ev-100zx™ scr motor controller

Maintenance

EV-100ZX™ SCRMOTORCONTROLLER

DESCRIPTION, ADJUSTMENTS,TROUBLESHOOTING, REPAIRS,

AND THEORY

ERC/P16-20AAF (ERC030-040AF) [A814];ERC070-120HD [A839]; ERP20-30ALF [B216];

ERC20-30AGF (ERC040-065RF/ZF) [E108]

PART NO. 524179947 2200 YRM 557

SAFETY PRECAUTIONSMAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-tened, and that the load being lifted is balanced. Make sure the crane, cables, and chainshave the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair onelectric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THELIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meetor exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before usingforce to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, orif the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel areflammable. Be sure to follow the necessary safety precautions when handling these fuelsand when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks awayfrom the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTIONIndicates a condition that can cause property damage!

EV-100ZX™ SCR Motor Controller Table of Contents

TABLE OF CONTENTS

General.................................................................................................................................................................. 1Model Number Data For EV-100ZX Controller.................................................................................................. 2

Register Parameters............................................................................................................................................ 16General ........................................................................................................................................................... 16Function Numbers........................................................................................................................................... 16

Control Card, Checks and Adjustments .............................................................................................................. 16Handset ............................................................................................................................................................... 17

How to Check and Adjust Registers................................................................................................................ 17How to Scroll through Fault Codes and Clear Them....................................................................................... 17Checks and Adjustments on Workbench ........................................................................................................ 18When Handset Is Connected to Control Card Installed In Lift Truck ............................................................... 19Function Numbers 1 through 15...................................................................................................................... 20Function Numbers 16 through 30.................................................................................................................... 20Function Numbers 48 through 62.................................................................................................................... 20

Control Cards ...................................................................................................................................................... 21Function Number Descriptions........................................................................................................................ 21Traction Control Cards (Label Letters - ZH and ZY)........................................................................................ 21

Function Number 1 STORED STATUS CODE............................................................................................ 21Function Number 2 CREEP SPEED........................................................................................................... 21Function Number 3 CONTROLLED ACCELERATION AND 1A TIME........................................................ 21Function Number 4 CURRENT LIMIT......................................................................................................... 22Function Number 5 PLUGGING DISTANCE (CURRENT).......................................................................... 22Function Number 6 1A DROP OUT CURRENT ......................................................................................... 22Function Number 7 FIELD WEAKENING PICK UP.................................................................................... 22Function Number 8 FIELD WEAKENING DROP OUT ............................................................................... 22Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT........................................................... 22Function Number 10 REGENERATIVE BRAKING START ......................................................................... 23Function Number 13 SPEED LIMIT 3 (SL3) ............................................................................................... 23Function Number 14 INTERNAL RESISTANCE COMPENSATION ........................................................... 23Function Number 15 BATTERY VOLTS ...................................................................................................... 24Function Numbers GREATER THAN 15..................................................................................................... 24Function Number 16 PEDAL POSITION PLUG.......................................................................................... 24Function Number 17 CARD TYPE SELECTION ........................................................................................ 24Function Number 18 STEERING PUMP TIME DELAY .............................................................................. 24Function Number 19 MAINTENANCE ALERT (Tens/Units) ....................................................................... 25Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)...................................................... 25Function Number 21 MAINTENANCE SPEED LIMIT................................................................................. 25Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS ....................................................... 25Function Number 29 HOURMETER (Tens/Units) ....................................................................................... 25Function Number 30 HOURMETER (Thousands/Hundreds) ..................................................................... 25Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE ..................................................... 25Function Number 48 CONTROLLED ACCELERATION AND 1A TIME...................................................... 26Function Number 49 FIELD WEAKENING PICK UP.................................................................................. 26Function Number 50 SPEED LIMIT 1......................................................................................................... 26Function Number 52 CONTROLLED ACCELERATION AND 1A TIME...................................................... 26Function Number 53 FIELD WEAKENING PICK UP.................................................................................. 26Function Number 54 SPEED LIMIT 1......................................................................................................... 27Function Number 56 CONTROLLED ACCELERATION AND 1A TIME...................................................... 27Function Number 57 FIELD WEAKENING PICK UP.................................................................................. 27Function Number 58 SPEED LIMIT 1......................................................................................................... 27Function Number 60 CONTROLLED ACCELERATION AND 1A TIME...................................................... 27

©2003 Yale Materials Handling Corp. i

Table of Contents EV-100ZX™ SCR Motor Controller

TABLE OF CONTENTS (Continued)

Function Number 61 FIELD WEAKENING PICK UP.................................................................................. 27Pump Control Card (Label Letter ZP) ............................................................................................................. 27

Function Number 1 STORED STATUS CODE............................................................................................ 28Function Number 2 INTERNAL RESISTANCE COMPENSATION START................................................. 28Function Number 3 CONTROLLED ACCELERATION ............................................................................... 28Function Number 4 CURRENT LIMIT......................................................................................................... 28Function Number 7 CONTROLLED ACCELERATION COMPENSATION.................................................. 28Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and Slow Auxiliary (Auxiliary andSlow Rotate for N30XMH)........................................................................................................................... 28Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lift and Medium Auxiliary(Slow Lift And Fast Rotate for N30XMH) .................................................................................................... 28Function Number 13 SPEED LIMIT 3 (SL3) ............................................................................................... 28Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift ................................................................................. 29Function Numbers Greater Than 15 ........................................................................................................... 29Function Number 16 INTERNAL RESISTANCE COMPENSATION ........................................................... 29Function Number 17 CARD TYPE SELECTION ........................................................................................ 29Function Numbers 18 through 28 TEMPORARY DATA REGISTERS ........................................................ 29Function Number 29 HOURMETER (Tens/Units) ....................................................................................... 29Function Number 30 HOURMETER (Thousands/Hundreds) ..................................................................... 29Function Number 48 CONTROLLED ACCELERATION ............................................................................. 30Function Number 49 SPEED LIMIT 2......................................................................................................... 30Function Number 50 SPEED LIMIT 3......................................................................................................... 30Function Number 52 CONTROLLED ACCELERATION ............................................................................. 30Function Number 53 SPEED LIMIT 2......................................................................................................... 30Function Number 54 SPEED LIMIT 3......................................................................................................... 30Function Number 56 CONTROLLED ACCELERATION ............................................................................. 30Function Number 57 SPEED LIMIT 2......................................................................................................... 30Function Number 58 SPEED LIMIT 3......................................................................................................... 30Function Number 60 CONTROLLED ACCELERATION ............................................................................. 31Function Number 61 SPEED LIMIT 2......................................................................................................... 31Function Number 62 SPEED LIMIT 3......................................................................................................... 31

Register Parameters ....................................................................................................................................... 31Troubleshooting ................................................................................................................................................... 31

General ........................................................................................................................................................... 31Status Codes................................................................................................................................................... 32Register Maps ................................................................................................................................................. 34

Status Code Charts ............................................................................................................................................. 45EV-100ZX SCR Motor Controller Repair ............................................................................................................. 86

Fuses .............................................................................................................................................................. 86SCR, Check .................................................................................................................................................... 86SCR Assembly ................................................................................................................................................ 88Thermal Protector ........................................................................................................................................... 88SCR 1 Assembly, Replace .............................................................................................................................. 88OFF Circuit for SCR 1 ..................................................................................................................................... 89

Reactor Assembly, Check ........................................................................................................................... 89Suppressors for SCR 2 and SCR 5, Check ................................................................................................ 89SCR 2 and SCR 5, Check........................................................................................................................... 89SCR 2 and SCR 5, Replace ....................................................................................................................... 90Capacitor C1, Check................................................................................................................................... 90

Diodes D3 and D4........................................................................................................................................... 90Diodes D3 and D4, Check .......................................................................................................................... 90

ii

EV-100ZX™ SCR Motor Controller Table of Contents


Diodes D3 and D4, Replace ....................................................................................................................... 90Motor Current Sensor...................................................................................................................................... 90Contactors....................................................................................................................................................... 91

Contactor, Repair ........................................................................................................................................ 91Control Card.................................................................................................................................................... 93Control Card Plugs.......................................................................................................................................... 94

Brush Wear Indicators ................................................................................................................................ 94Theory of Operation ............................................................................................................................................ 95

Electronic Speed Controls............................................................................................................................... 95Silicon Controlled Rectifier (SCR)............................................................................................................... 96Motor Circuit That Operates With Pulses.................................................................................................... 97Traction Circuit ............................................................................................................................................ 98Hydraulic Pump Motor ................................................................................................................................ 98SCR 1 OFF Circuit ...................................................................................................................................... 98

SCR 1 OFF Operation ............................................................................................................................ 99Induction Current from Motor ........................................................................................................................ 101Control Cards ................................................................................................................................................ 102

Pulse Monitor Trip (PMT) (Traction Circuit Only)....................................................................................... 102SRO Circuit (Traction Circuit Only) ........................................................................................................... 102

Sequence of Operation ................................................................................................................................. 103Control Card Adjustments (Traction Circuit).............................................................................................. 103Accelerator Control ................................................................................................................................... 107

SCR Control (Hydraulic Pump Motor) ........................................................................................................... 107Contactors..................................................................................................................................................... 107Circuit Protection........................................................................................................................................... 108

Traction Circuit Fuse ................................................................................................................................. 108Current Limit ............................................................................................................................................. 108Thermal Protection ................................................................................................................................... 108Suppressors.............................................................................................................................................. 109

Truck Management Module (TMM1) ............................................................................................................. 109Display Panels............................................................................................................................................... 110

Display Panel ............................................................................................................................................ 110Optional Basic Display Panel .................................................................................................................... 110

Features of the Optional Basic Display Panel....................................................................................... 110Description of Features on the Optional Basic Display Panel .............................................................. 111

Standard Display Panel............................................................................................................................. 111Features of the Standard Display Panel ............................................................................................... 111Description of Features on the Standard Display Panel ....................................................................... 112

Premium Display Panel............................................................................................................................. 113Features on the Premium Display Panel .............................................................................................. 113Description of Features on the Premium Display Panel ....................................................................... 114

Curtis 1215 Display Panel ............................................................................................................................. 116Description and Features.......................................................................................................................... 116Operation .................................................................................................................................................. 117

iii

Table of Contents EV-100ZX™ SCR Motor Controller


This section is for the following models:

ERC/P16-20AAF (ERC030-040AF) [A814];ERC070-120HD [A839];ERP20-30ALF [B216];

ERC20-30AGF (ERC040-065RF/ZF) [E108]

iv

2200 YRM 557 General

GeneralFour Service Manual sections are required for the com-plete Description, Checks, Adjustments, Troubleshoot-ing, and Repairs of this motor controller:• EV-100ZX SCR Motor Controller, Description, Ad-

justments, Troubleshooting, Repairs, and Theory2200 YRM 557 (this section)

• Troubleshooting and Adjustments With a Com-puter for EV-100ZX and EV-T100 Motor Con-trollers 2200 YRM 947

• EV-100ZX SCR Motor Controller, Parameter Ta-bles 2200 YRM 595 and 2200 YRM 624

• Electrical System, Repairs, Checks, and Adjust-ments 2200 YRM 560

This section describes the operation and the functionsof the EV-100ZX motor controller. The EV-100 and theEV-200 series of motor controllers, used to control theoperation of electric lift trucks, are made by the GeneralElectric Company.

The EV-100 and the EV-200 series of motor controllersare similar in design and function, but have differentcontrol cards.

The ZX letters identify the controllers that have the ZXseries of diagnostic control cards. These control cardscan use an adapter for a serial cable that will connectto a serial port on a personal computer for checks, ad-justments, and troubleshooting.• A Cable Kit, Control Card to Computer, is required

(Yale Part No. 518802649).• The SMARTSET™ software for a personal computer

is available on a 3.5-inch diskette (Yale Part No.524146551).

• The Cable Kit and the 3.5-inch diskette with theSMARTSET™ software are available from yourdealer for Yale lift trucks.

These control cards have logic circuits and registersthat control and keep a record of the operations of themotor controller. The registers also keep a record ofpossible malfunctions of the motor controller that canindicate the problems during troubleshooting.

This section has the following components:

• A Description for the EV-100ZX SCR Motor Con-troller.

• A series of Status Code Charts that describe an in-dication of a fault and its possible causes when thecode is shown on the instrument panel display.

• Checks and replacement of the components of themotor controller are described in Repairs.

• A basic Theory Of Operation on how an SCR motorcontroller operates.

An electronic diagnostic and adjustment device canalso be used to check and adjust the control cards.This electronic diagnostic and adjustment device iscalled a Handset and is described later in this section.A computer with the control software installed has ac-cess to 128 function registers on the control cards. TheHandset has access to less function registers on thecontrol card and can only make changes to a limitednumber of the registers on the ZX control cards.

A description and the replacement of the instrumentpanel display is also included in the repair section.

Most of the components of the EV-100ZX motor con-troller cannot be repaired, but must be replaced. Thissection describes the procedures for using the elec-tronic diagnostic and adjustment devices for checkingand adjusting the operation of the motor controller.

There are electrical components that are not part of themotor controller, but give input signals to it. These com-ponents include the following:• Key switch• Start switch (earlier production units only)• Brake switch• Foot switch• Seat switch• Direction (Forward and Reverse) switches• Accelerator potentiometer• Guidance and steering systems

Checks and replacement of these electrical compo-nents are described in Electrical System, Repairs,Checks, and Adjustments 2200 YRM 560.

1

General 2200 YRM 557

MODEL NUMBER DATA FOR EV-100ZXCONTROLLER

The model numbers for the EV-100ZX controller indi-cate the following information:

Example:

IC3645EV 100 T1 ZH 1

(01) (02) (03) (04) (05)

(01) The first series of letters and numbers indicate thebasic catalog number of the controller.

(02) The second set of numbers indicates the powerbase rating of the controller:

100 = EV100 Power Base [lift trucks less than3500 kg (7000 lb) capacity]200 = EV200 Power Base [lift trucks with 3500 kg(7000 lb) or greater capacity]

(03) This set of letters indicate the application and SCR1 options:

T1 = Standard Current Limit for traction motorT2 = High Performance Current Limit for traction mo-torP1 = Standard Current Limit for hydraulic pump mo-torP2 = High Performance Current Limit for hydraulicpump motor

(04) This set of letters indicate the control card options:ZH = Traction Controller with three-wire potentiome-ter and with Battery Discharge Indicator (BDI)ZP = Pump Motor Controller with Truck ManagementModule (TMM1)

ZY = Traction Controller with three-wire potentiome-ter and without Battery Discharge Indicator (BDI)

(05) This number indicates the revision code:1 = Active

The ZX series of motor controllers have an output to op-erate a digital display with four digits. A digital displayunit (instrument panel display) is available for the instru-ment panel of some lift trucks. The ZX control cardscan use an adapter for a serial cable that connects to aRS-232-C serial port on a personal computer (PC) forchecks and adjustments. A Handset with a digital dis-play is also available. All of the control settings are setusing a PC or the Handset.

The control card is a printed circuit board with electronicparts in a plastic case. The position of the control cardsin the controllers can be seen in Figure 1, Figure 2,and Figure 3. Two machine screws at the bottom of theplastic case fasten the control card to the mount plate.

The control card has two 6-pin plugs (PA and PB) thatconnect the signal wires between the parts of the con-troller and the control card. A terminal strip with sixscrew connections are inputs from control componentsof the lift truck. A 14-pin plug (PZ) connects the con-trol card to the functions for SCR 1, SCR 2, and SCR5. See Figure 4. Plug PY is a 14-pin plug that con-nects the instrument panel display, PC, or the Handsetto the control card. Some pins of plug PY are also usedto connect to the control card for the hydraulic pumpmotor. The functions of the of the signal wires are de-scribed in Table 1, Table 2, Table 3, and Table 4.

2


Figure 1. Typical Configurations of EV-100ZX Motor Controller in ERC/P16-20AAF (ERC030-040AF),ERC20-30AGF (ERC040-065RF/ZF) Model Lift Trucks

3


Legend for Figure 1

A. MOTOR CONTROLLER WITH REGENERATIVEBRAKING, 1A BYPASS, AND SCR CONTROLLERFOR HYDRAULIC PUMP

B. MOTOR CONTROLLER WITH REGENERATIVEBRAKING, 1A BYPASS, AND CONTACTORCONTROL FOR HYDRAULIC PUMP

1. TRACTION CONTROLLER2. SCR CONTROL FOR HYDRAULIC PUMP

MOTOR CONTROLLER3. HYDRAULIC PUMP MOTOR CONTACTOR4. FORWARD CONTACTOR5. REVERSE CONTACTOR6. 1A BYPASS CONTACTOR7. REGENERATIVE BRAKING CONTACTOR

(OPTION ON SOME MODELS)

8. FIELD WEAKENING CONTACTOR (OPTION ONSOME MODELS)

9. FIELD WEAKENING RESISTOR (OPTION ONSOME MODELS)

10. ELECTRONIC DRIVER11. TRUCK MANAGEMENT MODULE (TMM1)12. FUSE 1 (TRACTION CIRCUIT)13. FUSE 2 (HYDRAULIC PUMP CIRCUIT)14. FUSE PANEL (FU 7, FU 3, FU 5, FU 6)15. FUSE 4 (STEERING CIRCUIT)

4


A. MOTOR CONTROLLER WITH REGENERATIVEBRAKING, 1A BYPASS, AND SCR CONTROLLERFOR HYDRAULIC PUMP

B. MOTOR CONTROLLER WITH REGENERATIVEBRAKING, 1A BYPASS, AND CONTACTORCONTROL FOR HYDRAULIC PUMP

1. TRACTION CONTROLLER2. SCR CONTROL FOR HYDRAULIC PUMP

MOTOR CONTROLLER3. HYDRAULIC PUMP MOTOR CONTACTOR4. FORWARD CONTACTOR5. REVERSE CONTACTOR6. 1A BYPASS CONTACTOR7. REGENERATIVE BRAKING CONTACTOR8. FIELD WEAKENING CONTACTOR

9. FIELD WEAKENING RESISTOR10. COUNTERWEIGHT11. ELECTRONIC DRIVER12. TRUCK MANAGEMENT MODULE (TMM1)13. FUSE 1 (TRACTION CIRCUIT)14. FUSE 2 (HYDRAULIC PUMP CIRCUIT)15. FUSE PANEL (FU 7, FU 3, FU 5, FU 6)16. FUSE 4 (STEERING CIRCUIT)

Figure 2. Typical Configurations of EV-100ZX Motor Controller in ERP20-30ALF Model Lift Trucks

5


Figure 3. Configurations of EV-100ZX or EV-200ZX SCR Motor Controllers in ERC070-120HD Lift Trucks

6


Legend for Figure 3

NOTE: LABELS THAT HAVE A COMBINATION OF NUMBERS AND LETTERS ARE FOR POWER CABLES. LA-BELS THAT HAVE ONLY NUMBERS ARE FOR CONTROL WIRES.

A. EV-200ZX TRACTION AND SCR HYDRAULICCONTROLLERS

B. EV-100ZX OR EV-200ZX TRACTION AND DUALCONTACTOR HYDRAULIC CONTROLLERS

C. EV-100ZX TRACTION AND SCR HYDRAULICCONTROLLERS

D. EV-100ZX OR EV-200ZX TRACTION AND ONECONTACTOR HYDRAULIC CONTROLLER

1. TRACTION MOTOR CONTROLLER2. MOTOR CONTROLLER(S) FOR LIFT PUMP

MOTOR3. POWER STEERING CONTACTOR

1. CONTROL CARD (TRACTION OR HYDRAULICPUMP)

2. TB SCREW TERMINALS (6)3. PLUG GUIDES

4. PLUG PA (6-PIN) (WIDE GUIDES)5. PLUG PB (6-PIN) (CLOSE GUIDES)6. PLUG PY (14-PIN)7. PLUG PZ (14-PIN)

Figure 4. Control Card Connections

7


Table 1. Terminal and Plug Wire Connections for Control Card ZY, SCR Control of TractionCircuit, Contactor Control of Hydraulic Pump, Standard or GE Panel Display, Without Regenerative

Braking, Without Brush Wear or Motor Temperature Indicators

Plug orTerminal No.

