make sure other Motor Controller parameters are properly selected.

65 Motor Controller Throttle Fault: Check wiring. Make sure the correct throttle type is selected in the Motor Controller.

67 Motor Controller HPD Fault: Look at motor enable delay with the Scissor Programmer, it may be too short. Make sure other Motor Controller parameters are properly selected.

68 Low Voltage Fault: Check battery voltage and charge batteries if necessary. Check the battery connections and tighten or clean. Check the voltage to the ECU and PCU.

69High Neutral Current: The MC is sensing current in the motors when there should not be. This could occur anytime the MC thinks the brakes are on and the motors are still turning. This message sometimes comes just before other faults but should be ignored in those cases.

70

Steering Input Out of Range: There is an inappropriate voltage at the steering input of the motor controller. The controller may need to be “trained” for the three steering voltages (on Differential Steered machines). Or the steering voltage from the ECU was at some point outside of the range that was recorded during the “training” session. Retrain the controller and/or check for fluctuating voltages due to lose wires, etc.

71 Motor Controller Main Contactor Fault: Check the connections to the main contactor. Contact MEC Customer Service.

72 Motor Controller Over Voltage Fault: Check battery voltage and make sure the battery charger is not on. Then cycle power to the lift. If that does not resolve the issue, contact MEC Customer Service.

73 Motor Controller Thermal Cutback Fault: Drive or Lift Motor may be overheating. Let the lift cool down. If that does not help cycle power to reset the Motor controller. If that doesn't resolve the issue, contact MEC Customer Service.

74 Motor Controller Motor Fault: Check connections to the motors. Cycle power to the lift and if that does not resolve the issue, contact MEC Customer Service.

75 Motor Controller Pump Motor Fault: Check connections to the Pump Motor. Cycle power to the lift and if that does not resolve the issue, contact MEC Customer Service.

76 Motor Controller Left Drive Motor Fault: Check connections to the motors. Cycle power to the lift and if that does not resolve the issue, contact MEC Customer Service.

77 Motor Controller Right Drive Motor Fault: Check connections to the motors. Cycle power to the lift and if that does not resolve the issue, contact MEC Customer Service.

78 Pump Motor Short Fault: Check connections to the pump motor. Cycle power to the lift and if that does not resolve the issue, contact MEC Customer Service.

79 Left Drive Motor Short Fault: Check the Motor connections and make sure they are tight. Check the Motor for a short.

80 Over 80% Load Warning: Platform is getting close to its limit of weight. Consider not adding more load.

81 Right Drive Motor Short Fault: Check the Motor connections and make sure they are tight. Check the Motor for a short.

Error Code

Troubleshooting


PARAMETER ADJUSTMENT


PARAMETERS SHOULD BE ADJUSTED ONLY IF THE FUNCTION IS OPERATING OUTSIDE OF MACHINE SPECIFICATIONS, OR IF WRITTEN APPROVAL IS OBTAINED FROM MEC PRIOR TO MAKING THE CHANGE.

The following adjustments are made at the Platform Controls station using the LED Indicator to display the current settings. Follow the instructions to reach the desired setting. Change the setting by using the Steer Buttons on top of the control handle. The right button increases the setting. The left button decreases the setting.Number represent a percentage. 99 means 99%. 9°9 (dot between the digits) means 100%.

82 Right Brake Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.

83 Left Brake Coil Fault: Check the connections to the Coil's terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted.

90 Over 90% Load Warning: Platform is getting close to its limit of weight. Consider not adding more load.

99 Over 99% Load Warning: Platform has reached its limit of weight. Do not add more load.

Error Code

Troubleshooting

ART_5126

LED Indicator



SPEED ADJUSTMENT STATE

1. Set the keyswitch at the Base Controls to PLAT-FORM. Twist the Base Emergency Stop Switch out to the ON position.

2. Push the Platform Controls Emergency Stop Button in to the OFF Position.

3. Press and hold the HORN and LIFT buttons, then twist the Platform Emergency Stop Switch to the ON position.

4. “PS” and the current Lift Speed setting will alternate on the LED Indicator.

Refer to the following pages for individual operating adjustments.

SAVING NEW VALUES

New values must be saved immediately after adjustment.

To save new values, press and hold the Horn button for 3 seconds.To operate the machine with new values, press the Emergency Stop button, then rotate it to return to the ON position.

ART_5128

ART_5129

ART_5135



HIGH DRIVE SPEED

This parameter controls high speed drive when the platform is in the stowed position.

1. Press the Drive Mode Select button. The button will light up, indicating this mode is active, and the LED Indicator will show the present setting.

