Operator’s Manual, Standard Hydraulic Drive

Control System
 TABLE OF CONTENTS
1. BASIC OPERATION........................................................................................................................................................ 5
1.1. Main Power and Safety..............................................................................................................5
1.2. Lifting and Lifting Safety ..........................................................................................................5
1.3. Driving and Driving Safety .......................................................................................................6
1.4. Steering and Steering Safety ...................................................................................................6
1.5. Miscellaneous Operations........................................................................................................6
1.6. Low Power Operation ................................................................................................................6

2. PLATFORM CONTROL UNIT (PCU) AND ELECTRONIC CONTROL UNIT (ECU).................. 8

3. USER ADJUSTMENTS AND LIFT SET UP ........................................................................................................ 10
3.1. Battery Drain Shut-Off and Alarm State...............................................................................11
3.1.1. Change Shut-Off Delay .................................................................................................................... 13
3.1.2. Change Alarm Delay ....................................................................................................................... 14
3.2. Speed Adjust State ..................................................................................................................15
3.2.1. Drive High Speed (with Platform Stowed) ...................................................................................... 16
3.2.2. Drive Low Speed .............................................................................................................................. 17
3.2.3. Drive Elevated Speed ....................................................................................................................... 18
3.2.4. Lift Speed.......................................................................................................................................... 19
3.2.5. Steering Speed ................................................................................................................................. 19
3.3. Set Platform Height For Overload Descent..........................................................................20

4. MACHINE OPTIONS STATE.................................................................................................................................... 23

4.1. Selecting Machine Options ....................................................................................................23
4.2. Enabling Battery Drain Alarm.................................................................................................27
4.3. Save the New Values................................................................................................................28
4.4. List Of Machine Options .........................................................................................................29

5. FAULT STATE................................................................................................................................................................ 30
6. FAULT HISTORY STATE.......................................................................................................................................... 33
7. NORMAL OPERATING STATE .............................................................................................................................. 34
7.1. Driving Forward or Backward with the Platform Stowed .................................................34
7.2. Raising or Lowering the Platform..........................................................................................34
7.2.1. From the Platform Using the PCU................................................................................................... 34
7.2.2. From the Ground Using Chassis Controls ...................................................................................... 35
7.2.3. Software Revision and Machine Option Displayed ......................................................................... 36
7.3. Operating the Lift with the Platform Elevated .....................................................................36
7.4. Displays on the PCU and ECU in normal operation ..........................................................37
7.5. Battery Charge State................................................................................................................38

8. LOAD SENSING............................................................................................................................................................. 39
8.1. Limit Detection and Calibration with a Pressure Limit Switch ........................................39
8.1.1. Basic Description .............................................................................................................. 39
8.1.2. Calibration Process ........................................................................................................... 39
8.1.3. Overload Operation .......................................................................................................... 40
8.2. Load Sensing and Calibration with a Pressure Transducer ............................................40
8.2.1. Basic Description .............................................................................................................. 40
8.2.2. Calibration Process..................................................................................................................40
8.2.3. Overload Operation .......................................................................................................... 43
 Table of Figures
Figure 1: Operation Flow Chart ..................................................................................................... 7
Figure 2: Platform Control Unit (PCU) ......................................................................................... 8
Figure 3: Joystick Control Buttons ................................................................................................ 9
Figure 4: Electronic Control Unit (ECU)....................................................................................... 9
Figure 5: User Adjustments and Lift Set Up ............................................................................... 10
Figure 6: Getting to the PS State.................................................................................................. 11
Figure 7: Getting to the Battery Drain Shut-Off and Alarm State............................................... 12
Figure 8: Changing the Battery Drain Shut-Off Delay................................................................ 13
Figure 9: Changing the Battery Drain Alarm Delay ................................................................... 14
Figure 10: Getting to the Speed Adjust State............................................................................... 15
Figure 11: Drive High Speed Adjustment ................................................................................... 16
Figure 12: Drive Low Speed Adjustment .................................................................................... 17
Figure 13: Drive Speed while elevated ....................................................................................... 18
Figure 14: Lift Speed Adjustment................................................................................................ 19
Figure 15: Steering Speed Adjustment ........................................................................................ 20
Figure 16: Set Up for Platform Height Descent Limit.................................................................. 21
Figure 17: Final Set for Platform Height Descent Limit ............................................................. 22
Figure 18: Getting to the Machine Option Selection Mode.......................................................... 24
Figure 19: Entering the Machine Option Selection Mode ........................................................... 25
Figure 20: Adjusting the Machine Options Selection................................................................... 26
Figure 21: Battery Drain Alarm Enable........................................................................................ 27
Figure 22: Saving Option Changes .............................................................................................. 28
Figure 23: Chassis Control, Key Switch and Chassis Toggle Switch ......................................... 35
Figure 24: Obtaining the Machine Option Setting and the Software Revision ........................... 36
Figure 25: Overload Display........................................................................................................ 40
Figure 26: Switch Positions for No Load Calibration procedure ................................................ 41
Figure 27: 80% Load Limit Warning........................................................................................... 43
Figure 28: 90% Load Limit Warning........................................................................................... 43
Figure 29: 99% Load Limit Warning........................................................................................... 43
Figure 30: Overload Display........................................................................................................ 45
 Table of Tables
Table 1: Machine Options................................................................................................. 29
Table 2: List of Fault Codes............................................................................................. 30
Table 3: Troubleshooting Guide ...................................................................................... 31
Table 4: Displays on the PCU and ECU........................................................................... 37
Table 5: Battery Monitor ................................................................................................. 38
1. Basic Operation
For the following discussions:
SeeFigure 2and Figure 3for Platform Control Unit
(PCU) SeeFigure 4for Electronic Control Unit (ECU)
SeeFigure 23for Key Switch and Chassis controls