Wire Color or WireNumber

Function

PA1 70 Signal connection for Reverse alarm.

PA2 — Not used.

PA3 — Not used.

PA4 — Not used.

PA5 — Not used.

PA6 — Not used.

PB1 37 Electronic driver, Field Weakening contactor coil.

PB2 31 Not used.

PB3 60 Electronic driver, Steering pump motor coil. (Not used when equippedwith On Demand power steering.)

PB4 27 Forward contactor coil negative.

PB5 23 Reverse contactor coil negative.

PB6 41 1A contactor coil negative.

TB1 GRN/WHT Accelerator potentiometer input.

TB2 GRN Start switch input.

TB3 PNK Seat switch input. Voltage input from timer circuit.

TB4 RED/LT-BLU Key switch input. Battery voltage supply from key switch.

TB5 WHT-5 Forward direction switch input.

TB6 BLU-L Reverse direction switch input.

PY1 WHT-3 Instrument panel display number 4 input.

PY2 BLK-2 Instrument panel display number 3 input.




PY6 — Not Used.

PY7 — Not used.

8


Table 1. Terminal and Plug Wire Connections for Control Card ZY, SCR Control of TractionCircuit, Contactor Control of Hydraulic Pump, Standard or GE Panel Display, Without Regenerative

Braking, Without Brush Wear or Motor Temperature Indicators (Continued)

Plug orTerminal No.


Function

PY8 BRN/WHT Signal wire between pump (or TMM1) and traction control card. Frompump card PY12.

PY9 BRN/PNK Signal wire between pump (or TMM1) and traction control card. Frompump card PY11.

PY10 BRN/ORN Signal wire between pump (or TMM1) and traction control card. Frompump card PY10.

PY11 — Not used.

PY12 — Not used.

PY13 — Not used.

PY14 — Not used.

PZ1 BLK Signal wire from SCR 1 thermal protector.

PZ2 BRN Battery negative.

PZ3 YEL Signal wire from current sensor.

PZ4 GRN Signal wire from current sensor.

PZ5 GRY Signal wire from SCR 1 thermal protector.

PZ6 32 Accelerator potentiometer signal.

PZ7 WHT Battery positive.

PZ8 BLU/WHT Signal wire to SCR 1 gate.

PZ9 BLU Signal wire from SCR 1 cathode.

PZ10 WHT/RED Signal wire to SCR 2 gate.

PZ11 RED Connection between filter for SCR 2 and control card.

PZ12 WHT/PUR Signal wire to SCR 5 gate.

PZ13 PUR Connection between filter for SCR 5 and control card.

PZ14 ORN Sensor wire for voltage check across capacitor C1.

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Table 2. Terminal and Plug Wire Connections for Control Card ZH, SCR Control of TractionCircuit, Contactor Control of Hydraulic Pump, Enhanced Panel Display, With Regenerative

Braking, With Brush Wear and Motor Temperature Indicators

Plug orTerminal No.


Function


PA2 50 BDI pump interrupt signal.

PA3 — Not used.

PA4 22 Regenerative braking sensor 2 (YEL).

PA5 21 Regenerative braking sensor 2 (GRN).

PA6 17 Motor A2 input (with regenerative braking).


PB2 31 Electronic driver, Regenerative Braking contactor coil.

PB3 60 Electronic driver, steering pump motor coil. (Not used when equippedwith "On Demand" power steering.)







TB4 RED/BLU-L Key switch input. Battery voltage supply from key switch.



PY1 — Not used.

PY2 — Not used.

PY3 — Not used.

PY4 BLK-1 Instrument panel display number 9 input (ground).


PY6 — Not used.

PY7 — Not used.

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Table 2. Terminal and Plug Wire Connections for Control Card ZH, SCR Control of TractionCircuit, Contactor Control of Hydraulic Pump, Enhanced Panel Display, With Regenerative

Braking, With Brush Wear and Motor Temperature Indicators (Continued)

Plug orTerminal No.


Function

PY8 BRN/WHT Signal wire between TMM1 and traction control card (temperatureswitches, hydraulic pump motor and traction motor).

PY9 BRN/PNK Signal wire between TMM1 and traction control card (brush wearindicators, all motors).

PY10 BRN/ORN Signal wire between TMM1 and traction control card (brush wearindicators, all motors).

PY11 — Not used.

PY12 — Not used.

















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Table 3. Terminal and Plug Wire Connections for Control Card ZH, SCR Control of TractionCircuit, SCR Control of Hydraulic Pump, Enhanced Panel Display, With Regenerative Braking,

With Brush Wear and Motor Temperature Indicators

Plug orTerminal No.


Function


PA2 50 BDI pump interrupt signal.

PA3 48 Current limiter, hydraulic pump controller.

PA4 22 Regenerative braking sensor 2 (YEL).

PA5 21 Regenerative braking sensor 2 (GRN).

PA6 17 Motor A2 input (with regenerative braking).


PB2 31 Electronic driver, Regenerative Braking contactor coil.

PB3 60 Electronic driver, steering pump motor coil. (Not used when equippedwith On Demand power steering.)







TB4 RED/BLU-L Key switch input. Battery voltage supply from key switch.



PY1 — Not used.

PY2 — Not used.

PY3 — Not used.

PY4 BLK-1 Instrument panel display number 9 input (ground).


PY6 — Not used.

PY7 — Not used.

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Table 3. Terminal and Plug Wire Connections for Control Card ZH, SCR Control of TractionCircuit, SCR Control of Hydraulic Pump, Enhanced Panel Display, With Regenerative Braking,

With Brush Wear and Motor Temperature Indicators (Continued)

Plug orTerminal No.


Function

PY8 BRN/WHT Signal wire between hydraulic pump control card and traction controlcard (temperature switches, hydraulic pump motor and traction motor).

PY9 BRN/PNK Signal wire between hydraulic pump control card and traction controlcard (brush wear indicators, all motors).

PY10 BRN/ORN Signal wire between hydraulic pump control card and traction controlcard (brush wear indicators, all motors).

PY11 — Not used.

PY12 — Not used.

















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Table 4. Terminal and Plug Wire Connections for Controller with SCR Control of Traction Circuitand SCR Control of Hydraulic Pump Motor — Control Card - Type ZP

Plug orTerminal No.


Function

PA1 GRN/GRY Signal wire between pump control card and brush wear indicators,steering pump.

PA2 DK-BLU/YEL Signal wire between pump control card and brush wear indicators,steering pump.

PA3 ORN/PNK Signal wire between pump control card and temperature switch, tractionmotor.

PA4 DK-BLU/PNK Signal wire between pump control card and brush wear indicator,traction motor.

PA5 GRN/PUR Signal wire between pump control card and brush wear indicator,traction motor.

PA6 ORN/YEL Signal wire between pump control card and temperature sw. of hydraulicpump motor.

PB1 DK-BLU/GRY Signal wire between hydraulic pump control card and brush wearindicator, hydraulic pump motor.

PB2 GRN/PNK Signal wire between hydraulic pump control card and brush wearindicator, hydraulic pump motor.

PB3 50 Battery Discharge Indicator enable signal input.

PB4 — Not used.

PB5 — Not used.

PB6 — Not used.

TB1 — Not used.

TB2 GRY Input to TILT and low speed auxiliary hydraulic functions.

TB3 DK-BLU/GRN Input to low speed LIFT hydraulic function and high speed auxiliaryhydraulic functions.

TB4 10 Key switch input. Battery voltage supply from key switch.

TB5 — Not used.

TB6 DK-BLU Input to high speed LIFT hydraulic function.

PY1 — Not used.

PY2 — Not used.

PY3 — Not used.

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Table 4. Terminal and Plug Wire Connections for Controller with SCR Control of Traction Circuitand SCR Control of Hydraulic Pump Motor — Control Card - Type ZP (Continued)

Plug orTerminal No.


Function

PY4 BLK-3 Instrument panel display/number 10 input (ground).


PY6 — Not used.

PY7 — Not used.

PY8 — Not used.

PY9 — Not used.

PY10 BRN/ORN Signal wire between hydraulic pump control card and traction controlcard (brush wear indicators, all motors).

PY11 BRN/PNK Signal wire between hydraulic pump control card and traction controlcard (brush wear indicators, all motors).

PY12 BRN/WHT Signal wire between hydraulic pump control card and traction controlcard (temperature switches, hydraulic pump motor, and traction motor).








PZ6 — Not used.









15

Control Card, Checks and Adjustments 2200 YRM 557

Register ParametersGENERAL

The ZX series of control cards have an electronicdevice called an EEPROM (Electrically Erasable Pro-grammable Read Only Memory). The EEPROM has anumber of memory elements called registers. Theseregisters can have electronic data stored in them tocontrol an operation. The range of data that can bestored in the registers is called a parameter. A pa-rameter is a measurement number that works withother measurement numbers (parameters) to define asystem. The EEPROM in the control card is a controlsystem for the operation of the lift truck.

The EEPROM used in the ZX series of control cardshas 128 registers.

WARNINGEach register in each control card has a range ofnumbers so the control card can be used on differ-ent models of lift trucks. This variation is needed forlift trucks of different sizes and operating voltages.Adjustment of the register to the wrong number foryour lift truck model can cause the truck to operatedifferently than normal. This different operation ofthe truck can cause an injury.

Do NOT adjust any of the registers without usingthe parameters shown in EV-100ZX SCR Motor Con-troller Parameter Tables 2200 YRM 595.

NOTE: The Parameter Tables show the permittedranges and the default setting for each control function.The factory set parameters are the recommendedsettings for new units. These settings give satisfactoryperformance for most applications.

Some functions can be adjusted within the permittedrange to change the lift truck operation for a specificapplication. Adjustment of a register to a number thatis different than the factory setting is allowed, but followthe instructions carefully and stay within the minimumand maximum limits. Adjustments other than the factorysettings cause the lift truck to operate differently andcan cause increased wear of parts.

FUNCTION NUMBERS

The Function Numbers are code numbers for the differ-ent parameters that can be set for the ZX series con-trol cards. The personal computer or the Handset mustbe used to adjust the parameters for the control card.There is a description of the code numbers for the dif-ferent control cards in the Parameter Tables. TheseParameter Tables have the correct setting numbers forthe parameters on each control card.

Control Card, Checks and AdjustmentsA personal computer (PC) or a Handset is used topermit Authorized Personnel to make the followingchecks and adjustments:• Check the system status codes for both traction and

hydraulic pump SCR systems• Check for status codes that are not regular nor con-

stant• Check the state of charge of the battery on motor

controllers with type ZH and ZY control cards• Check the hourmeter readings on the traction circuit

and hydraulic pump SCR controllers• Monitor or adjust the following control functions:

– Creep Speed– Controlled Acceleration and 1A Time– Current Limit– Steering pump time delay and define signal input

(seat switch or directional switch)

– Plugging distance (Current)– Accelerator pedal position, plug range or disable– 1A drop out current or disable– Field Weakening dropout– Field Weakening pickup– Regenerative Braking current limit– Regenerative Braking dropout– Speed limit points (SL1, SL2, and SL3)– Internal resistance compensation for battery state

of charge indication– Battery voltage (36/48V is auto ranging)

• Selection of type of card operation:– Traction circuit with Field Weakening– Traction circuit with Regenerative Braking and Field

Weakening– High or low current limit for all of the above functions

16

2200 YRM 557 Handset

HandsetHOW TO CHECK AND ADJUSTREGISTERS

The Handset can be used with the EV-100ZX seriesmotor controllers. The Handset is used to access theregisters for the traction or pump motor functions, in-dicate status codes (possible faults), and make adjust-ments to the operating limits set in the control cards.Some of the registers in the ZX series of control cardscannot be accessed with the Handset. The Handsetcan access the registers that control the operation ofthe lift truck. The values for the limits on the controlcard functions must be set with either a PC or the Hand-set. The Handset has a Light Emitting Diode (LED) dis-play, a keypad for data entry, and an adjustment knobfor changing function values. See Figure 5.

Figure 5. Handset

Legend for Figure 5

1. ADJUSTMENT KNOB2. LED DISPLAY3. KEYPAD4. COIL CORD5. PLUG PY (14 PIN)6. MODULAR PLUG (8-PIN HANDSET)

NOTE: The vehicle operates with the Handset con-nected, however, the adjustment knob MUST be setfully clockwise to make sure the control can operateat maximum speed.

This section has the control card checks and adjust-ments that can be made using the Handset. The con-trol card checks and adjustments are usually made withthe control card installed in the lift truck. Bench checksand adjustments can also be made with the control cardconnected as shown in Figure 7. The checks show thestored setting numbers that have been stored for the dif-ferent control card functions. This section also includesa description of each of the different functions. Use theadjustment knob on the Handset to adjust the functionsettings. See Figure 5.

HOW TO SCROLL THROUGH FAULTCODES AND CLEAR THEM

The EV-100ZX controller has function registers (31through 47) that store the last 16 status codes thatcaused the operation of the lift truck to stop and thebattery charge at the time the fault occurred. A PMTfault is reset by turning the key to the OFF position andthen to ON position. The first of the 16 status codes isoverwritten each time a new status code occurs. Thestored status can be cleared from the register by usingthe Handset. The PC software program clears the faultregister automatically. Use the procedure in Figure 6to access and clear the fault code registers with theHandset.

17

Handset 2200 YRM 557

Figure 6. How to Scroll Through Fault Codes andClear Them

CHECKS AND ADJUSTMENTS ONWORKBENCH

WARNINGNEVER adjust any of the parameters without usingthe procedures and settings given in this section.

CAUTIONPrevent damage to the control card. The controlcard can be damaged if power is not correctlyconnected or disconnected. Always disconnectthe battery connector before connecting or discon-necting the control card plugs.

NOTE: The bench supply voltage does not need to bethe same as the voltage of the lift truck. A DC powersupply to a maximum of 84 volts can be used.

The Handset can also be used to check and adjust thefunctions of the control card when it is connected to abench power supply for bench checks and adjustments.The following parts are required:• A power source to supply a minimum of 24 DC volts

at 0.5 Amps. (A 12-volt battery that can supply 50milliamperes can be used if a PC is used for checksand adjustments. A Handset requires more powerfor its operation and a power supply or two 12-voltautomotive batteries in series must be used.)

• An electrical adaptor to connect to the Plug Z connec-tor of the control card must be made.

• A switch for the circuit.• Approximately 45 cm (18 in.) of 18 gage wire.• A PC or a Handset.

If batteries are not used, the power supply must have afull bridge rectifier with a filter to give a good quality DCvoltage. Make the following connections for the benchchecks and adjustments:

1. Connect the switch and a Plug Z to the powersource using the wire as shown in Figure 7.

2. Make sure the switch is in the OFF position andconnect the wire to TB4.

3. Connect Plug Z to the Plug PZ connector on thecontrol card and the PC or the Handset to the PlugPY connector.

NOTE: There are no connections to the Plug A or PlugB connectors of the control card.

NOTE: The bench checks and adjustments are doneusing the same procedures that follow.

18

2200 YRM 557 Handset

NOTE: IF THE HANDSET IS USED WITH THIS POWER SUPPLY CONNECTIONS TO TB3 AND TB4 MUST BEAVAILABLE SO ALL FUNCTION KEYS CAN BE USED.

1. CONTROL CARD2. PLUG A CONNECTOR3. PLUG B CONNECTOR4. TB TERMINALS5. PLUG Y CONNECTOR

6. PLUG Z CONNECTOR7. 24 VOLT DC 0.5 AMP POWER SUPPLY OR

BATTERIES8. PIN PZ7 (B+)9. PIN PZ2 (B )10. TERMINAL TB4 (B+)

Figure 7. Bench Checks and Adjustments

WHEN HANDSET IS CONNECTED TOCONTROL CARD INSTALLED IN LIFTTRUCK

WARNINGPrevent movement of the lift truck when makingchecks and adjustments. Before the Handset isconnected or disconnected to a control card that isinstalled in a lift truck, raise the drive wheels. Thenturn the key to the OFF position, disconnect thebattery, and discharge capacitor C1.

Make sure the power is off as described in the WARN-ING. If the lift truck has an instrument panel display con-nected, disconnect Plug Y at the SCR control card (trac-tion or hydraulic pump). Connect the Handset plug atthe connector for Plug Y on the control card. Connect

the battery and turn the key to the ON position. The fol-lowing display sequence will occur:• Display of 8888 for 1 second to check the display seg-

ments.• Status Code display of -01 if seat is in the UP position.• Another Status Code will be displayed if a possible

fault has occurred.• Blank display if the operator is on the seat and there

is NO Battery Indicator function installed.• Battery state of charge if the operator is on the seat

and there is a Battery Indicator function installed.

Turn the key to the OFF position. The following displaysequence occurs:• Display shows the hourmeter reading for the traction

motor for 4 seconds.• Display shows the hourmeter reading for the hydraulic

pump motor for 4 seconds. If there is no SCR controlfor the hydraulic pump, the display is blank.

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Handset 2200 YRM 557

The registers can be set when the operator is on theseat or when off the lift truck. Disconnect Plug Y at theSCR control card (traction motor or hydraulic pump mo-tor) if the instrument panel display is connected. SeeFigure 4. Connect the Handset plug at connection PYon the control card. Connect the battery. Push and holdthe CONT button of the Handset so that it is depressedwhen power is applied. Turn the key to the ON posi-tion or move the power switch of the bench setup to theON position. The display shows 8888 to check that allsegments of the display are working. The register pa-rameters can now be checked or changed.

FUNCTION NUMBERS 1 THROUGH 15

Push the keypad numbers for the desired register. Theregister and Handset numbers are shown in the Param-eter Tables.


NOTE: The seat switch must be open.

1. Push the keypad numbers for the desired register.Think of the CONT key equaling 15. Push andhold the CONT key plus the additional key num-ber above 15 to total the required Handset num-ber.

Example: for Function Number 18, push the CONTand key 3 (15+3=18). The display shows the se-lected register. After 1 second, the display showsthe parameter that has been set in that register.

2. Push and hold the CONT key for 1 second. Thedisplay number blinks.

3. To change the parameter, check for the correctparameter for that register in the Parameter Ta-bles. Change the parameter by turning the adjust-ment knob on the Handset. The display continuesto blink as the number changes.

4. Push and hold the STORE key for 1 second. Whenthe new parameter is set (stored), the display stopsblinking.

5. Push and hold the ESC key for 1 second. The dis-play shows 8888. To check or set another register,do Step 1 through Step 3. To return to normal op-eration (run mode), push and hold ESC again for 1second or longer. The display returns to the statuscode mode or displays the state of battery charge ifthe operator is in the seat. The display can also beblank (if there are no status codes and the batteryindicator is not installed).

NOTE: Make sure the motor controller control is in therun mode before disconnecting the Handset. If the mo-tor controller control is not in the run mode, the batterymust be disconnected and connected again to reset thesystem.

The vehicle can now be operated with the Handset con-nected or the Handset can be disconnected.

NOTE: If the vehicle is operated with the Handset con-nected, make sure to set the adjustment knob fullyclockwise to make sure the control can operate at topspeed.

Disconnect the plug at connection Y on the control cardto disconnect the Handset. Connect the plug for theinstrument panel display at connection Y.


NOTE: The seat switch must be closed.

