I am working on an EOP15 and I keep having an issue where moving the handle forward will result in it dumping the brake valve....This does not happen in reverse travel. The odd thing is, if you move the handle and start out slowly, then jamb it to full speed, it works fine. No codes from the EV100 system either. I thought for sure I had a bad master cylinder not holding pressure, but thats not the case
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...sorry, its been a while...customer FINALLY wanted to spend the money on the truck......The problem ended up being in the steering controller/trucktracker.......I swapped it with another one from another truck and it worked perfectly!! Thanks Swoop for all your guidance!!
if your not getting the ground signal to the deadman i would start there and back trace the circuit and find out where it is faulting out at.
could be something in the deadman switch, a harness connection, broken wire, if the truck has safety switches in the safety arms (if it has any on the sides).
since you've already swapped out the boards it's got to be something in those areas.
..Thats just it....I can't get the deadman to work beacuse its missing the ground going to the brake dump coil
yes ctforkliftguy, even the controls go through the steering card too, they have to because if any steering failure occurs it has to shut the truck down to avoid any accidents.
if possible when operating the truck can you monitor the steering card display and see if it is flashing any codes?
Find a way to jack up and block the truck and operate it and try to get it to duplicate the error. Watch the steering card display and see what it shows. It should be a single digit display, tell me what it shows during this error condition.
Thank you for your help Swoop.....No wire guidance and yes on the electric steering. We did find a schematic today, but even that doesnt seem to make sense. It states that the ground for the brake dump coil comes thru the electric steering? If I give the coil the ground it needs, then everything works, but that defeats the purpose of the whole safety!
ok a couple questions
does the truck have wire guidance?
does the truck have electronic steering?
and ivan if you dont have anything constructive to say please refrain from the negative comments, either help or just don't follow this thread
......customer doesnt just have money to throw away on the truck
Getting tired seeing your post here. Just replace what you have not replaced yet. Replace contactor base and reverse coil.
..Thanks Swoop!!I looked for some burnt traces but didnt find anything
no ground to the coil eh?
let me do some checking and i'll see what else may be causing this...
Ok now I'm really stumped!!As of friday, the truck now currently dumps the brakes all the time now!!! I checked and there is no ground going to the coil.....If I ground the coil, everything would work.....We replaced the following with known good parts from another truck......Carriage wiring card....Ev100 Card.....interface card....F/R contactor....Checked for smooth movement of the travel pot.....Just finished checking the mast cables also...have come to a dead end...any info?
no problemo :o)
now after you check this if it is still happening then we'll have to start thinking outside the box (so to speak).
Other components that are inline with that circuit that could trigger a false code. But we'll tackle that later if we have to.
(Im headin in to work shortly..hahah)...I already replaced the contactor with one from a known good truck. I will try replacing rec #3, I do believe I have a whole ev100 control plate around....The good thing about it, is the place the truck is at, has about 10 other EOP's there!! I'm just looking for a place to start!! Thank Swoop!
ok there are 2 things that can make this -48 pop up and shut the truck down.
One can be a problem with the directional contactors.
The GE EV100 troubleshooting code list refers to welded tips or slow moving contactors so i'd check the directional contactors very close. Use some electrical cleaner and try cleaning them.
The other thing it mentions is a bad/shorted #3 REC or defective snubber.
ahh ok.. you're on the forum now hehe... let me check something
Yes it does...it stops abruptly....If I watch the ev100 display...i will get the quick -48, then it dumps, then -01
ok, well we had to get that out of the way first being one of the most common problems on these.
Now....
in your description you say only in fwd direction it 'dumps' the brake valve? when this happens does the truck stop abruptly?
One other thing... is this truck equipt with manual steering? or electronic steering?
If electronic steering there should be a small steering control board mounted on the top plate above the battery along with the Vehicle Manager. Look on this steer control and there should be a small LED display. When the truck goes into this condition look at that LED and see if it is showing any numbers on it. Generally in normal condition it will just be cycling the LED segments or just be blank... if there are any issues with that it will show a number on it.
..Swoop...I checked the voltage and it is at 2.5volts for neutral and it swings smoothly to 1 volt for forward and smoothly to 4 volts for reverse.....completely stumped now
Hi Swoop...ser# 1EOP240796...I never thought of checking the throttle pot for voltage swing. I will check for the 2.5volts and hook up my meter to see if I have any flat spots. I thought it may have been the contactor. I swapped that and its still doing it.
whats the serial number?
I can give you more specific info with that
Sounds like a bad travel potentiometer to me from your description
check the neutral voltage setting and make sure it is at 2.50v in neutral. Also you can monitor the voltage sweep and see if there are any bad spots in the volt range sweep.
you can go into the maintenance menu and run a learn on the handle to verify it is set correctly and calibrate it.
Now unlike the raycat trucks these mitsu's have a different method to get to the learn mode. You will need the troubleshooting manual for this.
Good Luck
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