1.1. Main Power and Safety

1.1.1 The Key Switch supplies power to the Emergency Stop (E-Stop) and
selection of Chassis control or Platform control. The power is off in the center
position
and removal of the key in anyone of the three positions will maintain the lift
in that mode of operation.
1.1.2 The E-Stop buttons are located on both the chassis and platform controllers.
They are in series and must be pulled out for normal operation. Pressing either
switch turns off power to the chassis and platform. Safety is based on a
completed circuit and pushing in either E-Stop will open the circuit.
1.1.3 The Enable Button on the Joystick must be engaged to enable the drive, steer,
lift or lower functions

1.2. Lifting and Lifting Safety

1.2.1 The chassis tilt sensor indicates the chassis is either level or not.
1.2.2 If equipped with pothole guards, the platform will not rise above a preset
height unless the pothole guards are deployed.
1.2.3 The measured load must not exceed the ratings assigned to the model of
the machine.
1.2.4 Raising or lowering the platform can be accomplished from two positions:
at the Chassis or from the Platform. The Key Switch selects which control
position.
1.2.4.1 The Chassis position allows only up and down movement of
the platform through the use of the toggle switch on the
Chassis.
1.2.4.2 The Platform position allows the operator on the platform to select the
Lift Mode. The direction and speed are controlled by moving the
Joystick forward to raise the platform and backward to lower the
platform.
1.2.5 The Electronic Control Unit (ECU) in the Chassis will sound an alarm and
inhibit operation if the platform is overloaded and the Load Sensing
Machine Option was selected during setup. See Table 1: Machine Options.
 1.2.6 There is an option for stopping the platform for a safe descent after halt during
lowering if the Descent Delay Machine Option was selected during setup.
See Table 1: Machine Options.
1.2.7 Failure of the elevating or lowering valves are reported as a fault code on
the LED readout of both the PCU and ECU displays.

1.3. Driving and Driving Safety

1.3.1 Driving is controlled only by the Joystick on the PCU when the Key Switch
is set to the Platform position. See Figure 31.
1.3.2 The Drive Mode must be selected and the Enable button on the Joystick engaged.
1.3.2.1 The direction and speed is controlled by moving the handle forward or
backward.
1.3.2.2 “High Speed” or “Low Speed” can be selected while the platform is
stowed, but when the platform is elevated (and the pothole guards if
equipped are down) the lift will only operate in the “Elevated Speed”
.
1.3.2.3 Specific lift functions are inhibited if platform loads are in excess
of machine specifications.
1.3.2.4 The motor controller will decrease speeds if it is overheating internally.
1.3.2.5 Brakes are applied at all other times

1.4. Steering and Steering Safety

1.4.1 The Key Switch must be in the platform position. See Figure 31
1.4.2 Steering is controlled only by the buttons on the top of the Joystick on the PCU.
1.4.3 The Drive Mode must be selected and the Enable button on the Joystick
engaged.

1.5. Miscellaneous Operations

1.5.1 The Hour Meter on the chassis runs when lift or drive functions are enabled.
1.5.2 The 2-character LED display on the PCU indicates the battery status,
error conditions and setup data.