1. Turn the key to the ON position after the Handset isconnected to the traction card. Turn the key to theOFF position after the Handset is connected to thehydraulic pump card.

2. Push the keypad numbers for the desired register.Think of the CONT key equaling 47. Push andhold the CONT key plus the additional key num-ber above 47 to total the required Handset num-ber. Close the seat switch and the key switch.

Example: for Function Number 48, push the CONTand key 1 (47+1=48, 47+2=49, 47+3=50, 47+5=52,etc.). The display shows the selected register. After1 second, the display shows the parameter that hasbeen set in that register.

NOTE: Handset Numbers 47, 51, 55, and 59 are theregisters for the MODE numbers and are not used. Donot try to set these numbers with the Handset.

3. Push and hold the CONT key for 1 second. Thedisplay number blinks.

4. To change the parameter, check for the correctparameter for that register in the Parameter Ta-bles. Change the parameter by turning the adjust-ment knob on the Handset. The display continuesto blink as the setting changes.

5. Push and hold the STORE key for 1 second. Whenthe new parameter is set (stored), the display stopsblinking.

20

2200 YRM 557 Control Cards

6. Push and hold the ESC key for 1 second. The dis-play shows 8888. To check or set another register,

do Step 1 through Step 3. To return to normal op-eration (run mode), push and hold ESC again for 1second or longer.

Control CardsFUNCTION NUMBER DESCRIPTIONS

The following pages have descriptions for the differentFunction Numbers. The setting for each function is spe-cific for each control card. To identify the control card,check the label at the top edge of each card case. Thereare some painted letters and numbers followed by let-ters on the lower part of the label. The last two lettersidentify the type of card installed. The following typesof control cards are used:

ZH = Traction Controller with three-wirepotentiometer and with Battery DischargeIndicator (BDI).

ZY = Traction Controller with three-wirepotentiometer and without Battery DischargeIndicator (BDI)

ZP = Pump Motor Controller with TruckManagement Module (TMM1)

These same letters are also shown in the ParameterTables and in the section headings for the control cardsfor the traction motor and hydraulic pump motor.

TRACTION CONTROL CARDS (LABELLETTERS - ZH AND ZY)

NOTE: These control cards are used with the motorcontrollers that control the speed of the traction motor.

Function Number 1 STORED STATUSCODE

(Push 1)

WARNINGIf any of the parameters are changed, the operatorsmust be told that the lift truck will operate differ-ently.

Do not adjust the parameters outside of the range ofnumbers shown in the Tables. Parameters set out-side of the ranges can cause damage to the compo-nents of the traction system and can cause the lift

truck to operate differently than normal. This differ-ent operation of the lift truck can result in personalinjury.

This register contains the last status code of a possiblePMT fault that caused the lift truck to stop operation.These codes can be removed from the display by turn-ing the key to the OFF position. The code is stored inregisters in the control card. This status code will bereplaced with the same status code if another possiblePMT fault occurs. The status code can be cleared frommemory by adjusting the setting number to zero. Thenumber must be stored by pushing the STORE key for1 second. Adjustment of the values in this register doesnot change the operation of the lift truck. This registeris cleared when the battery is disconnected.

Function Number 2 CREEP SPEED

(Push 2)

This register adjusts the creep speed of the lift truck.The range of adjustment is from 0 (5%) to 255 (15%).The percentage values are the SCR 1 ON Time. Aconstant creep speed frequency is maintained when theaccelerator input voltage is between 3.7 and 3.5 volts (apotentiometer resistance value between 6K and 4.7Kohms).

Function Number 3 CONTROLLEDACCELERATION AND 1A TIME

(Push 3)

This register adjusts the maximum rate of acceleration.The setting determines the time allowed to reach max-imum SCR speed after the accelerator is set for max-imum speed from stop. The control stays in SCR ac-celeration for between 0.77 second (setting 8) and 21.5seconds (setting 255) before the 1A contactor closes.The numbers in parenthesis are the parameters for thetimes shown. The 1A contactor automatically closes0.2 second after the controlled acceleration stops. Thespeed control input is less than 0.5 volt (accelerator po-tentiometer set at less than 50 ohms). Do not adjust thenumber in the register to less than the minimum settingof 8.

21

Control Cards 2200 YRM 557

Function Number 4 CURRENT LIMIT

(Push 4)

This register adjusts the current limit of the motor con-troller. The current rating of the motor controller deter-mines the range of adjustment for this register. See theTables for the Parameter Registers. Do not adjust theregister to any number other than the factory setting.

Function Number 5 PLUGGING DISTANCE(CURRENT)

(Push 5)

This register adjusts the distance it takes to stop the lifttruck when plugging. A parameter set to higher num-bers makes the lift truck stop faster. Lower numbersdecrease the plugging for a longer stopping distance.

CAUTIONTraction motor or controller damage occurs if theparameter is set above the maximum shown in theTables for the Parameter Registers.

The number for this parameter, for the current value ofthis register, must be found if the Pedal Position Plug(Function Number 16 PEDAL POSITION PLUG is notused). To find the number for the current value, use thefollowing information:

Range 200 to 1000 amps

Setting Range 0 to 255

Resolution 3.14 amps per set unit

Example: Setting of 20=263A (EV-100)

20 × 31.4A = 62.8A or 63A

63A + 200A (range min) = 263A

Function Number 6 1A DROP OUTCURRENT

(Push 6)

This register adjusts the parameter for the current valueat which the 1A contactor de-energizes (opens). The1A contactor opens and the motor torque is limited to

SCR current to prevent motor currents that are too high.A value of 255 disables the 1A Drop Out function.

Function Number 7 FIELD WEAKENINGPICK UP

(Push 7)

CAUTIONA setting HIGHER than the setting shown in the Ta-bles for the Parameter Registers will make the FieldWeakening Contactor energize too soon. This op-eration can damage the traction motor.

This register adjusts the current value at which the FWcontactor energizes (closes). This parameter permitsthe FW contactor to close when the lift truck has re-turned to approximately 150 percent of its running cur-rent with a full load on a level surface.

Do NOT set this register to a number greater thanthe number set by Function Number 8. If this reg-ister is set to a number less than 5, the Field Weak-ening function is de-energized.

Function Number 8 FIELD WEAKENINGDROP OUT

(Push 8)

CAUTIONA parameter set HIGHER than the number shownin the Tables for the Parameter Registers will makethe Field Weakening Contactor remain energizedat high currents. This operation can cause motorheating and damage the traction motor.

This register adjusts the current value at which the FWcontactor de-energizes (opens). This parameter per-mits the FW contactor to open when the lift truck re-quires more than 300 percent of the running current witha full load on a level surface.

Function Number 9 REGENERATIVEBRAKING CURRENT LIMIT

(Push 9)

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WARNINGA parameter set greater than the number shown inthe Tables for the Parameter Registers will make thelift truck slow at a rate faster than normal. A param-eter set at less than the number shown will make thelift truck have a slower regenerative braking effect.This different operation of the truck can result inpersonal injury. A faster regenerative braking ratecan also damage the control system or the tractionmotor.

This register adjusts the Regenerative Braking currentlimit. The higher the current limit setting, the shorterthe stopping distance. The shorter stopping distancecauses faster wear on the drive train and brushes ofthe traction motor.

Function Number 10 REGENERATIVEBRAKING START

(Push 10)

CAUTIONA parameter set greater than the number shown inthe Tables for the Parameter Registers can preventregenerative braking. The lift truck will remain inthe plugging mode longer and increase brush wearin the traction motor.

This parameter adjusts the percent ON time at whichthe control starts to energize the regenerative brakingcircuit. The percent ON time can be between 0 and95 percent. This adjustment sets the speed where re-generative braking starts. This parameter prevents thecontroller from energizing the regenerative braking cir-cuit when motor current is too low.

Function Number 13 SPEED LIMIT 3 (SL3)

(Push 13)

This parameter adjusts the speed limit (maximum bat-tery volts to the motor). The range is 0 percent to 96percent. The adjustment sets the speed limit for thetime when the input signal from the SL3 limit switch isreceived by the control card. This signal can be from thesensor in the traction motor or the hydraulic pump mo-tor. If the sensor shows that a motor is too hot, the con-trol decreases the maximum motor speed to this speedsetting. The SL3 limit switch is a normally closed switchconnected to battery negative. When the switch opens,

it enables the speed limit function. A setting of 0 dis-ables the speed limit function. This zero setting permitstop speed when no limit switch is connected. A zerosetting does not slow the motor with an input from thesensor and can damage the motor. Some models oflift trucks do not use this function. This function is acti-vated by Status Codes -90 and -93.

Function Number 14 INTERNALRESISTANCE COMPENSATION

(Push 14)

CAUTIONAdjusting this function setting to the wrong numbercan cause battery damage.

This register is used when the control card has the Bat-tery Discharge Indicator (BDI) function. Control cardsthat have BDI are type ZH control cards. The Tablesfor the Parameter Registers show the parameters for abattery in average condition.

For the best use of your battery energy, the register canbe adjusted using the following procedure. However,you must use the procedure to change the parameterin the register as the battery changes during monthsthe battery is used or battery damage can occur. Set-ting the parameter too low for your battery can allow thebattery to discharge below the minimum specific grav-ity value. This minimum specific gravity is the specifica-tion given by the battery manufacturer to prevent batterydamage.

Use the following procedure to adjust the parameter:

1. Operate the lift truck on a normal work cycle. Travelat medium speeds.

2. When lift interrupt occurs, stop the lift truck and waitfor approximately 10 minutes.

3. Check the specific gravity of several battery cells. Ifthe specific gravity is between 1.140 and 1.150, thesetting is correct for that battery. If the specific grav-ity reading is high, adjust the parameter in the regis-ter to a lower number. If the specific gravity readingis low, adjust the parameter to a higher number.

NOTE: It may be necessary to charge the battery anddo Step 1 through Step 3 again to get an accurate num-ber for your battery.

23


Function Number 15 BATTERY VOLTS

(Push 15)

This register adjusts the operating voltage of the lifttruck. The adjustment also controls the Battery Dis-charge Indicator function for lift trucks equipped withBDI. For the controller and BDI to operate correctly, theparameter shown in the Tables for the Register Param-eters must be entered.

Battery Volts Parameter

36 volts Between 32 and 44




36/48 volts Between 184 and 250

No BDI Between 251 and 255

NOTE: If the parameter is set to a number other thanthe number shown for your lift truck in Tables for theRegister Parameters, a status code of -15 or -16 oc-curs. Make sure the battery is fully charged and batteryconnector has good connections before making this ad-justment. This check is especially important when ad-justing for 36/48 volt operation (numbers 184 to 250).

Function Numbers GREATER THAN 15

NOTE: For registers greater than 15, think of theCONT key as equal to 15. Push and hold the CONTkey plus the additional key number above 15 to totalthe required register number. Example: for Function18, push the CONT key and key 3 (15+3=18). The dis-play shows the selected function. After 1 second, thedisplay shows the setting number that has been set forthat register.

NOTE: The Seat Switch must be OPEN for FunctionNumbers 16 through 30.

Function Number 16 PEDAL POSITIONPLUG

(Push CONT and 1)

This register adjusts the range for pedal position plug-ging. The parameter in this register permits the pedal

position to control the plugging current and the pluggingdistance. The current value set by this register is en-abled as the accelerator is returned to the creep speedposition. There is maximum plugging current when theaccelerator is in the maximum speed position. To dis-able the pedal position plugging function, adjust the cur-rent value to the same current value as the plugging dis-tance current. See the description in Function Number5 PLUGGING DISTANCE (CURRENT).

Example: If Plugging Distance Current (Function Num-ber 5 PLUGGING DISTANCE (CURRENT)) is set at500 amps, then set pedal plugging current to 500 amps.The pedal position has no effect on the plugging dis-tance with this setting.

Use the following information to adjust the current value:

Range 100 to 930 amps

Parameter Range 0 to 255

Resolution 3.2A per set unit

Example: Parameter of 20 = 164 amps

20 × 3.2A = 64A

64A + 100 (range min) = 164A

Function Number 17 CARD TYPESELECTION

(Push CONT and 2)

WARNINGWrong parameters entered into the register in Func-tion Number 17 CARD TYPE SELECTION can causethe truck to operate differently than normal. Thisdifferent operation of the truck can cause an injury.NEVER set Function Number to a parameter that isnot shown for your lift truck.

This register permits the selection of the card type usedfor your lift truck application.

Function Number 18 STEERING PUMPTIME DELAY

(Push CONT and 3)

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WARNINGA parameter set lower than the number shown inthe Tables for the Parameter Registers can permitthe steering pump to stop if the seat switch opensmomentarily during normal operation. There is nopower steering if the steering pump stops. The sud-den and difficult steering effort that is not expectedcan cause injury or property damage.

This register selects input for the steering pump contac-tor. Closing the seat switch or the FWD/REV switch canbe the input. The parameter also sets the time delay forthe contactor to open after the switch opens.

NOTE: There is no delay time for the contactor to closeafter receiving the input signal from the seat switch orthe FWD/REV switch. Parameters in the 0-128 rangeadjust the delay after the seat switch opens. Param-eters in the 129-255 range adjust the delay after theFWD/REV switch opens. Adjust the setting to thenumber shown in Tables for the Register Parame-ters.

Function Number 19 MAINTENANCEALERT (Tens/Units)

(Push CONT and 4)

This register can be set by the service person to givea Status Code -99 when scheduled maintenance is re-quired. The range for this register is 0 to 99 hours.

Function Number 20 MAINTENANCEALERT (Thousands/Hundreds)

(Push CONT and 5)

This register can be set by the service person to givea Status Code -99 when scheduled maintenance is re-quired. The range for this register is 100 to 9900 hours.

Function Number 21 MAINTENANCESPEED LIMIT

(Push CONT and 6)

This register can be set by the service person to con-trol the speed limit (maximum battery volts to the motor)when the Maintenance Alert (Status Code -99) is acti-vated by the control card. The range for this register is0 to 180.

Function Numbers 22 Through 28TEMPORARY DATA REGISTERS

CAUTIONFunction Number 25 (temporary storage registerfor fault data) and Function Number 26 (temporarystorage register for battery charge data) must notbe changed by the user to any number above zero.Any number above zero can cause the instrumentpanel display to not operate correctly and the lifttruck can become disabled.

These registers can be read with the Handset, but thedata in them changes during lift truck operation. Do notchange the parameters in registers for Function num-bers 22 through 27. Function Number 28 is the faultindicator pointer and must be set to zero when allfaults or malfunctions have been fixed or removedfrom the controller.

Function Number 29 HOURMETER(Tens/Units)

(Push CONT and 14)

This register has the data for the accumulated operat-ing hours of the lift truck. This register is not normallychanged unless a new control card is installed. If anew control card is installed, the total hours from theold control card must be entered so that the total oper-ating hours of the lift truck is correctly recorded.

Function Number 30 HOURMETER(Thousands/Hundreds)

(Push CONT and 15)

This register has the data for the accumulated operat-ing hours of the lift truck. This register is not normallychanged unless a new control card is installed. If anew control card is installed, the total hours from theold control card must be entered so that the total oper-ating hours of the lift truck is correctly recorded.

Function Number 48 Through 62 SET LIFTTRUCK PERFORMANCE

If the lift truck is equipped with a Premium instrumentpanel, the lift truck can be set to four performance lev-els by the operator. (If the customer does not want thisfunction available to the operator, a service person canset all four levels to the same setting.) Each time theoperator pushes the button on the instrument panel, the

25


performance level will increase by one step. At the max-imum (rabbit) level, the performance levels will begin atthe lowest (turtle) level again. The four performancelevels set by the manufacturer are:

1. Low performance for handling fragile loads.

2. Medium speed for less consumption of batterycharge during a work shift.

3. Higher performance with higher consumption ofbattery charge during a work shift.

4. Maximum lift truck performance with higher con-sumption of battery charge.

The four performance levels can be set to any level upto the maximum limits. Two or more adjacent perfor-mance levels can be set to the same limits. The perfor-mance levels must be set at the same or in ascendingorder (from turtle to rabbit). The register interlocks willnot permit a higher performance level setting toward theturtle than the adjacent registers toward the rabbit.

NOTE: The Seat Switch must be CLOSED for Func-tion Numbers 48 through 62.


(Push CONT and 1 while the key switch and seatswitch are closed)

This register adjusts the maximum rate of accelerationin MODE 1 (Turtle). The parameter determines the timeallowed to reach maximum SCR speed after the accel-erator is set for maximum speed from stop. The controlstays in SCR acceleration for 3.5 seconds (setting 40)before the 1A contactor closes. The numbers in paren-thesas are the parameters for the times shown. The1A contactor automatically closes 0.2 seconds after thecontrolled acceleration stops. The speed control inputis less than 0.5 volt (accelerator potentiometer set atless than 50 ohms). Do not set the register to less thanFunction Number 52 CONTROLLED ACCELERATIONAND 1A TIME.



This register adjusts the current value at which the FWcontactor energizes (closes). This parameter permits

the FW contactor to close when the lift truck has re-turned to approximately 150 percent of its running cur-rent with a full load on a level surface. The minimumparameter is zero. Do not set the register greater thanFunction Number 53 FIELD WEAKENING PICK UP.

Function Number 50 SPEED LIMIT 1


This parameter adjusts the speed limit (maximum bat-tery volts to the motor). The range is 0 percent to 96percent. There is no speed limit switch for this function.This function is disabled if the parameter in the registeris set to zero. Do not set the register to less than Func-tion Number 54 SPEED LIMIT 1. Do not set the registergreater than 180.



This register adjusts the maximum rate of accelerationin MODE 2. The parameter determines the time al-lowed to reach maximum SCR speed after the accel-erator is set for maximum speed from stop. The con-trol stays in SCR acceleration for 2.6 seconds (setting30) before the 1A contactor closes. The numbers inparenthesis are the parameters for the times shown.The 1A contactor automatically closes 0.2 seconds af-ter the controlled acceleration stops. The speed controlinput is less than 0.5 volt (accelerator potentiometer setat less than 50 ohms). Do not set the register to lessthan Function Number 56 CONTROLLED ACCELER-ATION AND 1A TIME. Do not set the register greaterthan Function Number 48 CONTROLLED ACCELERA-TION AND 1A TIME.



This register adjusts the current value at which the FWcontactor energizes (closes). This parameter permitsthe FW contactor to close when the lift truck has re-turned to approximately 150 percent of its running cur-rent with a full load on a level surface. Do not set theregister to less than Function Number 49 FIELD WEAK-ENING PICK UP. Do not set the register greater thanFunction Number 57 FIELD WEAKENING PICK UP.

26




This parameter adjusts the speed limit (maximum bat-tery volts to the motor). The range is 0 to 96 percent.There is no speed limit switch for this function. Thisfunction is disabled if the parameter in the register isset to zero. Do not set the register to less than Func-tion Number 58 SPEED LIMIT 1. Do not set the registergreater than Function Number 50 SPEED LIMIT 1.



This register adjusts the maximum rate of accelerationin MODE 3. The parameter determines the time al-lowed to reach maximum SCR speed after the accel-erator is set for maximum speed from stop. The con-trol stays in SCR acceleration for 1.8 seconds (setting20) before the 1A contactor closes. The numbers inparenthesis are the parameters for the times shown.The 1A contactor automatically closes 0.2 seconds af-ter the controlled acceleration stops. The speed controlinput is less than 0.5 volt (accelerator potentiometer setat less than 50 ohms). Do not set the register to lessthan Function Number 60 CONTROLLED ACCELER-ATION AND 1A TIME. Do not set the register greaterthan Function Number 52 CONTROLLED ACCELERA-TION AND 1A TIME.