2. Adjust the speed using the steer left and steer right buttons on top of the Control Handle.

3. High Drive Speed may be changed from 00 to 9°9.Factory setting is 9°9.

4. Save the new setting (see "Saving New Values" on page 2-8).

LOW SPEED DRIVE

This parameter controls low speed drive when the platform is in the stowed position and Low Speed is selected (turtle icon).

1. Press the Drive Mode Select button. The button will light up, indicating this mode is active.

2. Press and hold the Low Speed Mode Select button (turtle icon). The button will light up, and the LED Indicator will show the present setting.


4. Low Drive Speed can be set from 00 to 9°9, but must not be set higher than 50.Factory setting is 50.

DO NOT ADJUST THE SETTING HIGHER THAN 50.


ART_5130

ART_5131



ELEVATED DRIVE SPEED

This parameter controls drive speed when the platform is elevated.


2. Press and hold the Low Speed Mode Select but-ton (turtle icon). The button will light up, indicating this mode is active.


4. Elevated Drive Speed can be set from 00 to 9°9, but must not be set higher than 50.Factory setting is 50.

DO NOT ADJUST THE SETTING HIGHER THAN 50.


LIFT SPEED

This parameter controls the speed at which the platform elevates.

1. Press the Lift Mode Select button. The button will light up, indicating this mode is active.


3. Elevated Drive Speed can be set from 00 to 9°9.Factory setting is 9°9.


ART_5132

ART_5133



STEERING SPEED

This parameter controls speed at which the steering wheels turn.


2. Press and hold the Horn button and the Low Speed Mode Select button (turtle icon).


4. Steering Speed can be set from 00 to 9°9.Factory setting is 30.


ART_5134



NOTES:


Section 3SCHEMATICS

CONTENTS PAGE

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Electrical Schematic, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Electrical Schematic, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6


HYDRAULIC SCHEMATIC

HYDRAULIC SCHEMATIC

ART_5053 1330SE HYDRAULIC SCHEMATIC

L ift C y linder

Steer Relief

Steer Valve

Main Relief

Lift Valve

G ear P um p

M otor

F ilte r

Tank

CBA

S teer C y linder


HYDRAULIC UNIT

HYDRAULIC UNIT

ART_5136 4555SE HYDRAULIC COMPONENTS

HydraulicReservoir

Breather Cap

Functions Manifold

FunctionsManifold

Lift Relief

Steer Relief

Lift Valve

Steer Valve

Motor

Pump

Filter


ELECTRICAL SCHEMATIC, 1 OF 2


ART_5141 4555SE ELECTRICAL SCHEMATIC, 1 of 2

Ground E-STOP

Key Switch

Pow

er S

witc

h

110-220VACInput

Charger

Joystick

DeadmanSteer Left

Steer Right

Lift Enable

Drive Enable

Low Speed

Horn Switch

Drive Joystick

6VDCBattery

GB1 GB2

GB3 GB4

B-3

BK

(20)

2B GN/RD(18)

1B GN/YE(16)

1C GN/RD(16)

4

3

5

2

1 WH(18)

YE(18)

BU(18)

RD(18)

GN(18)

010B BU/RD(16)

010A-1 GN/WH(16)J

21BuzzerB2

MNNPR

M

K

J

H

G

F

E

010A-5 RD(18)010A-4 RD(18)010A-3 RD(18)010A-2 RD(18)A

BCD

5A-2 RD(18)FB

Lift Down Limit Switch

Lift Up Limit Switch

Tilt Sensor

L

K

Lift Down Valve

Overload Indicator

010A-7 BU/RD(16)S

C

010A

-6 B

U/R

D(1

6)

010-

5 R

D/B

U(1

6)

SB2

4

3

5

2

1

Platform E-STOP

B4Buzzer

Right Pothole Switch

GND-3 BK(16)GND-2 BK(16)

3A BN(18)

010A-2 YE(16)010A BN/RD(16)

SS1

Left Pothole Switch

GND-1 BK(16)

010-1 BU/RD(16)

LS2

GND BK(14)

010-

4 YE

(14)

010-

2 R

D/B

U(1

6)

010-

3 R

D(1

4)01

0-1

BU

/RD

(16)

010

BN

/GN

(16)

Beacon

12C GN(20)010A-12 RD(20)

11B WH(20)LS1

010A-13 RD(20)

10B-2 WH/BU(20)LS4

LS3

B-1 WH(20)

010A-10 RD(20)

HL2

HL1

11C GN/VT(18)2

3

1010A-11 RD(18) TILT

RD(20)BU(20)

Relay

CR1

FU1

300A

FU2

7A

Lift Indicator

Drive Indicator

Low Speed Indicator

B-2 BK(20)010A-14 RD(20)