1.6. Low Power Operation

1.6.1 Battery power status is determined by operator settings of the battery levels
and is displayed as battery bars on the PCU display, see Table 4:
Battery Monitor.
1.6.2 Two or more battery bars allow normal driving.
1.6.3 At one battery bar travel speed is reduced.
 From
Use Chassis Toggle
Power Off
Switch to Raise or
Lower the Platform.

Power ON
With Key Switch in Chassis position.

Select Drive, then

Power ON
Select
With Key Switch in Platform position.
Slow Speed
if needed.

Power ON
With Key Switch in
Platform position,
and while LIFT, and User Adjustments
Engage Enable on
HORN are held. and Lift Set Up
Joystick and Move
Down.
Joystick Forward or
Reverse for speed .

Select Lift.

Engage Enable on
Halt For:
Joystick and Move Tilt (Display LL)
Joystick Forward Overload (OL)
(Raise) or Reverse Other Faults
(Lower).

Power Off

Figure 1: Operation Flow Chart

2. Platform Control Unit (PCU) and Electronic Control Unit (ECU)
Horn

Drive

Low
Speed
Lift

Display

Figure 2: Platform Control Unit (PCU)

 LEFT TURN

Reverse…Forward

RIGHT TURN

ENABLE

E-Stop

Figure 3: Joystick Control Buttons

Figure 4: Electronic Control Unit (ECU)

 From Power Off

3. User Adjustments and Lift Set Up

Set Lift Height for Power ON

Overload Descent. With the Key Switch in
Power ON Chassis position and the
With the Key Switch in Chassis Toggle switch
Chassis position and in the Up position.
while holding the
DRIVE and LOW
SPEED buttons down.

Power ON PC Programming
While holding the State.
HORN and LIFT
Battery Drain State. Speed Adjust State.
buttons down.

Change Lift Shut-Off Adjust Drive High Speed Hold

delay
Power ONChange Alarm delay Adjust Drive Low Speed The LIFT and LOW
While holding LIFT, Adjust Drive Elevated Speed SPEED buttons down
HORN, and LOW Adjust Lift Speed for 3 seconds.
SPEED buttons down. Adjust Steering Speed

Machine Options State.

Select the Machine

Configuration Option.
See Table 1.

Toggle Battery Drain

Alarm On and Off.

Cycle Power to get

to normal operation.

Figure 5: User Adjustments and Lift Set Up

 3.1. Battery Drain Shut-Offand Alarm State

The control allows adjusting Shut-Off and Alarm time values for Battery Drain
protection. Start with the E-Stop depressed (in) on the PCU.
Turn the Key Switch to the Platform Control position and ensure that the Chassis E-Stop
is active (out). See Figure 23.

Press HORN and LIFT and

LOW SPEED buttons
simultaneously and pull the
PCU’s E-Stop (out) to start
Battery Drain Shut-Off and
Alarm State.

ps “PS” and current Lift Speed

are alternately flashing on the
display.

Figure 6: Getting to the PS State

 Release HORN and LIFT
while keeping LOW SPEED
depressed until the blinking
“PS” disappears and the
current Shut-Off value is
displayed.

0.0.
The current setting is
displayed and two “dots” will
be displayed in this mode.
Note: factory setting is “00”
which is the “OFF” state.

Figure 7: Getting to the Battery Drain Shut-Off and Alarm State

Notes:

In the Battery Drain Protection adjustment state, both “dots” are displayed.

The battery drain alarm alerts the user that power is being drawn from the batteries.
A. After [Alarm Time, in minutes] of no activity-alarm starts beeping. Any activity
will silence the alarm and allow continued operation
B. After [Shut-Off Time, in minutes] of no activity-System goes into very low power
Sleep mode. Cycle power to restore normal operation.

The system will continue to drain the batteries in the low power mode. The operator or mechanic
should assure that power is turned off and the batteries are put on the charger at the end of each
working shift or day.
 3.1.1. Change Shut-Off Delay
Press LIFT button.

The LIFT LED indicates this

mode is active.

Adjust the delay using the

RIGHT TURN (increase) or
LEFT TURN (decrease)
button on the top of the
Joystick.
Refer to Figure 3.

6. 0 . The value can be changed

from 00 to 60 with the buttons
on top of the Joystick.