This register adjusts the current value at which the FWcontactor energizes (closes). This parameter permitsthe FW contactor to close when the lift truck has re-turned to approximately 150 percent of its running cur-rent with a full load on a level surface. Do not set theregister to less than Function Number 53 FIELD WEAK-ENING PICK UP. Do not set the register greater thanFunction Number 61 FIELD WEAKENING PICK UP.



This parameter adjusts the speed limit (maximum bat-tery volts to the motor). The range is 0 to 96 percent.There is no speed limit switch for this function. Thisfunction is disabled if the parameter in the register isset to zero. Do not set the register greater than Func-tion Number 58 SPEED LIMIT 1.



This register adjusts the maximum rate of accelerationin MODE 4 (Rabbit). The parameter determines thetime allowed to reach maximum SCR speed after theaccelerator is set for maximum speed from stop. Thecontrol stays in SCR acceleration for 0.94 seconds (set-ting 10) before the 1A contactor closes. The numbersin parenthesis are the parameters for the times shown.The 1A contactor automatically closes 0.2 seconds af-ter the controlled acceleration stops. The speed controlinput is less than 0.5 volt (accelerator potentiometer setat less than 50 ohms). Do not set the register to lessthan 8. Do not set the register greater than FunctionNumber 56 CONTROLLED ACCELERATION AND 1ATIME.



This register adjusts the current value at which the FWcontactor energizes (closes). This parameter permitsthe FW contactor to close when the lift truck has re-turned to approximately 150 percent of its running cur-rent with a full load on a level surface. Do not set theregister to less than Function Number 57 FIELD WEAK-ENING PICK UP. Do not set the register greater than110.

PUMP CONTROL CARD (LABEL LETTERZP)

NOTE: This control card is used with the motor con-troller that controls the speed of the motor for the hy-draulic pump.

27


Function Number 1 STORED STATUSCODE

(Push 1)

WARNINGIf any of the register parameters are changed, theoperators must be told that the lift truck will oper-ate differently. Do not adjust the register parame-ters outside of the range shown in the ParameterTables for the register parameters. Settings outsidethe ranges can cause damage to the components ofthe hydraulic system and different truck operation.This different operation of the truck can cause per-sonal injury.

This register contains the last status code of a possiblefault that caused the pump motor to run continuously.The battery must be disconnected to stop the motor if itruns continuously. This status code is replaced with thesame status code if another possible fault occurs. Thestatus code can be cleared from memory by adjustingthe setting number to zero. Any new number (includingzero) must be stored by pushing the STORE key for 1second. Adjustment of this register does not changeoperation of the hydraulic system.

Function Number 2 INTERNALRESISTANCE COMPENSATION START

(Push 2)

This register adjusts the current level required to startthe internal resistance compensation (Function Num-ber 16 INTERNAL RESISTANCE COMPENSATION).

Function Number 3 CONTROLLEDACCELERATION

(Push 3)

This register adjusts the maximum rate of acceleration.The parameter determines the time allowed to reachmaximum SCR speed after the switch closes. This pa-rameter determines how fast the hydraulic functions be-gin to operate. The control stays in SCR operation for0.1 to 22 seconds after the switch closes.

Function Number 4 CURRENT LIMIT

(Push 4)

This register adjusts the current limit of the control. Thecurrent limit is normally set at the maximum (255).

Function Number 7 CONTROLLEDACCELERATION COMPENSATION

(Push 7)

This register adjusts the rate (in seconds) for the con-troller to add the internal resistance compensation volt-age that is applied to motor. This function adds 0.375volts to the motor at the rate of time set in the registeruntil the total (current × resistance) compensation volt-age is added.

Range 0.0015 to 0.383 seconds

Set 0 to 255

Resolution 0.375 volts per set unit

Example: A parameter of 20 = 0.032 seconds

Example: If 2.08 volts is set in Function Number 16 andadded to the motor, this example would require 0.18seconds to add a total of 2.08 volts.

(2.08 volts/0.375 volts per unit) 0.032 seconds = 0.1775or 0.18 seconds

Function Number 11 SPEED LIMIT 1 (SL1)(Slow Speed) - Tilt and Slow Auxiliary(Auxiliary and Slow Rotate for N30XMH)

(Push 11)

This register adjusts the speed limit (maximum batteryvoltage applied to the motor). When switch SL-1 isclosed, the signal to TB2 on the controller card causesthe controller to apply the limit on battery voltage to themotor.

Function Number 12 SPEED LIMIT 2 (SL2)(Medium Speed) - Slow Lift and MediumAuxiliary (Slow Lift And Fast Rotate forN30XMH)

(Push 12)

This register adjusts the speed limit (maximum batteryvoltage applied to the motor). When switch SL-2 isclosed, the signal to TB3 on the controller card causesthe controller to apply the limit on battery voltage to themotor.

Function Number 13 SPEED LIMIT 3 (SL3)

(Push 13)

Not Connected.

28


Function Number 14 SPEED LIMIT 4 (SL4)Fast Lift

(Push 14)

This register uses SL4 limit switch for an input to TB6.This function adjusts the speed limit (maximum batteryvoltage the motor). The range is 0 to 96 percent. Aparameter set over the maximum parameter shown inthe Parameter Table can cause the motor or controllerto become too hot.

Function Numbers Greater Than 15

NOTE: For registers greater than 15, push andHOLD the CONT key and the additional key numberabove 15 to total the required register number.Example: for Function Number 18, push CONT keyand key 3 (15+3=18). The display shows the selectedregister. After 1 second, the display shows the param-eter that has been set in that register.

NOTE: The Seat Switch must be OPEN for FunctionNumbers 16 through 30.

Function Number 16 INTERNALRESISTANCE COMPENSATION

(Push CONT and 1)

This register gives the pump speed better stability byincreasing the motor voltage during heavy loads. Thisparameter is set using the information from the speedtorque curve of the motor used.

The voltage selected is added to the motor for each100 ampere increment starting with the parameter setin Function Number 2 INTERNAL RESISTANCE COM-PENSATION START. The voltage selected is added insteps of 0.375 volts until the entire voltage is added.For example, a parameter of 10 is adds 2.28 volts in sixsteps of 0.375 volts each.

Function Number 17 CARD TYPESELECTION

(Push CONT and 2)

WARNINGWrong parameters entered into the register in Func-tion Number 17 CARD TYPE SELECTION can causethe truck to operate differently than normal or causedamage to the controller. This different operation of

the truck can result in personal injury. NEVER setFunction Number 17 CARD TYPE SELECTION to aparameter that is not shown for your lift truck.

This register selects the card type used for your lift truckapplication. See the correct setting in the ParameterTables.

Function Numbers 18 through 28TEMPORARY DATA REGISTERS

CAUTIONFunction 25 (temporary storage register for faultdata) and Function 26 (temporary storage registerfor battery charge data) must not be changed by theuser to any number above zero. Any number abovezero can cause the instrument panel display to notoperate correctly and the lift truck can become dis-abled.

These registers can be read with the Handset, but thedata in them changes during lift truck operation. Do notchange the parameters in registers for Handset num-bers 21 through 27. Handset number 28 is the faultindicator pointer and must be set to zero when allfaults or malfunctions have been fixed or removedfrom the controller.

Function Number 29 HOURMETER(Tens/Units)

(Push CONT and 14)

This register has the data for the accumulated operatinghours of the hydraulic system. This register is not nor-mally changed unless a new control card is installed. Ifa new control card is installed, the total hours from theold control card must be entered so the total operatinghours of the hydraulic system is correctly recorded.

Function Number 30 HOURMETER(Thousands/Hundreds)

(Push CONT and 15)

This register has the data for the accumulated operat-ing hours of the lift truck. This register is not normallychanged unless a new control card is installed. If a newcontrol card is installed, the total hours from the old con-trol card must be entered so the total operating hoursof the lift truck is correctly recorded.

29




This register adjusts the maximum rate of accelerationin MODE 1 (Turtle). The parameter determines the timeallowed to reach maximum SCR speed from stop. Donot set the register to less than Function Number 52CONTROLLED ACCELERATION.



This register adjusts the speed limit for the hydraulicpump in MODE 1. The minimum parameter is zero. Donot set the register greater than Function Number 53SPEED LIMIT 2.



This parameter permits adjustment of the speed limit(maximum battery voltage to the motor). The range is0 to 96 percent. There is no speed limit switch for thisfunction. This function is disabled if the parameter isset to zero. Do not set the register to less than FunctionNumber 54 SPEED LIMIT 3. The maximum number inthe register is 255.



This register adjusts the maximum rate of accelerationin MODE 2. The parameter determines the time al-lowed to reach maximum SCR speed from stop. Do notset the number in the register to less than the parame-ter for Function Number 56 CONTROLLED ACCELER-ATION. Do not set the register greater than FunctionNumber 48 CONTROLLED ACCELERATION.



This register adjusts the speed limit for the hydraulicpump in MODE 2. Do not set the register to less than

Function Number 49 SPEED LIMIT 2. Do not set theregister greater than Function Number 57 SPEEDLIMIT 2.



This parameter adjusts the speed limit (maximum bat-tery voltage to the motor). The range is 0 to 96 percent.There is no speed limit switch for this function. Thisfunction is disabled if the parameter in the register isset to zero. Do not set the register to less than Func-tion Number 58 SPEED LIMIT 3. Do not set the registergreater than Function Number 50 SPEED LIMIT 3.



This register adjusts the maximum rate of accelerationin MODE 3. The parameter determines the time al-lowed to reach maximum SCR speed from stop. Donot set the register to less than Function Number 60CONTROLLED ACCELERATION. Do not set the reg-ister greater than Function Number 52 CONTROLLEDACCELERATION.



This register adjusts the speed limit for the hydraulicpump in MODE 3. Do not set the register to less thanFunction Number 53 SPEED LIMIT 2. Do not set theregister greater than Function Number 61 SPEEDLIMIT 2.



This parameter adjusts the speed limit (maximum bat-tery voltage to the motor). The range is 0 to 96 per-cent. There is no speed limit switch for this function.This function is disabled if the parameter in the registeris set to zero. The maximum number in the register is255.

30

2200 YRM 557 Troubleshooting



This register adjusts the maximum rate of accelerationin MODE 4 (Rabbit). The parameter determines thetime allowed to reach maximum SCR speed from stop.Do not set the number in the register to less than 8. Donot set the register greater than Function Number 56CONTROLLED ACCELERATION.



This register adjusts the speed limit for the hydraulicpump in MODE 4. Do not set the number in the registerto less than Function Number 57 SPEED LIMIT 2. Donot set the register greater than 110.



This parameter adjusts the speed limit (maximum bat-tery voltage to the motor). The range is 0 to 96 per-cent. There is no speed limit switch for this function.This function is disabled if the parameter in the registeris set to zero. The maximum number in the register is255.

REGISTER PARAMETERS

Parameters must be between the minimum and max-imum numbers shown in the tables of the section

EV-100ZX SCR Controller Parameter Tables foryour lift truck model. Do NOT adjust a parameter to anumber that is NOT SHOWN in the correct table. Makesure you use the correct table when you makeadjustments. It is a good procedure to check theparameter and compare the parameter to the numberin the table before making the adjustment. The factoryparameter, and the value (current, time, etc.) for thatparameter, are shown in the columns indicated asDefault. The minimum and maximum parameters andtheir values are shown in the columns indicated asPermitted Range.

NOTE: Check the label at the top edge of each cardcase to identify the control card on your lift truck. Thereare some painted letters and numbers followed by othernumbers and letters on the lower part of the label. Thelast two letters on the lower part identify theTYPE ofcard installed. The table titles show these card typesfor the EV-100ZX motor controllers.

CAUTIONDo not set the Field Weakening functions withoutchecking to make sure the traction motor is de-signed for Field Weakening. There can be tractionmotor damage if Field Weakening is used withmotors that are not designed for it.

NOTE: A control card that has the Field Weakeningfunctions can be installed on lift trucks that have trac-tion motors that are not designed for Field Weakening.The Field Weakening functions are set to not operateon these lift trucks.

Make sure to read the WARNINGS and CAUTIONS un-der each parameter description and in the section Pa-rameters, Checks, and Adjustments.

TroubleshootingGENERAL

Many electrical malfunctions of the lift truck are shownin the status code number on the digital display. Thereis a digital display on the Handset or instrument paneldisplay (optional on some lift trucks). There is a table, inthis Troubleshooting section, for each status code witha description of the malfunction, the circuit that has theincorrect input, and the possible causes.

NOTE: Make sure the parameters are correct for yourlift truck to make sure the trouble is not just a wrongsetting. See the Parameter Tables to set the parame-ters for the correct values. If there is no status code dis-play and the lift truck does not operate correctly, therecan be a fault in the control card.

See the procedures to connect and use the Handset.

31

Troubleshooting 2200 YRM 557

The following Status Codes indicate possible faults inthese areas:

Area of Fault Status Code #

Control Card Inputs Blank through 17

Contactor Panel 23 through 26

SCR Panel 41 through 57

Regenerative Braking 70 through 76

Truck Management 90 through 99

Hydraulic Pump Control 117 through 157

NOTE: A blank display on the instrument panel displayor the Handset, during operation, can mean that thediode D7 for regenerative braking has a short circuit.The indication for this malfunction is an open tractionpower fuse. If D7 has a short circuit, there is a shortcircuit across the battery as soon as the regenerativebraking contactor closes and will cause the power fuseto open. If D7 is open, the regenerative braking doesnot operate and the plugging is too quick.

NOTE: A short circuit in the 1A contactor coil causes thelift truck to suddenly stop when operating at the higherspeeds. The lift truck operates correctly until the 1Acontactor is energized. When the 1A contactor is en-ergized, the traction motor then stops and the directioncontactors open.

NOTE: If the coil of the Field Weakening contactor hasa short circuit, the lift truck will operate normally untilthe FW contactor is energized. Then the lift truck losespower and the direction contactors open.

The control card in the motor controller has a trou-bleshooting system that continuously checks the staticand operating conditions of the control and powercircuits for the motor. If the troubleshooting circuits finda condition that is not normal, the control card indicatesa status code on a display connected to plug PY. Somelift trucks can have an instrument panel display thatindicates the status codes from the control cards forthe traction motor and hydraulic pump motor.

Different control cards are used in the electric lift trucks.A replacement control card must have the same partnumber as the control card that is removed. A badcontrol card cannot be repaired by service persons andmust be replaced.

STATUS CODES

The status codes are code numbers for malfunctionsthat the control card can sense. The control card indi-cates this code number on the digital display of the in-strument panel display (optional on some units) or thedisplay on a Handset. The control card illuminate thenumbers of the status code on the display. The statuscodes are twice illuminated flash on the display approx-imately every 2seconds. Every third flash of the displayindicates the battery charge instead of the status code.

The control card senses the following malfunctions:• Input voltages that are too high or too low• Input voltages that have the wrong polarity• Input voltages in the wrong sequence• Correct input voltages that occur at the wrong time.

NOTE: A status code display does not always mean thatthere is a malfunction. A temporary operating conditioncan cause a status code display.

The status codes all have a dash (-) before the numbers.If the battery is disconnected, the dash (-) is missing onthe display of the Handset when a battery is connectedagain. If a status code number is indicated on the digitaldisplay, checks and adjustments cannot be done. SeeTable 5 and the following Status Code Charts to findand correct the malfunction. There are no checks oradjustments for the status codes. These code numbersare only codes to help identify a possible malfunction.Table 5 has a short description of the different statuscodes.

There is a Status Code Chart in this section for eachstatus code. These charts have a more complete de-scription of the status code, the circuit that generatedthe input for the status code, the symptom, and the pos-sible causes.

32


Table 5. Status Codes List

StatusCode

Description

CARD INPUTS

BLANK No input voltage to control card ordisplay

-01 No input signal from seat switch

-02 FWD switch closed on initial start

-03 REV switch closed on initial start

-04 Start switch, low voltage after start

-05 Start or brake switch did not close

-06 Accelerator depressed, no directionselected

-07 Accelerator input voltage too high

-08 Accelerator input voltage too low orpower to control card after key in ONposition

-09 Both FWD and REV switches closed atsame time

-11 The START switch is closed when thekey switch is closed and voltage isapplied to the control card

-15 Battery volts too low

-16 Battery volts too high

-17 Wrong control card installed

-21 Accelerator input is less than 0.25 volts

CONTACTOR PANEL, TRACTIONCIRCUIT

-23 Coil current low, Forward or Reversecontactor

-24 Voltage at T2 too high

-25 1A contactor does not open or openstoo slowly

-26 Short circuit in electronic driver for RB,SP or FW contactor

SCR CONTROL, TRACTION CIRCUIT

* Not used on all models of lift trucks. Status Codesin this group will flash on the display.NOTE: Motor speed is decreased when a status code-41 is indicated.

Table 5. Status Codes List (Continued)

StatusCode

Description

-41 Open thermal protector or motor controltemperature too high

-42 Motor sensor input missing (green wire)

-43 Motor sensor input missing (yellow wire)

-44 SCR 1 did not go OFF correctly

-45 SCR 1 did not go ON correctly

-46 T2 voltage too high

-47 SCR 2 does not go ON correctly

-48 T2 voltage too low


-50 C1 voltage too low

-51 C1 voltage too high with high motorcurrent

-52 C1 voltage too high with low motorcurrent

-53 SCR 1 does not go OFF during plugging

-54 Short circuit, FWD, REV or 1A electronicdriver

-57 Polarity check, current sensor outputvoltage

REGENERATIVE BRAKING

-70 Current sensor input missing (yellowwire)

-71 Current sensor input missing (greenwire)

-72 Regenerative braking contactor doesnot energize

-73 Regenerative braking contactor doesnot de-energize or de-energizes slowly

-74 Regenerative braking contactorenergizes too slowly

-75 SCR 1 does not go OFF duringregenerative braking


33



StatusCode

Description

-76 C1 voltage too high during regenerativebraking

LIFT TRUCK MANAGEMENT*

-90 Temperature too high, traction motor*

-91 Temperature too high, hydraulic pumpmotor*

-93 Brush wear, steering pump motor*

-94 Brush wear, traction motor*

-95 Brush wear, hydraulic pump motor*

-99 Maintenance Alert Code.

SCR CONTROL, HYDRAULIC PUMP

-117 Wrong control card installed

-123 Pump PMT contactor coil current is toolow

-124 Voltage at T2 too high.

-125 1A contactor does not de-energize oropens too slowly

-141 Open thermal protector or motor controltemperature too high

-142 Motor sensor input missing (green wire)

-143 Motor sensor input missing (yellow wire)

-144 SCR 1 did not go OFF correctly

-145 SCR 1 did not go ON correctly

-146 T2 voltage too high




StatusCode

Description

-148 T2 voltage too low


-150 C1 volts low

-151 C1 volts high with high motor current

-152 C1 volts high with low motor current

-154 Short circuit in electronic driver forthe hydraulic pump contactor or 1Acontactor

-157 Polarity check, current sensor outputvoltage


REGISTER MAPS

The information in the Register Maps shown in Table 6and Table 7 is not needed by most service people. Thisadditional technical information is for service engineerswho have special troubleshooting requirements. Theseregisters and their descriptions are designed by theGeneral Electric Company. Many of these registersare programmed by Hyster Company to do certainfunctions. These register maps as programmed byHyster Company are shown in the Parameter Tables.

NOTE: The number of the EEPROM register is off-setby one from the PC Register Number and the FunctionNumber in the Register Map Tables. The EEPROM be-gins its count from zero (0) while the PC and Handsetcount from one (1).

