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ELECTRIC TRUXTA - DIAGNOSTICS & TROUBLESHOOTING
The machine controller detects a wide variety of faults or errors.
Diagnostic information can be obtained on the 3100R fuel gauge display where an error code in the format ''Err ##''.
The troubleshooting chart below describes the Error code faults and their possible causes.
Whenever a fault is encountered the first action should be to turn off the ignition and push in the E stop button. Then pull out the E stop button and turn the ignition back
on to see if the fault clears. This is the RESET procedure:.
If the Error code does not clear after the machine RESET, turn off the ignition switch and remove the 35-pin connector. Check the connector for correction or damage,
clean it if necessary, and reinsert it.
If the Error is still seen then the wiring and connections on the machine should be checked for breakages or loose connections.
The table below should be used as a reference once the above checks have been carried out.
Error code
Description of Error
HW
1
Fail-safe
Main brake driver over
10
current
Main
15
Current dropped
Main
17
Contactor Welded
Supervisor DIR Check
33
Fault
34
External Supply Fault
EM-Brake Driver
36
Open Drain
54
Pre-charged Failed
HPD
80
Sequencing
92
Motor Open
99
Under-voltage Cutback Battery voltage too low
Quick checks if no reading on fuel gauge and machine does not operate:
1. Check 10A fuse in the control panel. Fuse holder is located to the right hand side of the main control panel, turn CCW to release the fuse holder.
2. Check main fuse located behind the rear motor housing cover & 100A fuse. Open the rear cover which is fixed in position with 2 x M6 screws, ensure the cover is
supported during this process. Main fuse is located on the left hand side of the battery housing.
When changing the 100 amp fuse, ensure that the positive battery lead is fully dis-connected. Electrical maintenance should be carried out by a qualified person.
AGM Battery Charging
To maximize the life of your AGM battery, it is important that it is
properly charged. As with all lead-acid batteries, both over- and under-
charging an AGM battery will result in shortened service life.
The TRUXTA mini dumpers are fitted with an on-board SMART charger
which maintains the battery full charge condition without resulting in
over charging.
The AGM batteries are sealed for life units and do not require any fluid
top up.
Please read the following instructions:
Charging system Inspection
The charger's AC (mains) cord should be free of breaks or cuts and the
wall plug socket should be clean and free from debris.
The cable connectors from the on-board charger should be clean and
properly mate with the battery terminals to ensure a sound connection.
Battery Inspection
Check battery cables are not damaged.
Connectors should be free of corrosion.
DC Cable post or eyelet connectors are tight to avoid arcing.
Possible Cause /
Reason for Error
Motor fault voltage (hardware failure)
Main contractor failed open.
Main contractor on fault
If fault is on an external signal, check that
signal first. If no problem with the external
signal, likely indicates an internal controller
fault.
Under voltage
Hold voltage is set at 90%
Pre-charge fault
HPD fault present > 10 seconds
Traction motor not connected.
ELECTRIC TRUXTA - DIAGNOSTICS & TROUBLESHOOTING - GB
Check points
1. Motor voltage does not correspond to throttle
request.
2. Short in motor or In motor wiring.
Short circuit or overloaded controller driver, Early
controllers were re-programmed
1. Clean the contactor switch
1. Main contactor failed closed, replace contactor.
Early controllers were re-programmed
1. Check control wiring circuit, potentiometer wiring in
particular.
1. Check bullet connectors to brake, check continuity or
2. The motor brake has failed.
1. Low battery voltage - 25V (11/12V) is good
condition, 22V (9/10V) or lower is bad batteries
condition.
2. Short circuit on traction motor outputs.
1. Misadjusted throttle
2. Broken throttle potentiometer or throttle
mechanism.
Controller can not see the motor.
Could be a short circuit in the motor.
1. Check the resistance across the motor leads.
Battery voltage < undervoltage threshold.
1. Bad connection at battery or controller.
2. Check no corrosion on the battery terminals.
Charging Guidelines
Fully charge batteries after batteries have been dis-charged to ¼ full on battery
gauge. The on-board charger mains cord should be plugged into the mains AC
supply. Leave batteries to complete full charge and do not disconnect until fully
charged. Once fully charged the on-board SMART battery charger will maintain
the battery fully charged status.
Do not opportunity charge batteries i.e. if the batteries have only dis-charged
to ¾ full on the battery gauge, there is no need to connect the charger to the
AC supply. It is recommended to use the dumper until the batteries have dis-
charged to ¼ full on the battery gauge, then place the dumper onto a full charge
cycle.
Charge in a ventilated area as gasses may be released through the pressure
relief valve if the batteries are excessively over-charged.
Never charge a frozen battery.
Ideal charging temperatures: (0°C to 40°C) 32°F to 104°F
Technical Bulletin
(see website)
TB10001
TB10010
TB10008
TB10004
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