00 = Disabled

Figure 8: Changing the Battery Drain Shut-Off Delay

 3.1.2. Change Alarm Delay

NOTE: If the Alarm is not working, it may need to be enabled. The Battery Drain Alarm can
be turned on or shut off while in the “SC” mode by pressing the HORN button. See
instructions in the Machine Options State, section4.

Press DRIVE button.

The DRIVE MODE LED

indicates this mode is active.

Adjust the time using the

RIGHT TURN (increase) or
LEFT TURN (decrease)
button on the top of the
Joystick.
Refer to Figure 3.

6. 0 . The value can be changed

from 00 to 60 with the buttons
on top of the Joystick.

00 = Disabled

Figure 9: Changing the Battery Drain Alarm Delay

 3.2. Speed Adjust State

The control allows adjusting high and low speed drive values. The Drive Speed for normal
and elevated travel can be changed from the PCU. The following panels show how to select an
individual function to change.

Start with the E-Stop depressed (in) on the platform controller.

Turn the Key Switch to the Platform Control position and ensure the Chassis E-Stop is
active (out). See Figure 23.

Press and hold HORN and

LIFT buttons while pulling
the PCU’s E-Stop (out) to
enter Speed Adjust State.

ps “PS” and current Lift Speed

are alternately flashing on the
display.

Figure 10: Getting to the Speed Adjust State

 3.2.1. Drive High Speed (with Platform Stowed)
Press DRIVE button.

The DRIVE LED indicates

this mode is active.

Adjust the speed using the

RIGHT TURN (increase) or
LEFT TURN (Decrease)
button on the top of the
Joystick.
Refer to Figure 3.

6. 0 . The value can be changed

.
from 00 to 100 (displays 9 9)
with the buttons on top of
the
Joystick.

Figure 11: Drive High Speed Adjustment

 3.2.2. Drive Low Speed
Press DRIVE button.

Press and hold the LOW

SPEED button to select Drive
Low Speed adjustment. Keep
it held while adjusting the
speed.

The display indicates present

set value.
Adjust using the RIGHT
TURN (increase) or LEFT
TURN (decrease) button on
top of the Joystick.
Refer to Figure 3.

9. 0
The value can be changed
.
from 00 to 100 (displays 9 9)
with the buttons on top of
the
Joystick.

Figure 12: Drive Low Speed Adjustment

3.2.3. Drive Elevated Speed
Press DRIVE button.

Press and hold the HORN

button to select Drive
Elevated Speed adjustment.
Keep it held while adjusting
the speed.

The display will indicate the

present set value.

Adjust the speed using the

RIGHT TURN (increase) or
LEFT TURN (decrease)
button on top of the
Joystick. Refer to Figure 3.

5 5 The value can be changed

from 00 to Max Speed 70 with
the buttons on top of the
Joystick.

Figure 13: Drive Speed while elevated

3.2.4. Lift Speed
Press LIFT button.

The LIFT LED indicates

this mode is active.

Adjust the speed using the

RIGHT TURN (increase) or
LEFT TURN (decrease)
button on top of the
Joystick.
Refer to Figure 3.

The value can be changed

.
9.9 from 00 to 100 (displays 9 9)
with the buttons on top of
the
Joystick.

Figure 14: Lift Speed Adjustment

3.2.5. Steering Speed

Press DRIVE button.

Press and hold the HORN and

LOW SPEED buttons to select
Drive Steering Speed
adjustment. Hold these buttons
while adjusting the speed.

Display indicates the present

set value. Adjust the speed
using the RIGHT TURN
(increase) or LEFT TURN
(decrease) button on top of the
Joystick.
Refer toFigure 3.
 The value can be changed
.
9.9 from 00 to 100 (displays 9 9)
with the buttons on top of
the
Joystick.

Figure 15: Steering Speed Adjustment

The lift can now be powered down (push E-Stop in on the PCU) and the new values will
be available for future operation.

3.3. Set Platform Height For Overload Descent

If the platform becomes overloaded, it is not allowed to lower unless the platform is already
under a specified height. If the overloaded platform is at a height lower than what
is established in the procedure below, then it can be lowered.

1. Ensure that one of the Load Sensing Machines Options was selected at setup. See
Table 1: Machine Options.
2. Put the Key Switch in the off position. SeeFigure 23.
3. Push the E-Stop in on the PCU and out on the Chassis.
4. Then turn the Key Switch to the Chassis Position.
5. Press and hold the DRIVE and LOW SPEED buttons while pulling the PCU E-Stop out.