NOTE: EEPROM = Electrically Erasable Pro-grammable Read Only Memory

34


Table 6. Register Map for Control Cards ZH and ZY (Traction)

EEPROMRegisterNumber

PCRegisterNumber

Handset(HS)

NumberDescription Access By: Restrictions

0 1 1 Fault Code HS or PC Erases when battery isdisconnected

1 2 2 Creep HS or PC None

2 3 3 Controlled Acceleration HS or PC None

3 4 4 Current Limit HS or PC None

4 5 5 Current Limit (Plugging) HS or PC None

5 6 6 1A Dropout HS or PC None

6 7 7 FW Pickup HS or PC None

7 8 8 FW Dropout HS or PC None

8 9 9 Regenerative BrakingCurrent Limit

HS or PC None

9 10 10 Regenerative Start HS or PC None

10 11 11 Speed Limit 1 HS or PC None



13 14 14 Battery VoltageCompensation

HS or PC None

14 15 15 Battery Voltage Selection HS or PC None

15 16 16 Pedal Position Plugging HS or PC None

16 17 17 Type of Control CardSelection

HS or PC None

17 18 18 Steering Pump TimeDelay

HS or PC None

18 19 19 Maintenance Alert(Tens/Units)

HS or PC None

19 20 20 Maintenance Alert(Thousands/Hundreds)

HS or PC None

20 21 21 Maintenance Speed Limit HS or PC None

21 22 22 Mode Reference HS or PC

22 23 23 Hourmeter (minutes) HS or PC None

23 24 24 Hourmeter (seconds) HS or PC None

24 25 25 Fault Register Data HS or PC GE Temporary Storage

25 26 26 Battery Charge Data HS or PC GE Temporary Storage

26 27 27 Battery Voltage Data HS or PC GE Temporary Storage

35


Table 6. Register Map for Control Cards ZH and ZY (Traction) (Continued)


PCRegisterNumber

Handset(HS)


27 28 28 Fault Count Pointer HS or PC None (Location of lastfault recorded)

28 29 29 Hourmeter (Tens/Units) HS or PC None

29 30 30 Hourmeter (Thousands/Hundreds)

HS or PC None

30 31 Auxiliary Hourmeter(Tens/Units)

PC Only Reset to Zero only

31 32 Auxiliary Hourmeter(Thousands/Hundreds)


32 33 Fault 1 PC Only Reset to Zero only

33 34 BDI 1 PC Only Reset to Zero only

34 35 Hours (Tens/Units) 1 PC Only Reset to Zero only

35 36 Hours (Thousands/Hundreds) 1























36




PCRegisterNumber

Handset(HS)




































37




PCRegisterNumber

Handset(HS)






















96 97 48 Instrument Panel DisplayCA-1

HS or PC None

97 98 49 Instrument Panel DisplayFWPU-1

HS or PC None

98 99 50 Instrument Panel DisplaySL1-1

HS or PC None

99 100 51 NOT USED HS or PC None


HS or PC None


HS or PC None


HS or PC None



HS or PC None

38




PCRegisterNumber

Handset(HS)



HS or PC None


HS or PC None



HS or PC None


HS or PC None


HS or PC None

111 112 NOT USED PC Only

112 113 Secure Hourmeter(Tens/Units)

PC Only Read Only

113 114 Secure Hourmeter(Thousands/Hundreds)

PC Only Read Only

114 115 Secure AuxiliaryHourmeter (Thousands/Hundreds)

PC Only Read Only


PC Only Read Only

116 117 PC Only GE Use Only




120 121 PC Only None








39


Table 7. Register Map for Control Card ZP (Hydraulic Pump)


PCFunctionNumber

Handset(HS)

FunctionNumber

Function Access By: Restrictions

0 1 1 Fault Code HS or PC Erases when battery isdisconnected

1 2 2 Internal ResistanceCompensation Start

HS or PC None

2 3 3 Controlled Acceleration HS or PC None

3 4 4 Current Limit HS or PC None

4 5 5 NOT USED

5 6 6 NOT USED

6 7 7 Internal ResistanceCompensation Rate

HS or PC None

7 8 8 NOT USED

8 9 9 NOT USED

9 10 10 NOT USED

10 11 11 Speed Limit (SL1) HS or PC None




14 15 15

15 16 16 Speed and TorqueCompensation

HS or PC None

16 17 17 Type of Control CardSelection

HS or PC None

17 18 18 NOT USED

18 19 19 NOT USED

19 20 20 NOT USED

20 21 21 NOT USED

21 22 22 Mode Reference HS or PC Reference forinstrument paneldisplay when batterypower is applied

22 23 23 Hourmeter (minutes) HS or PC None

23 24 24 Hourmeter (seconds) HS or PC None

24 25 25 Fault Register Data HS or PC GE Temporary Storage

25 26 26 NOT USED

40


Table 7. Register Map for Control Card ZP (Hydraulic Pump) (Continued)


PCFunctionNumber

Handset(HS)

FunctionNumber


26 27 27 NOT USED

27 28 28 Fault Count Pointer HS or PC None (Location of lastfault recorded)

28 29 29 Hourmeter (Tens/Units) HS or PC None

29 30 30 Hourmeter (Thousands/Hundreds)

PC Only None

30 31 Auxiliary Hourmeter(Tens/Units)

PC Only None

31 32 Auxiliary Hourmeter(Thousands/Hundreds)

PC Only None


33 34 NOT USED





37 38 NOT USED





41 42 NOT USED





45 46 NOT USED





49 50 NOT USED


41




PCFunctionNumber

Handset(HS)

FunctionNumber





53 54 NOT USED





57 58 NOT USED





61 62 NOT USED





65 66 NOT USED





69 70 NOT USED





73 74 NOT USED





77 78 NOT USED

42




PCFunctionNumber

Handset(HS)

FunctionNumber






81 82 NOT USED





85 86 NOT USED





89 90 NOT USED





93 94 NOT USED





HS or PC None


HS or PC None


HS or PC None



HS or PC None


HS or PC None

43




PCFunctionNumber

Handset(HS)

FunctionNumber



HS or PC None



HS or PC None


HS or PC None


HS or PC None



HS or PC None


HS or PC None


HS or PC None

111 112 NOT USED PC Only

112 113 Secure Hourmeter(Tens/Units)

PC Only Read Only

113 114 Secure Hourmeter(Thousands/Hundreds)

PC Only Read Only


PC Only Read Only


PC Only Read Only










44

2200 YRM 557 Status Code Charts



PCFunctionNumber

Handset(HS)

FunctionNumber





Status Code ChartsStatus Code Description Cause of Status Indication

NONE No display on the instrument paneldisplay or the Handset

No input voltage to the control card orthe display unit.

Indication of Fault

No display on the instrument paneldisplay or the Handset

Possible Cause

No control voltage

Memory RecallNo

Make sure the key switch is ON and thereis voltage between PZ7 and PZ3 (batterynegative). Check that there is voltagebetween TB4 and PZ3.

Open circuit between control card plug Y andthe instrument panel display or the Handset:

Check for an open circuit or looseconnections between each wire going to theplug on the control card and the instrumentpanel display or the Handset.

Malfunction of the instrument paneldisplay or the Handset:

Replace the instrument panel display.

CircuitTraction and

Hydraulic Pump

NOTE: A blank display, during operation, canindicate that the regenerative braking diodehas a short circuit. The symptom for this mal-function is: no operation and traction powerfuse open. If the diode has a short circuit,there is a short circuit across the battery assoon as the regenerative braking contactorcloses and the fuse opens. If the regenera-tive braking diode is open, there is no indi-cated fault except that there is stiff pluggingand no regenerative braking.

45

Status Code Charts 2200 YRM 557

Status Code

-01Description

No voltage from seat switchCause of Status Indication

This Status Code is indicated when TB3 isless than 50% of battery voltage.

Indication of FaultForward or Reverse contactor does not close.

Possible Cause

Seat switch malfunction or needs adjustment.

Memory RecallNo

Check that the seat switch closes correctly.

Open circuit between battery positiveand TB3

CircuitTraction

Check for loose connections or broken wiresbetween the seat switch and TB3, betweenthe key switch and the battery positive sideof the seat switch, between the seat switchand TB4.

Status Code

-02Description

FORWARD direction switch is closed whenthe key switch is turned on ON.

Cause of Status IndicationThis Status Code is indicated when TB5 isgreater than 60% of battery voltage when

the key switch is turned to ON.

Indication of FaultForward contactor does not close. StaticReturn to OFF (SRO) circuit activated.

Possible Cause

FORWARD direction switch is closed whenthe key switch is turned to ON.

Memory RecallNo

Move the direction control lever to NEUTRALand then select a direction.

FORWARD direction switch has ashort circuit.

Replace or adjust the direction switch so thatit opens when the direction control lever isin NEUTRAL.

Short circuit between TB2 and TB5.

Disconnect the wire from TB5 and check fora short circuit between TB2 and the wire.

Malfunction of the control card.

CircuitTraction

Disconnect the wire from TB5. Check forless than 60% of battery voltage at TB5.

46


Status Code

-03Description

REVERSE direction switch is closed whenthe key switch is turned to ON.



Indication of FaultReverse contactor does not close. Static

Return to OFF (SRO) circuit activated.

Possible Cause

REVERSE direction switch is closed whenthe key switch is turned to ON.

Memory RecallNo

Move the direction control lever to NEUTRALand then select a direction.

REVERSE direction switch has ashort circuit.

Replace or adjust the direction switch so thatit opens when the direction control lever isin NEUTRAL.

Short circuit between TB2 and TB6.

Disconnect the wire from TB6 and check fora short circuit between TB2 and the wire.

Malfunction of the control card.

CircuitTraction

Disconnect the wire from TB6. Check forless than 60% of battery voltage at TB6.

47


Status Code

-04Description

Low voltage when the START switchis closed after the key switch and the

seat switch are closed.

Cause of Status IndicationThis Status Code is indicated when the voltage

at TB2 is less than 60% of battery voltagewhen the START switch is closed after the key

switch and the seat switch are closed.


Possible Cause

FORWARD or REVERSE direction switch isclosed when the key switch is turned to ON.

Memory RecallYes

Push on the accelerator to close the STARTswitch. The Status Code changes to -03 ifthe REVERSE direction switch or to -02 ifthe FORWARD direction switch is closed.Move the direction control lever to NEUTRALand then select a direction.

Short circuit between TB2 and batterynegative.

Check the voltage at TB2 when the keyswitch and seat switch are closed and thedirection control lever is in NEUTRAL. Thecorrect voltage is greater than 60% of batteryvoltage.

CircuitTraction

If the voltage is less than 60% of batteryvoltage, disconnect the wire from TB2.Measure the resistance between the end ofthe wire and the negative side of SCR 1. Thecorrect resistance is less than 22k ohms.

48


Status Code

-05Description

START switch or brake switch does not closeCause of Status Indication

This Status Code is indicated when TB1is less than 2.5 volts and TB2 is less than

60% of battery voltage.


Possible Cause

Malfunction of the brake switch circuit.

Memory RecallNo

Check the brake switch to make sure itclosed when the brake pedal is released.

Check for an open circuit loose connectionsin the wires from the brake switch to the seatswitch, to TB3, and from the brake switch tothe START switch.

Malfunction of the START switch circuit.

Check the START switch to make sure itclosed when the accelerator is actuated.

CircuitTraction

Check for an open circuit or looseconnections in the wires from the brakeswitch to the START switch and from TB2to the START switch.

Status Code

-06Description

Accelerator actuated and no directionswitch is selected.

Cause of Status IndicationThis Status Code is indicated when TB5 and

TB6 are less than 60% of battery voltageand TB1 is less than 2.5 volts.


Possible Cause

Accelerator pedal is actuated before adirection switch is closed.

Memory RecallNo

The Status Code is cleared when a directionswitch is closed or the accelerator pedal isreleased.

Malfunction of the circuit for the FORWARDor REVERSE switches.

Check the direction switches to make surethey close when the direction control lever ismoved to that position.

Open circuit between the directionswitches and TB5 or TB6.

CircuitTraction

Check for an open circuit or looseconnections in the wires for the directioncontrol circuits to TB5 or TB6.

49


Status Code

-07Description

Accelerator input voltage is too high.Cause of Status Indication

This Status Code is indicated when theaccelerator input voltage of TB1 is higher than3.7 volts and a direction contactor is closed.

Indication of FaultForward or Reverse contactor closes,

but the motor controller does not operatewhen the accelerator pedal is actuatedor the -07 Status Code clears when the

lift truck begins to accelerate.

Possible Cause

Accelerator potentiometer has a malfunctionor needs adjustment.

Memory RecallNo

The correct output voltage of TB1 ismore than 3.0 volts. Repair or adjust theaccelerator potentiometer so that it correctlychanges from 3.5 to less than 0.5 volts(minimum 0.30 volts) when the acceleratorpedal is actuated.

Open circuit between battery negative andTB1 in the accelerator input circuit.

Check for broken wires or loose connectionsin the accelerator potentiometer circuit.

Short circuit from battery positive to a wirein the accelerator input circuit.

CircuitTraction

Disconnect the wire from TB1 and measurethe voltage between the end of the wire andbattery negative. The correct voltage is zerofor an accelerator with a potentiometer.

50


Status Code

-08Description

Accelerator input voltage is too low afterthe key switch is closed.

Cause of Status IndicationThis Status Code is indicated when the

accelerator input voltage at TB1 is less than3.0 volts and the battery connector, or the seatswitch, or the key switch is opened and closed.


Possible Cause

Accelerator potentiometer has a malfunctionor needs adjustment.

Memory RecallNo

The correct output voltage at TB1 ismore than 3.0 volts. Repair or adjust theaccelerator potentiometer so that it correctlychanges from 3.5 to less than 0.5 volts(minimum 0.30 volts) when the acceleratorpedal is actuated.

Short circuit between battery negative andTB1 in the accelerator input circuit.

Disconnect wire from TB1. Check for shortcircuit from the end of the wire to batterynegative. The correct resistance is greaterthan 4.7k ohms.

Control card malfunction.

CircuitTraction

Disconnect the wire from TB1 and measurethe voltage between TB1 and batterynegative. The correct voltage is greater than4.5 volts. If the voltage is wrong, replace thecontrol card.

51


Status Code

-09Description

Both FORWARD and REVERSE directionswitches are closed at the same time.

Cause of Status IndicationThis Status Code is indicated when TB5and TB6 are greater than 60% of battery

voltage at the same time.


Possible Cause

FORWARD or REVERSE direction switchesare welded closed or need adjustment.

Memory RecallNo

Replace or adjust the direction switches tomake sure that they are both open when thedirection control lever is in NEUTRAL.

Short circuit between battery positiveand TB5 or TB6.

Disconnect the wires from TB5 and TB6 andcheck for a short circuit between the end ofthe wire and the battery positive side of thedirection switch.


CircuitTraction

Disconnect the wires and measure thevoltage at TB5 and TB6. The correct voltageis less than 60% of battery voltage.

52


Status Code

-11Description

The START switch is closed when thekey switch is closed and voltage is

applied to the control card.


the key switch is closed.


Possible Cause

START switch needs adjustment oris damaged.

Memory RecallNo

Input voltage must be less than 60% ofbattery voltage when the key switch isclosed. Replace or adjust the START switch.

Short circuit between battery positive andTB2 in START switch circuit.

Disconnect the wire from TB2. Check fora short circuit between the end of the wireand the battery positive. Resistance must begreater than 4.7 kohms.


CircuitTraction (ZXControl Card

Only)

Disconnect the wire from TB3 and measurethe voltage from TB3 to battery negative. Ifthe voltage is not zero, replace the controlcard.

53


Status Code

-15Description

Battery voltage is too low.Cause of Status Indication

This Status Code is indicated when the batteryvoltage is less than 1.95 volts per cell when



Possible Cause

Discharged battery.

Memory RecallNo

Check the battery for the correct open circuitvoltage as shown in the illustration at theright and charge the battery as required.

Bad connection of battery connector orshort in the power cables.

Check the power cables and the batteryconnector.

Battery malfunction.

Check each battery cell for the correctvoltage (greater than 1.95 volts per cell).Replace or repair the battery.

Control card needs adjustment.

CircuitTraction

Check Function Number 15 BATTERYVOLTS for the correct adjustment forthe battery that is being used. See theinstructions for the Handset. Make thecorrect adjustments.

54


Status Code

-16Description

Battery voltage is too high.Cause of Status Indication

This Status Code is indicated when the batteryvolts are greater than 2.40 volts per cell when



Possible Cause

Control card needs adjustment.

Memory RecallNo

Check Function Number 15 BATTERYVOLTS for the correct adjustment forthe battery that is being used. See theinstructions for the Handset. Make thecorrect adjustments.

Open circuit in current sensor circuit forthe regenerative braking.

Check for a broken yellow wire from thecurrent RB sensor to PA4. Check for looseconnections or a broken weld at the currentsensor. Check PA4 for a loose plug or pinconnection.

Battery is charged wrong or wrongbattery is installed.

Check the battery for the correct open circuitvoltage (see the table in the illustration atthe right). If the battery voltage is too high,check the battery charger for the correctoutput voltage.

48-volt battery is too low (between WHTand BRN in Plug Z).

Function Number 15 is set for 36/48volt operation (184 to 250).

The controller has determined that a 36 voltbattery is installed that has a voltage toohigh.

CircuitTraction

If the battery voltage at the battery connectoris greater than 46.8 volts, check for a badconnector or other bad connections.

55


Status Code

-17Description

Selection for type of control card is wrong.Cause of Status Indication

This Status Code is indicated when the controlcard type selection is set to a wrong number.


Possible Cause

Memory RecallNo

Control card type selection is wrong.

CircuitTraction

Check Function Number 17 CARD TYPESELECTION in the instructions for theHandset. Make the correct adjustments forthe type of control card.

Status Code

-21Description

Accelerator input is less than 0.25 volts.Cause of Status Indication

This Status Code is indicated when the controlcard type selection is set to a wrong number.

Indication of FaultController does not operate.

Possible Cause

Accelerator potentiometer needsadjustment or is damaged.

Memory RecallNo

Input voltage of TB1 must be greater than0.25 volts when the accelerator pedal is fullyreleased. Adjust or replace the acceleratorpotentiometer.

Short circuit between battery negative andTB1 in accelerator input circuit.

Disconnect wire from TB1 and check forshort circuit from end of wire to batterynegative. Resistance must be greater than4.7k ohms.

Open circuit between acceleratorpotentiometer and PZ6.

Make sure 5 volts is present from PZ6 toaccelerator potentiometer.



Only)

Disconnect the wire from TB1 and measurethe voltage between TB1 and batterynegative. If the voltage is not greater than4.5 volts, replace the control card.

56


Status Code

-23Description

Forward or Reverse contactor or anyother contactor has a short circuit or

low current to the coil.

Cause of Status IndicationThis Status Code is indicated when there

is a current draw in a contactor coil ofless than 100 ma.

Indication of FaultForward or Reverse contactor does notclose. The Status Code can change

between code -23 and code -24. Do all ofthe Possible Cause checks for this StatusCode. If the problem is not found, do the

checks in Status Code -24.

Possible Cause

Memory RecallNo

Malfunction of the coil circuit for Forwardand Reverse contactors.

Check for open circuit or loose connectionbetween PB4 and the positive side of theForward contactor coil and between PB5 andthe positive side of the Reverse contactorcoil.

Remove Plug B. Check the resistance in thewire from PB4 to the positive side of theForward contactor coil. The correct value is10 to 14 ohms. Do the same check for theReverse contactor coil.

Check for an open Forward-Reverse controlfuse.

Malfunction of the coil circuit for 1A,RB, PS, or FW contactors.

CircuitTraction

Remove Plug B. Check the resistance in thewire from the positive side of each contactorcoil to its plug connection. The correct valueis 10 to 14 ohms. The coil resistance for thepower steering contactor is 52 ohms.

