LUCAS CONTROL CE010-153 User manual

Réf. : CE010-153(U)
As of series n° 100419 O 1801
CONTROL CE010-153
(Telescopic Raptor)

I –General malfunction: no light comes on -1/2
SERVICE MANUAL SHEET
Reference:
00 01 MR 86
I –General Malfunction: No light comes on
T10 Telescopic handler’s electrical power supply test
Condition:
oPlug between the machine and the telescopic handler disconnected.
oTelescopic handler in operation (in order not to be disturbed by the connections after
contact).
Mean of control:
oVoltmeter in direct current.
Process:
oMake sure that the power supply U=13Vcc ±1 at the lift truck plug terminals.
Résultat :
Result
Observation
Action
0 Vcc
Power supply problem
on telescopic handler.
Repair the telescopic
handler’s electrical
power supply.
+ 13 Vcc ±1
Power supply is ok.
Test ok, go on with
the tests.
- 13 Vcc ±1
Change of polarity.
Repair the telescopic
handler’s electrical
power supply.
The control box doesn't
switch on when the M
button is pressed
Telescopic handler’s
electrical power
supply test
Board electrical
power supply test
Repair telescopic handler’s
power supply
Act according to the test conclusions
Control at fault
See Chap. II –Malfunction of a controlled
hydraulic function: Main control at fault
T10
Bad
Bad
Good
Good
T11

I –General malfunction: no light comes on -2/2
SERVICE MANUAL SHEET
Reference:
00 01 MR 86
T11 Board’s electrical power supply test
Condition:
oControl box open and switched on.
oPlug between the machine and the telescopic handler is connected.
oTelescopic handler in operation (in order not to be disturbed by the connections after contact)
Mean of control:
oVisual
Process:
oCheck the state of the 4 control leds inside the control box (Led INV, led ALIM, led FUSE 12V, led FUSE
5V)
Result:
State of the Leds: Led ON.
Led OFF.
Led INV
Led ALIM
Led FUSE 12V
Led FUSE 5V
Observation
Action
Case 1
Power supply OK.
Test OK, go on with the tests.
Case 2
Change of polarity.
Check the complete line (cable, plug, telescopic
handler’s power supply,…).
Case 3
No electrical power supply.
Case 4
Motherboard faulty.
Change the motherboard.
Case 5
Overconsumption.
Resettable fuses heat up.
Go on with the following test.
1- Disconnect the plug between the machine and the telescopic handler,
2- Disconnect the whole outputs (electrovalves and auxiliary boards),
3- Connect the telescopic handler’s electrical power supply again,
4 –Check the state of the control Leds.
Led INV
Led ALIM
Led FUSE 12 V
Led FUSE 5V
Observation
Action
Case 5.1
Motherboard is not at
fault.
External short circuit
Reconnect the outputs and the boards one by one until
you find out the one which is at fault.
Repair or replace it
Case 5.2
Motherboard is at fault.
Replace the board (follow the procedure here after).
Be careful :
The fault on the board is certainly due to an external short-circuit (output –auxiliary board).
During replacement you should first only connect the inputs (power supply –handle) and start-up.
Then you must reconnect the outputs and the auxiliary boards one by one and check for each that they do not blow fuses
(Led FUSE goes off and fuses heat up).
Then return to the case 5.1.
This procedure must be respected so that the new board is not damaged.

II –Malfunction of a controlled hydraulic function: the main control is faulty -1/4
SERVICE MANUAL SHEET
Reference:
00 01 MR 87
II - Malfunction of a hydraulic function
Main CONTROL is at fault.
Prior checks:
Make sure that the electrical power supply is ok.
(Chap. I-General malfunction: No light comes on)
The controlled function does
not react when the
button(s) is/are pressed.
Control operation
external test
T20
Bad
Button test
The main control is not faulty.
Continue to the chap.
III –Malfunction of a controlled hydraulic
function: Fault due to the electrovalves.
Replace the
faulty
buttons
Control cable test
Replace the
control or the
cable or the
plug
Bad
Bad
Good
Good
Replace the
control
Bad
Good
Replace the motherboard
T22
T23
T24
Control
electrical
power supply
test
Connection faulty.
Good
Power supply faulty
T21
Control board test
Good

II –Malfunction of a controlled hydraulic function: the main control is faulty -2/4
SERVICE MANUAL SHEET
Reference :
00 01 MR 87
T20 External test : control operation
Condition:
oPlug between the machine and the telescopic handler connected.
oTelescopic handler in operation (in order not to be disturbed by the connections after
contact).
oControl box switched on in normal operating mode.
Mean of control:
oVisual.
process:
oInvolves checking that the green « ON » pilot light on the front side of the control box flashes
when a button is pressed. This test must be performed for all the buttons one after the other.
Résult:
oThe test is considered « OK » if the green pilot light flashes for ALL the buttons.

II –Malfunction of a controlled hydraulic function: the main control is faulty -3/4
SERVICE MANUAL SHEET
Reference:
00 01 MR 87
T21 Control electrical power supply test
Condition:
oPlug between the machine and the telescopic handler connected.
oTelescopic handler in operation (in order not to be disturbed by the connections after
contact).
oControl box switched on in normal operating mode and open.
Mean of control:
oVisual.
Process:
oInvolves checking that the control power supply control led lights up.
oInvolves checking that the control’s 3 wires are properly connected inside the control box +
connecting plugs (machine and telescopic handler).
Résult:
oIf the control’s power supply control led does not light up the motherboard is faulty and you
have to replace it (make sure before that the motherboard’s electrical power supply is ok).
oIf the control’s cables are connected wrongly please connect them again.
oIf no fault is found out go on with the tests.