Press and hold DRIVE and

LOW SPEED buttons while
pulling the PCU E-Stop out.
H 9 Continue to hold the buttons
for 10 seconds and H9 will
be displayed.

Figure 16: Set Up for Platform Height Descent Limit

6. Raise the platform to the desired height using the Chassis Toggle Switch (seeFigure 23)
for the desired height for Overload Descent.

7. Hold the Joystick ENABLE in and press the horn button. Both the horn and alarm will
sound while the height value is being stored.

Hold the Joystick ENABLE (see

Figure 3) for 3 seconds.

Overloaded Platform Height

Descent Limit is now set.

Figure 17: Final Set for Platform Height Descent Limit

8. Wait for the Alarm to Stop, which signals that the new value has been stored.

9. Cycle the power (reset either one of the E-Stops) to return the controller to
normal operation.
4. Machine Options State
4.1. Selecting Machine Options
Press and hold the LIFT
and HORN buttons
while pulling the PCU’s
E-Stop out to select
Machine Options
adjustment.

“PS” and Elevated

ps Speed value will
alternatively flash on the
display.

Release LIFT and

HORN buttons.

“PS” will change to Lift

Speed.
9.9

Figure 18: Getting to the Machine Option Selection Mode

 Press and hold the
LIFT and LOW
SPEED buttons for 3
seconds to enter the
Machine Option
selection mode.

“SC” is displayed when

in Machine Option
selection mode.

s The LIFT button

can now be released.
c
Figure 19: Entering the Machine Option Selection Mode
 Momentarily press
DRIVE button to edit
the right digit. The
digit will be flashing.

See 错误!未找到引用
源。1 for list of
options.

Then press LIFT

button to edit the left
digit.

The Left digit will now

be flashing.

The buttons on the top

1 0 of the Joystick increase

(LEFT TURN button)
or decrease (RIGHT
TURN button) the
flashing digit.
Refer to Figure 3.

Figure 20: Adjusting the Machine Options Selection

4.2. Enabling Battery Drain Alarm

Momentarily press the

DRIVE button.

Momentarily pressing the

HORN button while in the
DRIVE Mode turns the Left
“DOT” ON and OFF.

1 0.
This enables and disables
the Battery Drain Alarm
option.

DOT ON = Enabled.

Figure 21: Battery Drain Alarm Enable

4.3. Save the New Values

Press and hold the

HORN button for 3
seconds to save
changes

Turn Off power and

ON to operate the
machine with the new
values.

Figure 22: Saving Option Changes

 4.4. List Of Machine Options
Among the options listed below are the special options that can be selected individually
or in combinations with each other. Some configure mechanical options of the lift
itself and others are used setup how the lift functions (firmware options).

4.4.1 Descent Delay: If this firmware option has been selected and the platform
is descending it will stop at a safety checkpoint to give the operator or
bystanders time to remove obstructions from between the scissors. The
Joystick enable must be disengaged and then re-engaged (or the Chassis
Toggle switch must be released and returned to the down position) and then a
short delay must time out before the platform will continue to descend.

4.4.2 Load Sensing: If this firmware option is selected, the lift will expect that
either a pressure switch or pressure transducer is installed in the scissors lift
and lift will notify the operator if an overload condition exists on the platform.

4.4.3 Motion Alarm: If this firmware option is selected, the option will enable an
alarm which will then sound anytime the lift is being driven or the platform is
being elevated or lowered.
Table: Lift Options

Machine Type Option Code Decent Delay Motion Alarm Load Sensing
00 ●
01 ● ●
02 ● ●
03 ● ● ●
Hydraulic Drive 04-07 is not valid
Scissor Lift 08
09 ●
10 ●
11 ● ●
12-15 is not valid
16 ●
17 ● ●
18 ● ●
19 ● ● ●
DC Drive 20-23 is not valid
Scissor Lift 24
25 ●
26 ●
27 ● ●
28-31 is not valid
 5. Fault State

In the fault state, a fault code from the list will be displayed flashing once a second on both
the PCU and the ECU displays.