57


Status Code

-24Description

T2 voltage is greater than 12% ofbattery voltage.

Cause of Status IndicationThis Status Code is indicated when T2 voltageis greater than 12% of battery voltage and thecircuit for the direction contactors is energized.

Indication of FaultThe motor controller does not operate. TheStatus Code can change between code -23and code -24. Do all of the Possible Cause

checks for this Status Code. If the problem isnot found, do the checks in Status Code -23.

Possible Cause

Memory RecallNo

Most common cause is that the contactson one of the direction contactors or theRB contactor does not close correctly to

make an electrical connection.

Clean the contact of the direction contactorsand the RB contactor with alcohol. Newcontacts can have a surface condition thatprevents conducting electric current. Checkthat the contacts close correctly.

Malfunction of coil circuit for Forwardand Reverse.

Check for welded contacts or contactors thatdo not close correctly.

Malfunction of RB contactor.

Check that the contacts and contactor closecorrectly.

Check for an open circuit or looseconnections between the positive side of theRB contactor coil and PB2.

Open motor circuit.

Check for an open circuit or looseconnections in the motor circuit from the A1connection to the A2 connection on the SCRcontrol panel.

Malfunction of the 1A, RB, PS, orFW contactors.

CircuitTraction

Do the checks described in Status Code -23.

58


Status Code

-25Description

1A Contactor does not open or opens slowly.Cause of Status Indication

This Status Code is indicated when the 1AContactor opens in greater than 0.060 seconds.

Indication of FaultForward and Reverse, and 1A contactswear rapidly. Status Code -46 can be

indicated and no fault is found.

Possible Cause

Memory RecallYes

NOTE: This Status Code can only be foundwhen the Handset is connected. This StatusCode is shown here as additional informationfor Status Code -46.

Malfunction of 1A Contactor.CircuitTraction Check 1A Contactor for slow operation when

it opens.

Status Code

-26Description

Electronic driver in control card for the RB,PS, or FW contactor has a short circuit.

Cause of Status IndicationThis Status Code is indicated when there isa short circuit in the electronic driver for the

1A, RB, or PS contactor coil.

Indication of FaultThe 1A, RB, or PS contactor closed

immediately when the key switch is closed.

Possible Cause

Memory RecallNo

Malfunction of an electronic driverin the control card.

CircuitTraction

Replace the control card.

59


Status Code

-41Description

Open thermal protector or motorcontroller is too hot.

Cause of Status IndicationThis Status Code is indicated when the voltagebetween PZ1 and PZ5 is greater than 1.8 volts.

Indication of FaultThe traction motor has reduced power on

no power in the SCR range.

Possible Cause

Open circuit, thermal protector.

Memory RecallNo

Check for a loose or broken wire betweenthe following points:Black wire between thermal protector andPZ1.Gray wire between thermal protector andPZ5.

Malfunction of thermal protector.

Disconnect the wires from PZ1 and PZ5.When the temperature is approximately 25 C(77 F), measure the resistance between theblack and gray wire. The correct resistanceis approximately 300 ohms.

Thermal protector is operating becausemotor controller is too hot.

CircuitTraction

Permit the motor controller to cool.

Status Code

-42Description

Input missing from motor current sensor.Cause of Status Indication

This Status Code is indicated when thevoltage between PY7 and battery negative is

greater than 1.6 volts and no current is flowingthrough the traction motor circuit.

Indication of FaultNo power to the traction motor in

the SCR range.

Possible Cause

Memory RecallNo

Open sensor wire circuit to PZ4.

CircuitTraction

Check for a loose or broken wire (green wire)between the current sensor and PZ4 on thecontrol card.

60


Status Code

-43Description


This Status Code is indicated when the voltagebetween PY7 and battery negative is lessthan 0.84 volts and no current is flowing

through the traction motor circuit.

Indication of FaultStall currents in the SCR range are higherthan normal and cannot be controlled with

the current link adjustment.

Possible Cause

Memory RecallNo


CircuitTraction

Check for a loose or broken wire (yellowwire) between the current sensor and PZ3on the control card.

Status Code

-44Description

SCR 1 does not go to OFF correctly.Cause of Status Indication

This Status Code is indicated when SCR 1 doesnot go to OFF correctly during operation.

Indication of FaultForward or Reverse contactors open

and close, then close only when the keyswitch is opened and closed.

Possible Cause

Malfunction of SCR 5 circuit.

Check for a short circuit across SCR 5.

Check for a short circuit across thesuppressor for SCR 5.

Memory RecallYes

Check for an open circuit across SCR 2 oran open gate lead to SCR 5.





Open Inductor 1X.

Check for an open circuit between T5 andT3. The correct resistance is zero ohms.

Malfunction of SCR 1.

CircuitTraction

The OFF time for SCR 1 is not withinspecifications. No easy test is possible.Replace SCR 1 after the other checks havebeen done and no other problem is found.

61


Status Code

-45Description

SCR 1 does not go to ON correctly.Cause of Status Indication

This Status Code is indicated when SCR 1 doesnot go ON correctly during operation.



Possible Cause




Memory RecallYes



Check for an open circuit or looseconnections between SCR 1 and PZ8(white/blue wire).

Check for an open circuit or looseconnections between SCR 1 and D3suppressor and PZ9 (blue wire).


CircuitTraction

An open or bad gate circuit to SCR 1. Noeasy test is possible. Replace SCR 1 afterthe other checks have been done and noother problem is found.

Status Code

-46Description

Short circuit across SCR 1.(Also see Status Code -25).


at T2 is greater than 85% of battery voltage.

Indication of FaultForward or Reverse contactors do not close.

Possible Cause



Memory RecallYes

Check for a short circuit across the insulatorbetween the heat sink for SCR 1 and thebase plate.

Malfunction of Contactor 1A.CircuitTraction Check for welded contacts on Contactor 1A

that hold the contactor closed.

62


Status Code

-47Description

SCR 2 does not go to ON correctly.(Also see Status Code -25).

Cause of Status IndicationThis Status Code is indicated when SCR 2

has a failure and does not go ON.



Possible Cause


Memory RecallYes

Check that SCR 2 goes ON with a gatesignal.

Check for an open circuit or loose connectionbetween SCR 2 gate and PZ10 (white/redwire).

Check for an open circuit or loose connectionbetween SCR 1 and C1 and through theSCR 2 circuit.

Malfunction of Forward or Reversecontactors.

CircuitTraction

Check for Forward or Reverse contactorsmomentarily opening and closing duringoperation when traveling over bumps anddock plates.

Status Code

-48Description

Voltage check at T2 is less than 12%of battery voltage.

Cause of Status IndicationThis Status Code is indicated when a voltage

check at T2 is less than 12% of battery voltage.

Indication of FaultForward or Reverse contactors do not close.

Possible Cause


Check for welded contacts that hold aForward or Reverse contactor closed.

Memory RecallYes

Check for slow operation of a Forward orReverse contactor.

Malfunction of diode D3 circuit.

Check for a short circuit across D3.

CircuitTraction

Check for a short circuit across thesuppressor for D3.

63


Status Code

-49Description

SCR 5 does not go ON correctly.Cause of Status Indication

This Status Code is indicated when SCR5 does not go ON correctly.



Possible Cause




Memory RecallYes


Check for an open circuit or a looseconnection between SCR 5 and PZ12(white/purple wire).





Malfunction of C1.

Check for an open capacitor C1.

CircuitTraction

Check for loose connections at capacitorterminals.

64


Status Code

-50Description

Low voltage on capacitor C1.Cause of Status Indication

This Status Code is indicated when SCR 2has a failure and does not go ON.

Indication of FaultForward or Reverse contactor closes, but

motor controller does not operate.

Possible Cause


Check for an open circuit or loose connectionbetween spider assembly and SCR 5.

Memory RecallNo

Check for an open circuit or loose connectionbetween SCR 5 and SCR 2.

Check for an open circuit or loose connectionbetween SCR 2 and PZ11 (red wire) andbetween SCR 2 gate connection and PZ10(white/red wire).

CircuitTraction


Status Code

-51Description

Voltage on C1 too high when motorcurrent is high.

Cause of Status IndicationThis Status Code is indicated when the voltageon C1 is greater than 225 volts and the motor

current is greater than 300 amps.



Possible Cause

Too much inductance from cables.

Memory RecallYes

Check that the battery cables are too long.

Check that additional cables for otherequipment have been added.

Motor current too high.

Check for a short circuit at a field winding.

CircuitTraction

Check for a short circuit across an armaturewinding.

65


Status Code

-52Description

Voltage on C1 too high when motorcurrent is low.


current is less than 200 amps.



Possible Cause


Memory RecallNo





Check for an open circuit or loose connectionin the D4 circuit.


CircuitTraction


66


Status Code

-53Description

SCR 1 does not go OFF correctlyduring plugging cycle.

Cause of Status IndicationThis Status Code is indicated when any failure of

SCR 1 to go OFF during the plugging cycle.



Possible Cause

SCR 1 failure is not caused by plugging.

Memory RecallYes

Cause the traction motor to stall in bothdirections and check for a new statuscode that also indicates the failure. DoTroubleshooting for the new or additionalStatus Code.

SCR 1 failure is caused by plugging.

Check for an open circuit across D4.


Check current sensor for loose or openconnections. Check the yellow and greenwire from the current sensor to the controlcard for open or loose connections.

Malfunction in motor circuit.

Check motor circuit for open or looseconnections.

Check motor brushes for wear and correctinstallation.


CircuitTraction


67


Status Code

-54Description

Short circuit in an electronic driver for theForward, or Reverse, or 1A contactor.

Cause of Status IndicationThis Status Code is indicated when thecontrol card has a short circuit in one ofthe electronic drivers for the Forward or

Reverse, or 1A contactor.

Indication of FaultMotor controller does not operate.

Possible Cause

Fuse 7 is open.

Memory RecallYes

Check for a short circuit that can cause Fuse7 to open. Replace Fuse 7.

Control card malfunction.CircuitTraction Replace the control card.

Status Code

-57Description

Polarity check of the output voltagefrom the current sensor.

Cause of Status IndicationThis Status Code is indicated when the inputvoltage to PZ4 and PZ3 is the wrong polarity.



Possible Cause

The yellow and green wires from thecurrent sensor to the control card are

connected wrong.

Memory RecallYes

Check the yellow wire is connected to PZ3and the green wire is connected to PZ4.

Check from the current sensor to the controlcard for open or loose connections.

Power cables are connected wrongin motor circuit.

CircuitTraction

Check that the power cables are connectedcorrectly in the motor circuit.

68


Status Code

-70Description

No voltage input from current sensor forregenerative braking (yellow wire).


input signal to PA4 is missing.


Possible Cause

Memory RecallNo


CircuitTraction

Check for a broken yellow wire from thecurrent RB sensor to PA4. Check for looseconnections or a broken wire at the currentsensor. Check PA4 for a loose plug or pinconnection. Check that the control card typeis set correctly.

Status Code

-71Description

No voltage input from current sensor forregenerative braking (green wire).


input signal to PA5 is missing.


Possible Cause

Memory RecallNo


CircuitTraction

Check for a broken green wire from thecurrent RB sensor to PA5. Check for looseconnections or a broken wire at the currentsensor. Check PA5 for a loose plug or pinconnection. Check that the control card typeis set correctly.

69


Status Code

-72Description

Regenerative braking contactor doesnot close.

Cause of Status IndicationThis Status Code is indicated when the control

card is ready to operate and the voltage atPA6 is 2.5 volts or greater.

Indication of FaultRegenerative braking control does

not operate.

Possible Cause

Open circuit in the PA6 circuit.

Memory RecallNo

Check for open circuit or loose connectionsbetween PA6 and the A2 connection (positiveconnection) of the RB contactor.

CircuitTraction

Check for open circuit or loose connectionsbetween D7 and the A2 connection (positiveconnection) of the RB contactor.

Status Code

-73Description

Regenerative braking contactor doesnot open or opens slowly.

Cause of Status IndicationThis Status Code is indicated when the RB

contacts do not open within 100 milliseconds afterpower is removed from the RB contactor coil.



Possible Cause

RB contactor malfunction.

Memory RecallYes

Check the RB contactor for smooth operationand wear on the moving parts.

Input signal to PA6 is not regular.CircuitTraction Check for open circuit or loose connections in

the PA6 circuit from PA6 to the A2 connection(positive connection) of the RB contactor.

70


Status Code

-74Description

Regenerative braking contactorcloses slowly.

Cause of Status IndicationThis Status Code is indicated when the RB

contacts do not close within 100 millisecondsafter power is applied to the RB contactor coil.



Possible Cause

RB contactor malfunction.

Memory RecallYes

Check the RB contactor for smooth operationand wear on the moving parts.

Input signal to PA6 is not regular.

Check for open circuit or loose connections inthe PA6 circuit from PA6 to the A2 connection(positive connection) of the RB contactor.

Malfunction of coil circuit for RB contactor.

Check the resistance of the RB contactorcoil. The correct resistance is 10 to 14 ohms.

Check for loose connections from PB2 to thenegative side of the RB coil.

CircuitTraction

Check for loose connections from batterypositive to the positive side of the RB coil.

71


Status Code

-75Description

SCR 1 does not go OFF duringregenerative braking.

Cause of Status IndicationThis Status Code is indicated when SCR 1 fails

to go OFF during regenerative braking.



Possible Cause

To find if SCR 1 fault is caused byregenerative braking:

Memory RecallYes

Cause the traction motor to stall in bothdirections and check for a new statuscode that also indicates the failure. DoTroubleshooting for the new or additionalStatus Code.

If Status Code 75 continues:

Check for loose connections on all powercircuits for regenerative braking.

Check for an open circuit or loose connectionin the following input circuits for regenerativebraking:Yellow wire from RB sensor to PA4.Green wire from RB sensor to PA5.Wire 17 from the RB contactor to PA6.

Malfunction in motor circuit.

Check motor circuit for open or looseconnections.

Check motor brushes for wear and correctinstallation.


CircuitTraction


72


Status Code

-76Description

Voltage on C1 too high duringregenerative braking.

Cause of Status IndicationThis Status Code is indicated when thevoltage on C1 is greater than 225 volts

during regenerative braking.



Possible Cause

Bad connection or irregular connectionin battery power circuit.

Memory RecallYes

Check battery power circuit for looseconnections.

Check the power fuse and batteryconnections that can open duringregenerative braking.


CircuitTraction

Check that battery cables are too long.

Status Code

-90Description

Traction motor temperature too high.Cause of Status Indication

This Status Code is indicated when thevoltage at terminal PA3 of the hydraulic pump

control card is at zero volts.

Indication of FaultStatus Code is indicated as a flashing

number on the instrument panel display.The lift truck speed is reduced when

either the hydraulic pump motor or thetraction motor are too hot.

Possible Cause

Traction motor is too hot. Temperaturesensor has closed battery negative.

Memory RecallNo

Permit traction motor to cool.

Other causes.

PA3 has a short circuit to battery negative.

There is a short circuit in the sensor wires.

CircuitTraction and

Hydraulic Pump

There is a short circuit or other malfunctionin the sensor.

73


Status Code

-91Description

Hydraulic pump motor temperatureis too high.


voltage at terminal PA6 of the hydraulic pumpcontrol card is at zero volts.


number on the instrument panel display.The lift truck speed is reduced when

either the hydraulic pump motor or thetraction motor is too hot.

Possible Cause

Hydraulic pump motor is too hot.Temperature sensor has closed to

battery negative.

Memory RecallNo

Permit the hydraulic pump motor to cool.

Other causes.



CircuitHydraulic Pump


Status Code

-93Description

Steering pump motor brushes are wornand must be replaced.

Cause of Status IndicationThis Status Code is indicated when the voltageat terminal PA1 or PA2 of the hydraulic pump



number on the instrument panel display.

Possible Cause

Steering pump motor brushes are worn. Thesensor has closed circuit to battery negative.

Memory RecallNo

Replace the brushes.

Other causes.

PA* or PA* has a short circuit to batterynegative.


CircuitSteering Pump


74


Status Code

-94Description

Traction motor brushes are worn andmust be replaced.

Cause of Status IndicationThis Status Code is indicated when the voltageat terminal PA4 or PA5 of the hydraulic pump




Possible Cause

Traction motor brushes are worn. Thesensor has closed to battery negative.

Memory RecallNo


Other causes.

PA4 or PA5 has a short circuit to batterynegative.


CircuitTraction and

Hydraulic Pump


Status Code

-95Description

Hydraulic pump motor brushes are wornand must be replaced.

Cause of Status IndicationThis Status Code is indicated when the voltageat terminal PB1 or PB2 of the hydraulic pump




Possible Cause

Hydraulic pump motor brushes are worn.The sensor has closed to battery negative.

Memory RecallNo


Other causes.


There is a short circuit in the sensor wire.



75


Status Code

-99Description

Maintenance Alert Code.Cause of Status Indication

This Status Code is indicated when themaintenance alert hours are reached.

Indication of FaultStatus Code flashes ON and OFF.

Memory RecallNo

Possible Cause


Only)

Maintenance Alert Hours have beenreached. Do the scheduled maintenanceand reset the Maintenance Alert hours.See Function Number 19 MAINTENANCEALERT (Tens/Units) and FunctionNumber 20 MAINTENANCE ALERT(Thousands/Hundreds) in the Handsetinstructions.

Status Code

-117Description

Wrong control card type is selected.Cause of Status Indication

This Status Code is indicated when the wrongnumber for the control card is selected.

Indication of FaultHydraulic motor controller does not operate.

Possible Cause

Memory RecallNo

Wrong control card type is selected.


See Function Number 17 CARD TYPESELECTION in the instructions for theHandset. Set the control card type correctly.

76


Status Code

-123Description

Low voltage to hydraulic pump contactor coil.Cause of Status Indication

This Status Code is indicated when the currentto the coil circuit of the hydraulic pump contactor

is less than 100 milliamps.

Indication of FaultThe contactor for the hydraulic pump does

not close. Status code can change betweencode -123 and code -124. Do the checks for

Status Code -123 first. If the problem notfound, do the checks for Status Code -124.

Possible Cause

Malfunction in coil circuit of hydraulicpump contactor.

Memory RecallNo

Check for open circuit or loose connectionsbetween PB4 and the battery positive sideof contactor coil.

Disconnect Plug A and check the resistancebetween PB4 and the battery positive sideof contactor coil.

Coil for contactor 1A is damaged.


Disconnect Plug A and check the resistancebetween the battery positive side of thecontactor coil and its Plug A connection. Thenormal resistance is 10 to 14 ohms.

77


Status Code

-124Description

T2 voltage is greater than 12% ofbattery voltage.

Cause of Status IndicationThis Status Code is indicated when T2voltage is greater than 12% of batteryvoltage and the electronic driver for the

hydraulic pump is energized.

Indication of FaultThe motor controller does not operate. TheStatus Code can change between code -123

and code -124. Do the checks for StatusCode -124 first. If the problem is not found,

do the checks for Status Code -123.

Possible Cause

Malfunction of hydraulic pump contactor.

Memory RecallNo

Check for welded contacts or contactors thatdo not close correctly.

Check that the armature assembly movesfreely.

Check the contactor coil. (See Status Code-123.)

Open motor circuit.

Check for an open circuit or looseconnections in the motor circuit from the A1connection to the A2 connection on the SCRcontrol panel.

Coil for contactor 1A is damaged.


Do the checks in Status Code -123.

Status Code

-125Description

Hydraulic pump contactor does notopen or opens slowly.

Cause of Status IndicationThis Status Code is indicated when T2voltage is greater than 12% of batteryvoltage and the electronic driver for the

hydraulic pump is energized.

Indication of FaultContacts wear quickly on contactor 1A or

the hydraulic pump contactor.