010A-5 RD(20)010A-4 RD(20)

BU(20)B BK(20)

D

E

Up

Down

SS2

12A BN/GY(16)

12B BN/WH(16)010A-1 BN/WH(16)

010A

-2 Y

E(16

)

SB1

YV2

SB3

LED

010-

3 R

D(1

4)00

1 R

D(1

4)

A

001

RD

(14)

CAN_H

CAN_L

LNPE

- +

RD

(4/0

)

BK

(4/0

)

PCU JS1

Platform Control Module

SB4

SB5

SB6

SB7

SB8

S2

B+-A RD(16)

10B-2 WH/BU(18)

010-

5 R

D/B

U(1

6)

GN

D-1

BK(

16)

1C G

N/R

D(1

6)1B

GN

/YE(

16)

RD(4/0)

BK(4/0)

GND-1 BK(16)




ART_5142 4555SE ELECTRICAL SCHEMATIC, 2 of 2

ALL WIRES ARE 18AWG OR 0.8mm2 UNLESS NOTED OTHERWISE

K =16 Position DELPHI Connector, 2 locations

4 =5 Position SIBAS Connector 7 locations

F =16 Position DELPHI Connector 3 locations

2 =2 Position AMP Connector 4 locations

HMHourmeter

21

RD(4)

RD(4)

GND-11 BK(16)

GND-1 BK(16)

GND-11 BK(16)

RD(4/0)

Drive Motor

Drive Motor

Brake

HN3A3A BN/YE(18)

2B2B GN/RD(18)

2C2C RD(16)4A4A RD(16)5A5A-1 RD(16)

6A 6A VT/YE(16)

1B GN/YE(16)

4B4B WH/VT(18)

6B6B WH/BU(18)

7B 7B WH/BU(16)

8B 8B BN/RD(16)

9B9B WH/BK(16)

10B10B-1 WH/BU(16)

11B11B BU/RD(18)

1C GN/RD(16)

3C3C GN/RD(18)

7C 7C WH/BU(16)

11C11C GN/VT(18)

12C12C GN/BU(18)

LED

Horn

Lift Up Valve

Steer Left Valve

Steer Right Valve

8A-2 BN/GN(16)

GND-3 BK(16)

GND-4 BK(16)

GND-5 BK(16)

2

GND-6 BK(16)

GN

D-1

0 B

K(16

)

MGND-2 BK(18)GND-7 BK(18)GND-8 BK(18)GND-9 BK(18)

B- BK(14)

NNPR

M

K

J

H

G

F

L B1

12A12A BN/GY(18)

12B12B BN/WH(18)D

E

YV3

YV4

YV1

RD(4/0)

BK(4/0)

ECU

GN

D-3

BK(

16)

1

2

3

7

4

109BM1

R22k?

R12k?

586

Brake

RD(16)

BK(16)

BK(16)

RD(16)

010A

-6 R

D(1

6)

7A

8A 8A-1 BN/GN(16)

9A 9A BN/BK(16)

6C

8C

5C

5B

4C

8C WH/VT(16)

6C BN/GY(16)

4C RD(16)

7A BN/WH(16)

5B GN/RD(16)

5C BN/YE(16)

10C 10C GN/VT(16)

9C 9C BU/RD(16)

10A 10A GN/BU(16)

M1Pump Motor

F1

T1

F2

T2

P

15

2

3

4

5

14

25

34

10

11

1

9A BN/BK(16)

8C WH/VT(16)

6C BN/GY(16)

4C RD(16)

7A BN/WH(16)

5B GN/RD(16)

5C BN/YE(16)

8A BN/GN(16)

12

B+-B RD(16)

CO

NTR

OL+

RD

/BU

(16)

CO

NTR

OL-

BU

(16)

1710B WH/BU(16)

8

9

EXCITATION BU/RD(16)

M2

M3

B+ B-

CON1

DC Contactor

RD(16)

BK(4)

RD(16)

BK(4)

BK(4/0)

RD

(4/0

)

BK(4/0)

MC1Excitation

Excitation

1B1C

10B WH/BU(16)

3B3B BN/BK(18)

010A-6 RD(16)

B+-B RD(16)

GND-1 BK(16)


WIRING DIAGRAM

WIRING DIAGRAM

ART_5143 4555SE WIRING DIAGRAM

Battery ChargerInput: 100-240VACOutput: 24VDC 25A 750W

Batteries

DC Contactor

Pump MotorMotor Controller

Drive Motor

Drive Motor300A Fuse

Power Switch

section 2 - mec aerial work platforms...angle sensor fault: check the wiring to the sensor and then...

Documents