Table 1: List of Fault Codes

Display Description Lift Reaction
01 System Initialization Fault Disables All Motion
02 System Communication Fault Disables All Motion
03 Invalid Option setting Fault Disables All Motion
12 Chassis Toggle 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
42 Platform Left Turn Switch ON at power-up Message Diagnostic Message Only
43 Platform Right Turn Switch ON at power-up Message Diagnostic Message Only
46 Platform Joystick Enable Switch ON at power-up Fault Disable Platform Control
47 Platform Joystick not in neutral at power-up Message Lift Slows to Elevated Speed
52 Forward Coil Fault Disable Lifting and Driving
53 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 (presently disabled because Disable Lifting and Driving
the brake output is optional)
68 Low Voltage Fault Disable All Motion
80 Over 80% Load Warning Warning Only
90 Over 90% Load Warning Warning Only
99 Over 99% Load Warning Warning Only
0Λ Overloaded Platform Fault Disable All Motion
ΛΛ Machine Tilted Beyond Safe Limits Fault Disable Lifting and Driving

For displays see Figure 2andFigure 4.

 Table : Troubleshooting Gui
Display Description
01 System Initialization Fault: ECU maybe malfunctioning, replace it.
02 System Communication Fault: Check communications cable connections and other
wiring. If that does not resolve the problem, try replacing the PCU or ECU.
03 Invalid Option setting Fault: Set appropriate option for this lift.
12 Chassis Toggle Switch ON at power-up Fault: Check 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, consider replacing the Joystick or
PCU.
43 Platform Right Turn Switch ON at power-up Message: Ensure that nothing is holding
the Joystick Toggle Switches down. If OK, consider replacing the Joystick or PCU.
46 Platform Joystick Enable Switch ON at power-up Fault: Ensure that nothing is holding
the Enable switch closed. If OK, consider replacing the Joystick or PCU.
47 Platform 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 the LabView
Programmer. If it’s OK, consider replacing the Joystick or the PCU.
52 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 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.
68 Low Voltage Fault: Check battery voltage and charge if necessary. Check the
battery connections and tight or clean. Check the voltage to the ECU and PCU.
80 Over 80% Load Warning: Platform is getting close to its limit of weight. Consider
not adding more load.
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.
0Λ Overloaded Platform Fault: Remove the excess load immediately.
ΛΛ Machine Tilted Beyond Safe Limits Fault: If the machine is tilted, find away to
make it level. If the machine is level, check the wiring to the tilt sensor and then the
sensor itself.
6. Fault History State

The control allows the displaying of the last 10 faults. Holding down the RIGHT TURN
button on the top of the Joystick for 10 seconds (Without engaging the ENABLE button)
enters the
Fault History state. See Figure 3.

The LEFT TURN button scrolls through the fault history from the mostrecent to the oldest event
occurred while the RIGHT TURN button scrolls in the opposite direction from the oldest to the
mostrecent fault. The fault codes are summarized in Table 1.

Engaging the ENABLE button on the Joystick returns the display to normal operation.
7. Normal Operating State

After setting each of the desired parameters the lift can now be operated as desired.

7.1. Driving Forward or Backward with the Platform Stowed

Place the Key Switch in the platform position and pull out both the Chassis E-Stop switch and
the PCU E-Stop switch. Momentarily press the DRIVE button on the PCU (see Figure 2).
Pull in on the ENABLE switch of the Joystick and then push the Joystick forward for forward
movement and backward for backward movement (seeFigure 3for switches on the Joystick).
The farther the Joystick is pushed in either direction the faster the lift will move. Pushing down
on the LEFT TURN button or the RIGHT TURN button on the top ofthe Joystick will allow the
operator to steer the lift.

7.2. Raising or Lowering the Platform

7.2.1. From the Platform Using the PCU

With the lift stationary and with the lift in platform mode (see section above) push the LIFT
button on the PCU (seeFigure 2). The platform can now be raised by pushing forward on the
Joystick while the ENABLE switch is engaged (i.e. pulled in, see Figure 3). Pulling back on
the Joystick with the ENABLE engaged will lower the lift.
 7.2.2. From the Ground Using Chassis Controls

Chassis
Position

Turn the Key Switch to Chassis Position.

ch “CH” is Displayed.

Once in Chassis mode the platform will blink “CH” on its display.

Move the Chassis Toggle Switch up or down to raise or lower the Platform.

Figure 23: Chassis Control, Key Switch and Chassis Toggle Switch
 7.2.3. Software Revision and Machine Option Displayed

The ECU displays the Machine Options setting and Software Revision when raising and
lowering the platform in normal operation.

Note: Iferrors are present these software states will not be displayed.

The Machine Option

number will be displayed on
the ECU as the Platform
rises.

The Software Revision

number will be displayed on
the ECU as the Platform
lowers.