Possible Cause

Memory RecallNo

NOTE: This status code can only be seenby using the Handset or a PC and looking atFunction 1. This status code is added as helpwhen troubleshooting Status Code -146.

Coil for contactor 1A is damaged.CircuitHydraulic Pump Do the checks in Status Code -146.

78


Status Code

-141Description

Open thermal protector or motorcontroller is too hot.

Cause of Status IndicationThis Status Code is indicated when the voltagebetween PZ1 and PZ5 is greater than 1.8 volts.

Indication of FaultThe hydraulic pump motor has reducedpower or no power in the SCR range.

Possible Cause

Open circuit, thermal protector.

Memory RecallNo

Check for a loose or broken wire betweenthe following points:Black wire between thermal protector andPZ1.Gray wire between thermal protector andPZ5.

Malfunction of thermal protector.

Disconnect the wires from PZ1 and PZ5.When the temperature is approximately 25 C(77 F), measure the resistance between theblack and gray wire. The correct resistanceis approximately 300 ohms.

Thermal protector is operating becausemotor controller is too hot.


Permit the motor controller to cool.

Status Code

-142Description


This Status Code is indicated when the voltagebetween PY7 and battery negative is greater

than 1.6 volts and no current is flowing throughthe hydraulic pump motor circuit.

Indication of FaultNo power to the hydraulic pump motor

in the SCR range.

Possible Cause

Memory RecallNo



Check for a loose or broken wire (green wire)between the current sensor and PZ4 on thecontrol card.

79


Status Code

-143Description


This Status Code is indicated when the voltagebetween PY7 and battery negative is less than

0.84 volts and no current is flowing throughthe hydraulic pump motor circuit.

Indication of FaultStall currents in the SCR range are higherthan normal and cannot be controlled with

the current link adjustment.

Possible Cause

Memory RecallNo



Check for a loose or broken wire (yellowwire) between the current sensor and PZ3on the control card.

Status Code

-144Description

SCR 1 in the hydraulic pump controllerdoes not go OFF correctly.

Cause of Status IndicationThis Status Code is indicated when SCR 1 does

not go to OFF correctly during operation.

Indication of FaultHydraulic pump motor continues to operate

until the battery is disconnected.

Possible Cause




Memory RecallNo





Check for a open circuit across SCR 5 or anopen gate lead to SCR 2.

Open Inductor 1X.

Check for an open circuit between T5 andT3. The correct resistance is zero ohms.



The OFF time for SCR 1 is not withinspecifications. No easy test is possible.Replace SCR 1 after the other checks havebeen done and no other problem is found.

80


Status Code

-145Description

SCR 1 in the hydraulic pump controllerdoes not go to ON correctly.

Cause of Status IndicationThis Status Code is indicated when SCR 1 does

not go ON correctly during operation.

Indication of FaultThe hydraulic pump control does not operate.

Possible Cause




Memory RecallYes



Check for an open circuit or looseconnections between SCR 1 and PZ8(white/blue wire).

Check for an open circuit or looseconnections between SCR 1 and D3suppressor and PZ9 (blue wire).



An open or bad gate circuit to SCR 1. Noeasy test is possible. Replace SCR 1 afterthe other checks have been done and noother problem is found.

Status Code

-146Description

Short circuit across SCR 1 in thehydraulic pump controller.


at T2 is greater than 85% of battery voltage.

Indication of FaultHydraulic pump motor continues to operate

until the battery is disconnected.

Possible Cause


Memory RecallNo

Check for a short circuit across SCR 1. (SeeStatus Code -144.)

Check for a short circuit across the insulatorbetween the heat sink for SCR 1 and thebase plate.

Malfunction of SCR 1 OFF circuit.CircuitHydraulic Pump

See Status Code -144.

81


Status Code

-147Description

SCR 2 does not go to ON correctly.Cause of Status Indication

This Status Code is indicated when SCR 2has a failure and does not go ON.

Indication of FaultHydraulic pump motor does not operate or

continues to operate until the batteryis disconnected.

Possible Cause


Memory RecallYes


Check for an open circuit or loose connectionbetween SCR 2 gate and PZ10 (white/redwire).


Check for an open circuit or loose connectionbetween SCR 1 and C1 and through theSCR 2 circuit.

Status Code

-148Description

Voltage check at T2 in the hydraulic pumpcontroller is less than 12% of battery voltage.

Cause of Status IndicationThis Status Code is indicated when a voltage

check at T2 is less than 12% of battery voltage.

Indication of FaultHydraulic pump control does not operate.

Possible Cause



Memory RecallNo

Check for a short circuit across thesuppressor for D3.

Control card type is wrong.CircuitHydraulic Pump If the hydraulic pump control is used without

a pump contactor, the control card must beset correctly. Check for the correct setting.

82


Status Code

-149Description

SCR 5 in the hydraulic pump controllerdoes not go ON correctly.

Cause of Status IndicationThis Status Code is indicated when SCR

5 does not go ON correctly.



Possible Cause





Memory RecallYes

Check for an open circuit or a looseconnection between SCR 5 and PZ12(white/purple wire).





Malfunction of C1.

Check for open capacitor C1.


Check for loose connections of capacitorterminals.

83


Status Code

-150Description

Low voltage on capacitor C1 in the hydraulicpump motor controller.

Cause of Status IndicationThis Status Code is indicated when SCR 2

has a failure and does not go ON.



Possible Cause


Check for an open circuit or loose connectionbetween spider assembly and SCR 5.

Memory RecallNo

Check for an open circuit or loose connectionbetween SCR 5 and SCR 2.

Check for an open circuit or loose connectionbetween SCR 2 and PZ11 (red wire) andbetween SCR 2 gate connection and PZ10(white/red wire).



Status Code

-151Description

Voltage on C1 in Hydraulic pump controlleris too high when motor current is high.


current is greater than 300 amps.



Possible Cause



Memory RecallYes


Motor current too high.

Check for a short circuit at field winding.


Check for a short circuit across an armaturewinding.

84


Status Code

-152Description

Voltage on C1 in the hydraulic pumpcontroller is too high when motor

current is low.


current is less than 200 amps.


Possible Cause


Memory RecallYes


Malfunction of diode D3 circuit.CircuitHydraulic Pump Check for an open circuit or loose connection

in the D3 circuit.

Status Code

-154Description

Short circuit in electronic driver for thehydraulic pump contactor.

Cause of Status IndicationThis Status Code is indicated when the electronic

driver in the control card has a short circuit.


Memory RecallNo

Possible Cause

Control card has a problem.CircuitHydraulic Pump Replace the control card.

Status Code

-157Description

Polarity check of the output voltagefrom the current sensor.

Cause of Status IndicationThis Status Code is indicated when the inputvoltage to PZ4 and PZ3 is the wrong polarity.


Possible Cause

The yellow and green wires from thecurrent sensor to the control card are

connected wrong.

Check that the yellow wire is connected toPZ3 and the green wire is connected to PZ4.

Memory RecallYes

Check from the current sensor to the controlcard for open or loose connections.

Power cables are connected wrongin motor circuit.


Check that battery negative cable connectsto SCR negative and the motor A2 cableconnects to SCR A2.

85

EV-100ZX SCR Motor Controller Repair 2200 YRM 557

EV-100ZX SCR Motor Controller Repair

WARNINGSome adjustments in this section must be donewith the battery connected and power applied tothe controller. When making these adjustments,make sure the drive wheels are raised from thefloor.

Some voltage measurements must be made withthe SRO circuit complete. Make sure the drivewheels are raised from the surface before doingtroubleshooting. If you are working alone, put aweight in the seat to close the seat switch. If yourlift truck has a seat brake, use a block behind thelower actuator bar to release the seat brake whenthe operator is not in the seat. Put the voltmeter sothat you can see it from the operator area. You canoperate the controls with your hand and also makethe voltage measurements.

Make sure you disconnect the battery and separatethe connector before you disassemble any part ofthe controller. The capacitor stores electrical en-ergy and can cause injury if a person discharges acapacitor through parts of the body. AFTER the bat-tery is disconnected, make sure you also dischargethe capacitor C1 by putting a metal bar (screwdriveror similar tool) with an insulated handle across thetwo connections to the capacitor.

NOTE: The electronic controller in many SitDrive lifttrucks cannot be seen from the operator area. Somechecks and adjustments are difficult to do unless an-other person can operate the controls.

NOTE: The bolts and screws connected to the elec-tronic components are normally metric sizes. Makesure that you use the correct fastener for the part thathas been disassembled.

For a typical configuration of an EV-100ZX motor con-troller refer to Figure 8.

FUSES

The fuses are found on the EV-100 control panel. Thepower fuses for the traction circuit (500 amperes) andfor the hydraulic pump (325 amperes) are found on the(+) bus bar. The condition of the fuses can normally bechecked by looking at them or checking them with anohmmeter. The location of the fuses can be found inFigure 1.

SCR, CHECK

In this section, there are instructions to check the SCRs.See Figure 9.

WARNINGMake sure you disconnect the battery and separatethe connector before you disassemble any part ofthe controller. Make sure you also discharge ca-pacitor C1.

NOTE: The following checks indicate most SCRs withdefects. The checks do not always indicate a fault thatdoes not occur regularly during operation. An SCR witha type of fault that does not occur regularly or normallyindicates a resistance between the anode and cathodeof less than 100,000 ohms.

To check the SCRs, 6-volts is needed for a gate signal.Use an ohmmeter and a 6-volt supply for a gate signalor use a Cir/Kit meter to check the SCRs. The Cir/Kithas a 6-volt supply for testing SCRs.

1. Disconnect the (+) or ( ) connection to the SCR tomake a check for a short circuit. Touch the probesof the Cir/Kit or ohmmeter to the power connectionson the heat sinks (anode and cathode of SCR 1).Measure the resistance. Change the probe con-nections to the reverse direction and measure theresistance. Replace the SCR if the resistance indi-cates less than 50,000 ohms in either direction.

2. Measure the resistance between the gate connec-tion and the cathode. Change the probe connec-tions to the reverse direction and measure the re-sistance again. Replace the SCR if the resistanceindicates zero or infinity on the R × 1 scale in eitherdirection.

CAUTIONMake sure you touch the gate connection onlymomentarily with the 6-volt connection or you candamage the SCR. Make sure the polarity of yourtest circuit is correct.

3. Connect the (+) probe of the ohmmeter to the an-ode and the ( ) probe to the cathode. Momen-tarily connect 6-volts from the Cir/Kit [or a batterybetween the gate (+) and the cathode ( )]. The

86

2200 YRM 557 EV-100ZX SCR Motor Controller Repair

resistance indication on the Cir/Kit or the ohmme-ter decreases to less than 10 ohms on the R × 1Scale. Replace the SCR if the resistance does not

decrease when a 6-volt gate signal is applied mo-mentarily.

1. CONTROL CARD2. CAPACITOR C13. BASE PLATE4. SCR 15. DIODE D36. MOTOR CURRENT SENSOR7. DIODE D4

8. REACTOR (INDUCTOR L1 AND 1X)9. SCR 2 AND SCR 4 (NOT SHOWN)10. SPIDER ASSEMBLY11. SCR 5 AND SCR 2 SUPPRESSOR12. SCR 5 AND SCR 2 SUPPRESSOR13. D4 SUPPRESSOR14. D3 SUPPRESSOR

Figure 8. EV-100ZX Motor Controller

87


1. SCR 12. THERMAL PROTECTOR3. CATHODE (POWER CONNECTION)4. ANODE (POWER CONNECTION)5. GATE6. SCR 2 OR SCR 5

Figure 9. How to Check SCR 1, SCR 2, or SCR 5

SCR ASSEMBLY

CAUTIONDO NOT USE this silicon compound on the threadsof the diodes.

NOTE: Silicon compound (Yale Part Number504223239) is used between the heat sinks and theparts of the controller. The purpose of this compound isto fill in the micrometer size spaces between the partsto give better heat flow. Always use a very thin layerof compound between the parts. Too much compoundcan be an insulator and cause both electrical and heatfaults. It is better to use no compound instead of toomuch.

The SCR assembly cannot be disassembled. The SCRassembly includes an SCR fastened between two metalblocks used as heat sinks. The heat sinks are also thepower connections for the SCR. A plastic case holds thecomplete assembly. There is a thin sheet of electricalinsulation between the SCR 1 assembly and the baseplate. The insulator permits heat to transfer from theheat sinks to the base plate.

THERMAL PROTECTOR

The SCR 1 has a thermal protector fastened to the cath-ode heat sink. See Figure 9. The thermal protector is a

resistor that changes resistance when the temperaturechanges. When the temperature is greater than 85 C(185 F), the thermal protector changes the signal volt-age to the control card. The control card decreases thepercent of ON time to decrease the SCR 1 temperature.The normal resistance for the thermal protector is 120to 150 ohms at 18 C (65 F) when measured betweenpins PZ1 and PZ5.

SCR 1 ASSEMBLY, REPLACE

1. Make notes of the positions of the suppressors andremove the suppressors from the mount over SCR1. Disconnect the electric connections to the SCR1 assembly.

2. Remove the thermal protector from the heat sink.Remove the two capscrews that connect the powercables to the heat sinks (make a note of the cathodesensor wire). Remove the two mounting screwsthat hold the SCR 1 assembly to the base plate.

CAUTIONThe insulator is very thin. Dirt between the surfacesof SCR 1 and the base plate can damage the insu-lator and cause a short circuit.

3. Check the insulator between the SCR 1 assem-bly and the base plate. Replace the insulator if itis damaged. The insulator is also a heat conduc-tor. Use a very thin coat of silicon compound (YalePart Number 504223239 or approved equivalent)between the surfaces of the parts. Keep dirt fromthe surfaces.

4. Install the new SCR 1 assembly. Make sure theheat sinks make full contact with the insulator andbase plate. Check the resistance between bothheat sinks and the base plate with an ohmmeter.A correct installation indicates infinity on the ohm-meter.

5. Install the electrical connections to the SCR 1 as-sembly. Install the thermal protector on the heatsink.

6. Install the mount and the suppressors over the SCR1 assembly. Make sure the connections are madecorrectly.

88


OFF CIRCUIT FOR SCR 1

WARNINGMake sure you disconnect the battery and separatethe connector before you disassemble any part ofthe controller. Make sure you also discharge ca-pacitor C1.

The OFF circuit for SCR 1 has the following parts:Reactor assembly (Inductor L1 and 1X)SCR 2SCR 5Suppressors for SCR 2 and SCR 5Capacitor C1

The inductor and a capacitor assembly generate thereverse polarity voltage to change the SCR 1 to OFFfor each pulse. SCR 2 and SCR 5 control the operationof the OFF circuit. The suppressors protect the SCRsfrom electrical noise.

Reactor Assembly, Check

The reactor assembly is in a plastic case that fastensto the base plate. The connections for the reactor areunder the mount for the suppressors and are difficult tocheck with an ohmmeter. A fault does not often occurin the reactor assembly. Most faults that do occur atthe reactor assembly are caused by loose connections.The normal repair of the reactor assembly is to replaceit. This reactor assembly has two inductor windings (L1and 1X) joined by a common connection. A good induc-tor winding indicates approximately zero ohms on the R× 1 scale.

Suppressors for SCR 2 and SCR 5, Check

The suppressors are one or more resistors, diodes, andcapacitors in a small plastic block. See Figure 8. Thesuppressors prevent damage to the SCRs from electri-cal noise. Sometimes a suppressor does not indicatea defect except when in an operating circuit and cancause a fault that does not occur regularly during lifttruck operation. A bad suppressor can cause a faultsimilar to a bad SCR 2 or a bad SCR 5.

The best method to check for a bad suppressor is toreplace it and then check the operation of the lift truck.The same suppressor is used for all functions.

SCR 2 and SCR 5, Check

NOTE: The plastic cases for SCR 2 and SCR 5 are thesame, but the part numbers are different because theelectrical components inside of the cases are different.

An SCR 2 has a higher electrical rating than an SCR 5.An SCR 2 can be used as an SCR 5, but do not use anSCR 5 as an SCR 2. Check the part number to makesure that you are using the correct SCR.

1. Disconnect either the (+) or ( ) power connection.(The power connections have a (+) and ( ) markin the plastic case.) Touch the probes of an ohm-meter to the (+) and ( ) power connections of theSCR. Measure the resistance. Change the probeconnections to the reverse direction and measurethe resistance. Replace the SCR if the resistanceindicates less than 50,000 ohms in either direction.See Figure 10.

1. ANODE2. GATE

3. CATHODE

Figure 10. SCR 2 and SCR 5

2. Measure the resistance between the gate connec-tion and the cathode. Change the probe connec-tions to the reverse direction and measure the re-sistance again. Replace the SCR if the resistanceindicates zero or infinity on the R × 1 scale in eitherdirection.

CAUTIONMake sure you touch the gate wire momentarily withthe 6-volt connection or you can damage the SCR.Make sure the polarity of your test circuit is correct.

NOTE: To check the SCRs, 6 volts are needed as a gatesignal. Use an ohmmeter and a 6-volt supply for a gatesignal.

3. Momentarily connect 6-volts from the battery be-tween the gate (+) and the cathode ( ). The re-sistance indication on the ohmmeter decreases toless than 10 ohms on the R × 1 Scale. Replacethe SCR if the resistance does not decrease whena 6-volt gate signal is applied momentarily.

89


SCR 2 and SCR 5, Replace

Disconnect the electrical connections to the SCR. Re-move the two screws that hold the SCR.

Use a thin layer of silicon compound (Yale Part Number504223239 or approved equivalent) between the sur-faces of the heat sink and the replacement SCR. Installthe SCR. Connect the electrical connections.

Capacitor C1, Check

Discharge C1 and disconnect the terminals beforechecking C1 for a short circuit. Measure the resistancebetween the terminals. The ohmmeter indicates a lowresistance and increase to more than 100,000 ohms.A capacitor with a short circuit must be replaced. Thecapacitor is fastened with two screws and brackets.

DIODES D3 AND D4

The heat sink assembly for the diodes D3 and D4 isalso the connection for the ( ) power cable. The heatsink assembly is connected to the base plate. A thininsulator with a silicone surface separates the heat sinkassembly from the base plate. See Figure 11.

1. DIODE D32. DIODE D4

3. HEAT SINK

Figure 11. Diodes D3 and D4

NOTE: The optional SCR controller used for the hy-draulic pump has only diode D3.

Diodes D3 and D4, Check

You need an ohmmeter to check the diodes. Disconnectthe cathode cables from the connectors. The diodescan stay attached to the heat sinks to make checks.

Touch the probes of the ohmmeter to the heat sink andthe cathode cable. Measure the resistance. Change

the probe connections to the reverse direction and mea-sure the resistance. A good diode indicates 7-14 ohmson the R × 1 Scale in one direction and greater than50,000 ohms in the other direction.

Diodes D3 and D4, Replace

CAUTIONDo not use a hammer and punch to loosen ortighten diodes.

NOTE: Diodes D3 and D4 have a suppressor con-nected in parallel to the diode. Replace the suppressorand test the operation if troubleshooting indicates thatthe suppressor is bad.

Disconnect the cathode cable. Use a deep socket toremove the diodes. Put the wire through the top of thesocket and use a handle or wrench to turn the socket.Use a thin layer of silicone grease (Yale Part Number504224252) between the surfaces of the heat sink andreplacement diode. Tighten the diode to a torque of3.4 N•m (30 lbf in).

MOTOR CURRENT SENSOR

The motor current sensor is a short piece of the circuitbus bar with two sensor wires connected to it. All ofthe traction motor current flows through this power con-nector. The metal between the connection points of thesensor wires has a small resistance. This small resis-tance between the two sensor wires sends a voltagesignal to the control card. The voltage signal increasesas the motor current increases. The control card com-pares the voltage with the current limit (C/L) adjustment.The control card controls the current flow so that thetraction circuit is not damaged. See Figure 12 and Fig-ure 8.