II –Malfunction of a controlled hydraulic function: the main control is faulty -4/4
SERVICE MANUAL SHEET
Reference:
00 01 MR 87
T22 Button test
Condition:
oPlug between the machine and the telescopic handler disconnected.
oControl box switched off.
Mean of control:
oOhmmeter in continuity position.
oVisual.
Process :
oCheck the button continuity by placing the ohmmeter et the button’s terminals and pressing
it.
oCheck that the wires between the buttons and the handle’s board are not cut or unsoldered.
Result:
oIf the continuity results are bad for some buttons please replace them.
oIf some wires are cut please replace them.
oIf some wires are unsoldered please solder them again.
T23 Control cable test
Condition:
oPlug between the machine and the telescopic handler connected.
oControl box switched off.
oControl wires disconnected from the terminal inside the control box.
Mean of control:
oOhmmeter
Process:
oCheck the continuity for each wire of the control bundle.
oCheck the short-circuit for each wire of the control bundle.
Result:
oIf one of the cables on the telescopic handler side is faulty (between the handle and the
connecting plug of the telescopic handler), replace the whole main control.
oIf one of the cables on the machine side is faulty (between the connecting plug and the
control box), replace the handle bundle, machine side.
oIf a connecting plug is at fault, replace it.
T24 Control board test
Condition:
oDisconnect the control wires from the terminal inside the control box, and connect a handle in
working order (do this with control box switched off).
oConnecting plug between the machine and the telescopic handler connected.
oTelescopic handler in operation (in order not to be disturbed by the connections after
contact).
oControl box switched on in normal operating mode.
Mean of control:
oVisuel
process:
oInvolves checking that all the hydraulic functions are operating properly.
Result:
oIf all the hydraulic functions are ok, that means that the control’s board is faulty, replace the
main control.
oIf just one hydraulic function is at fault, the motherboard has a defect, replace it.

III –Malfunction of a hydraulic function: Fault due to the electrovalves-1/5
SERVICE MANUAL SHEET
Reference:
00 01 MR 88
III –Malfunction of a hydraulic function:
Fault due to the electrovalves
Prior checks:
Make sure that the electrical power supply is ok.
(Chap. I-General malfunction : no light comes on)
Make sure that the main control is operating properly.
(Chap. II –Malfunction of a hydraulic control: Fault due to the main control)
Make sure that the hydraulic power supply coming from the telescopic handler is ok (continuous
pumping activated, connection valves rightly mounted)
The controlled function does
not react when the
button(s) is/are pressed.
Output control
led test
T31
Bad
Good
The leds
LIGHT UP
The leds
FLASH
The Leds remain
OFF
The elctrovalves are correctly
excited.
Hydraulic problems :
- Pollution (replace the filter)
- Slide valve blocked
- Spring broken
- …
The electrovalves are not
excited.
Output circuit OPEN
Suspicion of short-circuit at
the output:
DISCONNECT all the
outputs concerned
Output control
Leds test
T32
Change the configuration
and start again the T31 test
Check program
configuration
Short-circuit at
the output
Coil test
Coil link test
Electronic problem
Replace the motherboard.
Replace the
coil
The Leds
FLASH
The Leds remain
OFF
Bad
Mauvais
Bad
Good
Good
T34
T35
Good
Test with hand
control
Bad
Good
T31
Coil and bundle
test
Bad
T30
T33
Bad
Repair the
connection

III –Malfunction of a hydraulic function: Fault due to the electrovalves-2/5
SERVICE MANUAL SHEET
Reference:
00 01 MR 88
T30 Function test with hand control
Condition:
oConnection plug between the machine and the telescopic handler connected.
oTelescopic handler in operation (in order not to be disturbed by the connections after contact).
oControl box switched on in normal operation mode.
oHydraulic power supply in continuous pumping.
Mean of control:
oVisual.
Process:
oFind out the coils corresponding to the function at fault and to the inverse one, using the table
see chap. IV –Electrovalve excitation table.
oUsing an appropriate tool, press at the end of the concerned coils.
oRepeat the previous stage for the inverse function.
Location of the electrovalves in the main block:
Location of the electrovalves in the fan block:
Résult:
oThe test is considered « ok » if the faulty function is operating in both directions. Go on with
the tests : electric or electronic problem.
oThe test is considered « bad » if the function does not operate, hydraulic problem (pollution,
slide valve blocked, spring broken, flow regulator…). If the function does not operate only in
one direction make sure it is not protected with a specific pressure limiter and check that this
limiter is not set (concerned function: loading door line A3 (130 bar) and line B3 (185 bar)).

III –Malfunction of a hydraulic function: Fault due to the electrovalves-3/5
SERVICE MANAUL SHEET
Référence :
00 01 MR 88
T31 Output control led test
The output control leds can have 3 different states:
- ON : output activated,
- FLASHING (quickly): output activated but in open circuit (ex.: electrovalve not connected),
- OFF: 2 cases, either the output is not activated, or it is, but in short-circuit (ex. Electrovalve’s
coil faulty).
Condition:
oConnection plug between the machine and the telescopic handler connected.
oTelescopic handler in operation (in order not to be disturbed by the connections after contact).
oControl box switched on in normal operation mode.
oControl box open.
Mean of control:
oVisual.
Process::
oFind out the outputs corresponding to the function at fault using the table, see chap. IV –
Electrovalve excitation table.
oSwitch off the control box, then switch it on again (this ACTION is VITAL, as each time it is
put into service the box performs an output status self test (normal, open, or short circuited).
oActivate the faulty function and check the state of the output control Leds in question.
Résult:
oThe concerned control Leds are ON, no electronic problem, but hydraulic problem.
oThe concerned output Leds are FLASHING, the circuit is open, go on with the tests.
oThe concerned control leds are OFF, the circuit may be short-circuited, go on with the tests.