Figure 24: Obtaining the Machine Option Setting and the Software Revision

7.3. Operating the Lift with the Platform Elevated

Driving the lift while the platform is elevated is the same as driving it when the platform is
stored except that the machine will not allow itself to move as fast in either direction. This is
for operator safety reasons. Press the DRIVE button and operate the lift with the Joystick as
before, again the lift will need to be in the platform mode (see sec.7.1above).

7.4. Displays on the PCU and ECU in normal operation

The following table shows what you can expect to see on the PCU and ECU displays
during normal operation:

Table 3: Displays on the PCU and ECU

Operating Mode PCU Display ECU Display
Powered up but not Moving Battery Level

Driving Forward or Backward Battery Level

- -
Elevating the Platform Battery Level
- -
Machine Option code, see
Table 1.
Lowering the Platform Battery Level Software Version is
Displayed
Faults in either Platform or Fault Code Fault Code
Chassis Mode
In Chassis Mode
ch ch
For displays see Figure 2andFigure 4.
 7.5. Battery Charge State

In normal operating mode after proper initialization, the battery charge level is presented on the
PCU display in percentage: 10, 20, 30, 50, 70, and 90. At 10% the display flashes every
second.

Table 4: Battery onitor

Platform Battery Description
Display Percent

Battery is fully charged

90-100

70 percent of battery charge

50 percent of battery charge

30 percent of battery charge

20 Must Charge Battery

Very low charge.

10 (Note: Lift operates at low speeds
automatically)
8. Load Sensing

8.1. Limit Detection and Calibration with a Pressure Limit Switch

8.1.1.Basic Description
For lifts using a simple on/off detection of platform overload, a pressure limit switch can be
used to measure the pressure inside the hydraulic cylinder that elevates the platform. In this
case, if
the ECU detects an overload on the platform, the lift will simply stop lifting, sound an alarm,
and display the overload message on both the PCU and the ECU.

An example of an adjustable pressure limit switch is the Ashcroft

APAN41G00MHB022000#R. This switch has three wires connected to an internal SPDT
switch. For a SPDT device like this
connect +24V to theN/O connection, ground to theN/C connection and the signal to COMMON.
The firmware will detect an overload when ECU pin10A is pulled to +24V.

Note: when a limit switch is used the correct machine option code must be selected. This would
be either a 1x or a 3x number. See section 4 and Table 1 of this manual.

8.1.2.Calibration Process
If the pressure switch is adjustable, calibration is done by simply adjusting the pressure limit
switch itself. On the Ashcroft switch there is a small slotted screw that can be turned for this
purpose. Note: a small ring needs to be pulled down to expose the adjustment screw. If a
fixed pressure limit switch is used, no calibration is necessary.

1. Turn the adjustment on the pressure switch to its highest pressure setting. (Clockwise
on the Ashcroft switch).
2. Add weights equivalent to 110% of expected full load unto the platform.
3. Raise the platform to a point above its lower limit switch.
4. Using proper safety protocol adjust the limit switch down until the overload alarm
comes on and “OL” is displayed on the PCU and ECU.
5. The lift can still be lowered but it cannot be raised any further. With the platform still
loaded bring it down into the stowed position then raise the lift a second time. It should
indicate overload as soon as the lift is out of its stowed position (i.e. above the lower
limit switch).
6. Pressure can spike when starting and stopping the lifting process. Therefore after
getting the base adjustment made it maybe necessary to raise and lower the lift with the
110%
weights stopping at various heights. If the pressure switch triggers an overload as a
result of the stopping or starting, back off on the pressure setting until satisfied with the
results.
7. Stow the platform and remove the weights.
 8.1.3.Overload Operation

When the pressure limit has been reached the lift will simply stop lifting, sound an alarm,
and display the overload message on both the PCU and the ECU:

0
Figure 25: Overload Display

8.2. Load Sensing and Calibration with a Pressure Transducer

8.2.1.Basic Description
For lifts where apressure transducer is incorporated instead of the limit switch, the
transducer measures the pressure in the hydraulic cylinder that elevates the platform. It must
provide an analog voltage within a range of 0.5V to 4.5V to the input of the ECU.

In addition an angle sensor is mounted on one of the arms of the scissors for scissor position
information. The mechanical advantage of a scissors mechanism changes as it raises and lowers.
As a result, the pressure in the hydraulic cylinder will change even when the load is kept
constant depending on the position of the scissors. This sensing mode uses the angle and
pressure sensors to compensate to some degree for this variation. Load indicators of 80%, 90%,
and 99% are
displayed and provide an estimate of how close the platform is to full load. When the ECU
calculates that an overload has occurred “OL” is displayed and an alarm sounds followed by
a reduction in lift functions.

8.2.2.Calibration Process
For lifts with a pressure sensor on the lifting cylinder this section details the procedure for
calibrating the load-sensing feature. The pressure input to the ECU has a limited range of
0.5V to 4.5V with higher voltage representing higher pressure. Some pressure transducers will
therefore require a 5V power supply. Other transducers have an internal voltage regulator that
can take in a range of 20V to 28V and will output 0.5V to 4.5V for its full pressure range. An
example of a pressure transducer is the Sensepa HP330-250BG-4V. The maximum pressure
on
 this transducer is 250 BAR (3626psi). The actual choice of pressure transducer, and
specifically the maximum pressure, will depend on the characteristics of the lift.

An automated calibration process is initiated by activating a sequence of button presses. This

process should be performed twice; once with No Load on the platform, and a second time
with the 100% Full Load on the platform. The push button sequence is different for each.

During the initialization sequence each button must be pressed for a minimum of 0.15 seconds
and for no more than 2.50 seconds. Any button press outside of this time frame will nullify the
sequence and you will have to start over. After calibration, the load sensing feature of the
ECU will disable lifting motion when 110% of the rated load is detected on the platform.

1. Start with an unloaded Platform in the stowed position (“No Load”).

2. Turn the Key Switch to the “Platform” position. This will prevent the platform from
rising while the start sequence is being entered on the Ground Controller.

Key Switch Chassis Toggle Switch

Platform
Position

Figure 26: Switch Positions for No Load Calibration procedure

3. Press the Chassis Toggle switch in the following sequence:

“Down”, “Down”, “Down”, “Down”, “Down”, (5 “Downs”)

“Up”,
“Down”, “Down”, “Down”, “Down”, “Down”, (5 more “Downs”)
“Up”,
“Down”,
“Up”,
“Down”, “Down”, “Down” . (3 more “Downs”)

Each button must be pressed for a minimum of 0.15 seconds and for no longer than
2.50 seconds.

Any button press outside of this time frame will nullify the sequence and require
starting over from the beginning. Correctly entering the calibration sequence results in
5 audible blasts from the horn.
 The lift will now go through an automated calibration procedure with the empty platform.
The calibration process will be complete when the platform is all the way down and the horn
has stopped sounding.

This procedure must now be repeated with 100% rated load on the platform (“Full Load”).

4. Place the load on the platform, while it is in the full down or “Stowed” position.

5. Enter the toggle switch sequence for the 100% rated platform load:

“Down” “Down”, “Down”, “Down”, “Down”, “Down”, (5 “Down”)

“Up”, (1 Up)
“Down”, “Down”, “Down”, “Down”, “Down”, (5 “Down”)
“Up”, (1 Up)
“Down”, “Down”, “Down”, “Down”, “Down”, (5 “Down”)

The lift will perform an automated calibration procedure for the fully-loaded platform. The
calibration process after full elevation is obtained and has returned down automatically. The horn
will stop sounding when the platform returns to the chassis.

If the procedure failed, horn will sound several times. The process must be

repeated. If successful,the lift load-sensing feature has now been fully calibrated.

If the lift should need to be recalibrated due to wear or component replacement, repeat the
above procedure.
 8.2.3.Overload Operation

80

Figure 27: 80% Load Limit Warning

The first indication of the Platform reaching its weight capacity will be at 80% of overload.
“80” will be displayed on the PCU and the overload LED on the chassis will blink to indicate to
ground personnel that the load is nearing the machine’s limit.

90

Figure 28: 90% Load Limit Warning

At 90% of overload the alarm will sound and “90” is displayed. The overload LED on the
chassis will continue to blink.

99

Figure 29: 99% Load Limit Warning

If the platform has been loaded to 99% of overload, “99” will appear and the alarm will
continue to sound. The overload LED on the chassis will continue to blink.
 0

Figure 30: Overload Display

If the Platform has been loaded above capacity OverLoad “OL” will appear and the PCU’s
alarm will begin to sound along with the chassis’s alarm, both at a faster rate. The lift maybe
lowered ONLY by manual means unless the Platform is below the “Platform Height Descent
Limit” (see Section3.3) or the load is reduced to a level where the alarm stops sounding.

Warning: All recommended safety procedures should be followed to remove an overload

condition.