1. SENSOR WIRES 2. SENSOR SHUNT

Figure 12. Motor Current Sensor

90


CONTACTORS

The FORWARD and REVERSE (direction) contactorassemblies control the direction of current flow throughthe traction motor. See Figure 13. The contactor isa heavy-duty switch that opens and closes the powercircuit. The traction circuit has a FORWARD and RE-VERSE contactor assembly. Each contactor assemblyhas the following parts: two sets of normally open (NO)contacts, two sets of normally closed (NC) contacts,and a coil. The coil is an electromagnet that moves theNO contacts to the closed position against spring pres-sure. The coil is in the control circuit. The contactor tipsare in the traction circuit.

1. POWERTERMINALS

2. NC CONTACTS3. NO CONTACTS

4. COIL TERMINALS5. MOUNT BRACKET6. COIL

Figure 13. Direction Contactor

When a contactor coil is energized, the normally open(NO) contacts close and the normally closed (NC) con-tacts open. This action gives direction control to thetraction motor. The contacts normally have a long ser-vice life because the current flow through the contactsis stopped before the contacts open. The SCR 1 is OFFbefore the contactor coil is de-energized. The only con-dition where the contacts open during a large currentflow is a Pulse Monitor Trip (PMT).

The other contactors used in the motor controller haveone set of NO contacts. These contactors are not the

same, but their operation is similar. A typical contactorof this kind is shown in Figure 14.

1. POWERTERMINALS

2. CONTACTS3. SUPPRESSOR


Figure 14. Typical Contactor Assembly(Regenerative Braking Shown)

Contactor, Repair

Make an identification and disconnect the wires and ca-bles from the contactor assembly. Remove the mount-ing screws and remove the contactor assembly. SeeFigure 15.

CAUTIONALWAYS replace all of the contacts in a contactor atthe same time. Replace the contacts in the contac-tor for the hydraulic pump after 1000 hours of oper-ation. Replace the contacts in the other contactorswhen the thickness of any area of a contact is lessthan 30 percent of the thickness of a new contact orif there is any transfer of contact material. DO NOTUSE A FILE ON THE CONTACTS. DO NOT LUBRI-CATE THE CONTACTS.

Contactor Contacts. The contacts in a contactor aremade of special silver alloy. The contacts look blackand rough from normal operation. This condition doesnot cause problems with the operation of the lift truck.Cleaning is not necessary.

91


1. MAGNET BASE2. COIL3. MAGNET FRAME4. BUS5. BUS6. SPACER7. BUS CLAMP8. BUS

9. COVER10. BUS11. BUS12. RETURN SPRING13. ARMATURE14. BUS BASE15. MOVABLE TIP CARRIER16. PLUNGER BUSHING

17. MOVABLE TIP18. SPRING SEAT19. TIP SPRING20. UPPER BUS INSULATION21. NUT22. WASHER


92


Coil. Check the coil with an ohmmeter for an open cir-cuit or a short circuit. Replace the coil if it is damaged.Make sure the coil wires are connected again to thecorrect terminals. The coils in the contactors for thehydraulic pump and the regenerative braking have anexternal suppressor. The coil and the suppressor canbe checked separately with an ohmmeter.

A suppressor diode (and sometimes a resistor in se-ries) is part of the coil. The diode causes the ohmmeterto indicate a difference in resistance in one direction.Reverse the probes of the ohmmeter to the oppositeterminals and measure the resistance. Use the highestresistance indication.

CONTROL CARD

NOTE: Do NOT remove the circuit board from the casewhen replacing a control card. There are no internal re-pairs that can be made by service personnel. The con-trol card and case must be replaced as a unit. There arespecial repair services available that can repair dam-aged control cards. See your dealer for Yale lift trucks.

See Figure 16.

1. CONTROL CARD (TRACTION OR HYDRAULICPUMP)

2. TB SCREW TERMINALS (6)3. PLUG GUIDES

4. PLUG PA (6-PIN) (WIDE GUIDES)5. PLUG PB (6-PIN) (CLOSE GUIDES)6. PLUG PY (14-PIN)7. PLUG PZ (14-PIN)

Figure 16. Control Card Connections

93


CONTROL CARD PLUGS

All control card connections are made at plugs A, B, Y,or Z or at the six screws of TB terminals. If a wire of oneof the plugs must be replaced, the operation to removea pin connector must be done carefully. A special tool(Yale Part Number 504238294) must be used to removethe pin connector from the plug. How the pin connectorsare held in the plug is shown in Figure 17. Use the toolas shown to release the lock so that the pin connectorcan be removed from the plug. If a pin connector mustbe removed, the service person must work carefully sothat the pin connectors and the plug are not damaged.

1. PLUG2. RUBBER SEAL3. PIN CONNECTOR (REMOVED FROM PLUG)4. LOCK5. PIN CONNECTOR (INSTALLED IN PLUG)6. TOOL (YALE PART NUMBER 504238294)

(UNLOCKS PIN CONNECTOR FOR REMOVAL)

Figure 17. Control Card Plug

When a new pin connector is installed in the plug, makesure it is not damaged and is locked into the correct po-sition in the plug. If the pin connection becomes looseduring operation of the lift truck, the malfunction is notregular and is very difficult to find and repair.

Brush Wear Indicators

The brush wear indicators illuminate when the motorbrushes must be replaced. The sensor wires for thebrush wear indicators are an insert in the brush mate-rial when it is made. The sensor wires are insulatedfrom the brush material. When the brush wears withinapproximately 1.5 mm (0.060 in.) of the brush lead, theinsulation between the sensor wire and the brush ma-terial is destroyed. The connection between the brushand the sensor wire causes the indicator to illuminate.

The operation of the brush wear indicators can bechecked during periodic maintenance. The batterymust be removed from the lift truck for access to themotors.

Use a jumper cable so that the battery can be con-nected for operation of the motors. See Figure 18. Dis-connect the sensor wires from the outside of the mo-tor case. Touch the ends of the sensor wires together.The warning light illuminates if the circuit is operatingcorrectly. The thermal switch can be replaced if it isdamaged. However, the motor must be disassembledto replace the thermal switch.

WARNINGPrevent damage and injury if the lift truck moves.Raise the drive wheels from the floor during thesetests.

Use a jumper cable so that the battery can be con-nected for operation of the motors. See Figure 18. Dis-connect the sensor wires, one at a time, from outsideof the motor case. Touch the end of the sensor wire tobattery negative. The warning light illuminates if the cir-cuit is operating correctly. The motor brushes must bereplaced when they are worn. If equipped with brushwear indicators, the condition of the commutator andthe motor brushes must still be checked during periodicmaintenance.

94

2200 YRM 557 Theory of Operation

Figure 18. Connect Battery for Motor Operation

Legend for Figure 18

NOTE: CONNECT THE BATTERY SO THAT THEMOTOR CAN BE OPERATED. THE BATTERY MUSTBE REMOVED FOR ACCESS TO THE MOTOR. USEA JUMPER CABLE TO CONNECT THE BATTERY TOTHE LIFT TRUCK. RAISE THE DRIVE WHEELS. SEEHOW TO RAISE DRIVE TIRES IN THE PERIODICMAINTENANCE SECTION OR THE OPERATINGMANUAL.

1. RAISE DRIVEWHEELS

2. JUMPER3. BATTERY

Theory of OperationELECTRONIC SPEED CONTROLS

NOTE: The description of the current flow in the elec-trical circuits in this section uses the Conventional The-ory of Current Flow. This theory describes the currentas flowing from positive to negative. An electric lift truckuses a two-wire electrical system. There is no commonground through the frame. Both the positive supply andthe negative return current flow through wires and ca-bles. There must be a minimum resistance of 50,000ohms between the electrical circuits and the frame ofthe lift truck.

The EV-100ZX series of motor controllers havesolid-state electronic circuits that control the oper-ation of a DC motor. The speed of DC motors iscontrolled by the average applied voltage. The higherthe average applied voltage, the faster the motor ro-tates. If a switch is put in the traction motor circuitand the switch is changed to OFF and ON quickly, thetraction motor rotates. See Figure 19. The speed of ro-tation increases as the time the switch is ON increases.The speed of rotation decreases if the switch is OFFfor a longer time than it is ON. The speed of the motorcan be controlled using this principle.

An electronic switch called an SCR is used to generatethe rapid ON and OFF times. It has no moving parts.

(An SCR is also called a thyristor in some countries.SCR is used in this manual.)

1. BATTERY2. STEERING MOTOR3. HYDRAULIC PUMP MOTOR4. TRACTION MOTOR ARMATURE5. TRACTION MOTOR FIELD6. CONTACTOR7. SCR 1 SWITCH

Figure 19. Basic Motor Circuit

95

Theory of Operation 2200 YRM 557

Silicon Controlled Rectifier (SCR)

A silicon controlled rectifier (SCR) is a solid-state de-vice that operates like a very fast switch. Rectifiers anddiodes are electronic devices that permit electricity toflow in only one direction. (See Figure 20.) A rectifieror diode permits electricity to flow easily from the anodeto the cathode. An SCR is a rectifier that has an addi-tional element called a gate. An SCR only permits elec-tricity to flow when a positive signal voltage is appliedmomentarily to the gate. An SCR permits electricity toflow from the anode to the cathode after the signal tothe gate is removed. The following conditions stop theflow of electricity through an SCR:• The signal voltage to the gate must be removed and

the current flow through the SCR must be momentar-ily stopped.

• The voltage at the anode and the cathode must beequal so that there is no current flow. The currentflow can be changed momentarily to charge a largecapacitor so that the current flow through the SCR ismomentarily interrupted.

When the SCR is used as a switch:• The SCR is ON when electric current flows through it.• The SCR is OFF when electric current cannot flow

through it.

C. SCR OND. SCR OFF

1. BATTERY2. SCR 1 SWITCH3. CURRENT FLOW THROUGH SCR 14. POSITIVE GATE SIGNAL5. TRACTION MOTOR FIELD6. TRACTION MOTOR ARMATURE7. CURRENT SENSOR8. NO GATE SIGNAL9. MOMENTARY INTERRUPTION OF CURRENT

FLOW

Figure 20. SCR Control

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Motor Circuit That Operates With Pulses

Part of a schematic that shows an SCR in a tractioncircuit is shown in Figure 20. (This main SCR that is inseries with the motor is called SCR 1 in this manual.)An SCR controller is also used to control the speed ofthe hydraulic motor in some lift trucks. The operation ofan SCR controller is the same for a traction circuit and ahydraulic motor. The controller for a traction circuit hasmore functions, which are described in the section forthe traction circuit.

When a signal is momentarily applied to the gate, theSCR permits current flow from the battery through themotor. When the gate signal is removed and the cur-rent flow is suddenly changed to charge a large capac-itor, the SCR is changed to OFF. The battery voltageis applied to the motor in pulses. The pulses of energythrough the SCR to the motor are very fast. The motorcannot follow each pulse, but the motor runs smoothlyon the average voltage generated by the ON and OFFtimes. The average motor voltage applied to the trac-tion motor is shown in Figure 21. The frequency of thepulses also changes the average motor voltage. As thefrequency of the pulses increases, the average motorvoltage increases. The controller for the motor circuithas an oscillator that controls the ON time by sendinga gate signal to the SCR (begin the pulse).

The oscillator sends another signal to the special cir-cuit that changes the SCR to OFF (end of the pulse).The controller has a variable ON time and variable OFFtime and is controlled by the position of the acceleratorpedal.

A potentiometer on the accelerator pedal sends asignal (5 volts decreasing to 0 volts) to the controller.The controller has a voltage controlled oscillator that in-creases in frequency when the voltage decreases fromthe accelerator potentiometer. The oscillator controlsthe ON time by sending a gate signal to SCR 1 (beginthe pulse). The oscillator sends another signal to thespecial circuit that changes SCR 1 to OFF (end of thepulse). The position of the accelerator pedal causesa variation in the 0 to 5 volts supplied to the oscillatorand controls the pulse rate and the speed of the motor.

A low average voltage applied to the motor is the re-sult of a short ON time and a long OFF time. (SeeFigure 21.) The minimum pulse that the controller cangive is 1 millisecond ON and 45 milliseconds OFF. Thisminimum pulse occurs at the slowest speed of lift trucktravel. The pulse rate is also least.

When the oscillator frequencies give equal ON and OFFtimes (approximately 1.7 milliseconds each), the pulserate is the greatest. Approximately 50% of the averagebattery voltage is available to the motor.

Figure 21. Average Motor Voltage

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The maximum average voltage to the motor gives thehighest operating speed. This voltage occurs when theON time is long compared to a short OFF time. Thepulse rate is again least. At the maximum speed, theON time is approximately 20 milliseconds and the OFFtime is approximately 0.8 milliseconds. This maximumspeed sends approximately 96 percent of the batteryvoltage to the motor. Many EV-100 controllers for thetraction motor use a 1A bypass contactor and a fieldweakening contactor to increase the maximum travelspeed of the lift truck. These functions are describedlater in this section.

The pulse rate is approximately 50 Hertz at a low av-erage motor voltage. See Figure 22. When the pulserate increases to a maximum of 300 Hertz, the aver-age motor voltage increases. This increase in voltageis caused by an increase in the ON time and a decreasein the OFF time. The continued increase in ON timecauses the pulse rate to decrease again toward a min-imum of 50 Hertz when the average motor voltage isgreater than 50 percent.

Figure 22. SCR Oscillator Frequency

Traction Circuit

The control card supplies approximately 5.0 volts tothe accelerator potentiometer for the traction circuit.When the accelerator potentiometer is connected andcorrectly adjusted, the voltage is 3.5 to 3.7 volts whenmeasured between the accelerator potentiometer andbattery negative. This voltage is measured at theslowest speed (CREEP speed) of the lift truck and theaccelerator potentiometer is at its highest resistance.The accelerator potentiometer decreases this voltage

by decreasing the resistance between the control cardand battery negative. This accelerator voltage controlsthe oscillator in the control card when the acceleratorpotentiometer is moved by the operator. The oscillatorcontrols the ON time of SCR 1 and controls the travelspeed of the lift truck. When the accelerator pedal ispushed farther down, the control voltage to the controlcard decreases. The maximum ON time (fast travelspeed) occurs when the control voltage is 0.0 to 0.2volts. Most lift trucks are equipped with a bypass circuit(1A) that is energized when the accelerator voltagedecreases to less than 1.0 volts. The 1A bypass circuitdisables the SCR control and applies battery voltagedirectly to the traction motor.

Hydraulic Pump Motor

Some lift trucks are equipped with an SCR controllerto control the speed of the hydraulic pump motor. Theswitches fastened to the linkage for the main controlvalve change the resistance in the control circuit. Thesechanges in the resistance change the voltage that con-trols the oscillator in the control card. The changes inmotor speed are controlled in 3 steps instead of the con-tinuous variation when the voltage is controlled with apotentiometer.

SCR 1 OFF Circuit

A special circuit is necessary to generate a momentaryinterruption in current flow to change SCR 1 to OFF.The parts of this circuit are the capacitor C1, inductorassembly L1, SCR 2, and SCR 5. SCR 2 discharges thecapacitor C1 to the cathode of SCR 1. This dischargechanges SCR 1 to OFF. SCR 5 and the inductor L1 areused to charge the capacitor C1 with the correct polarity.

An SCR controller uses the principle of self-induction inits operation. It is important to remember that self-in-duction is like a flywheel in a mechanical device. Whenthe torque is increased or decreased in a mechanicaldevice, the flywheel gives a resistance to any changein speed. Self-induction does the same function in anelectric circuit and resists any change in current flow.

The current flow through the motor circuit creates amagnetic field around the power cables. When SCR 1 ischanged to OFF, this magnetic field decreases rapidlyand creates an induction voltage that is proportional tothe current flow. At maximum current flow, this inductionvoltage can be greater than 300 volts when measuredacross the capacitor C1.

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SCR 1 OFF Operation

STEP 1.When the battery is first connected, the top plate of C1 isconnected to battery positive. The direction contactor isclosed in preparation to operate the lift truck. C1 cannotcharge immediately to battery voltage because there isno electrical path to the bottom plate. C1 slowly chargesto battery voltage in approximately 4 minutes becausethere is a high resistance path through the control card.The SCRs are not ON.

STEP 2.A signal is sent to SCR 2 to go ON, which closes theelectrical path to the bottom plate of C1. This actionleaves the bottom plate of C1 equal to battery nega-tive and C1 is charged to battery voltage. When C1 ischarged, SCR 2 goes OFF because there is no currentflow.

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STEP 3.A signal is sent to SCR 1 and SCR 5 to go ON. Currentflows through SCR 1, the motor circuit and returns tobattery negative. The polarity at point A is now positivecompared to the bottom plate of C1 because SCR 1 isON.

NOTE: The inductor L2 shown in STEP 4 is not a com-ponent in the motor controller. L2 is the symbol for theinductance caused by the power cables when electriccurrent flows through them.

STEP 4.When SCR 5 is ON, the positive charge at point Anow moves through SCR 5 to change the charge onC1. The momentary current flow through L1 createsa magnetic field. When C1 is charged, the currentflow through SCR 5 stops and SCR 5 goes OFF. Themagnetic fields decreases and the induction voltagecauses a current flow from L1 into the bottom plate ofC1. This action of L1 charges C1 to a voltage higherthan battery voltage, making the battery side of thecapacitor (+) to appear ( ) when compared to thecharge on the bottom plate. This action leaves the topplate of C1 negative compared to the bottom plate, andC1 now has a reverse charge. This action takes lessthan 1 millisecond.

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STEP 5.The current flows through SCR 1 until a signal is sentto SCR 2 to go ON. When SCR 2 goes ON, the higherpositive voltage moves from C1 and momentarily makespoint B more positive than the battery. This momentarypositive voltage makes SCR 1 go OFF.

STEP 6.When SCR 1 is OFF, the magnetic field around thepower cables begins to decrease. This decrease inthe magnetic field generates a voltage that causesthe bottom plate of C1 to become more negative thanbattery negative. The voltage across C1 can now beas high as 150 volts. When the current flow throughSCR 2 stops, SCR 2 goes OFF. This action leaves C1charged at a much higher voltage. C1 is now chargedfor the next cycle.

The fast pulse times and the necessary signals to theSCRs require a special electronic control. These controlcards cannot be repaired except by the manufacturer. Aservice person must replace a bad control card with anew or rebuilt control card.

INDUCTION CURRENT FROM MOTOR

When a DC motor is controlled by a pulsed circuit, themagnetic field in the armature and field is continuouslyexpanding and decreasing. This expansion and de-crease of the magnetic field is lost energy for doing workunless the controller is designed to use this energy. Adiode D3 is added to the circuit for this purpose.

When SCR 1 goes OFF, the decreasing magnetic fieldgenerates a voltage and current in the motor. Diode D3permits the current to flow through the field and arma-ture again to do work. See Figure 23. The torque of aDC motor is directly proportional to the amount of cur-rent flow through it. At slower speeds, the motor torqueis high, and SCR OFF time is relatively long. When

SCR 1 is OFF, the decreasing magnetic field generatesa voltage and current in the motor. (This current is oftencalled the flyback current.) Diode D3, often called theflyback diode, permits the current to flow through thefield and armature again to do work. At slower speeds,motor torque is high without a high current draw fromthe battery. (High current draw from the battery is tobe avoided if possible, because it is less efficient.) Athigher speeds, the torque requirement is less, but SCR1 OFF time is also less, so that less induction current(flyback current) is generated. Most of the motor cur-rent comes from the battery at high speeds.

The graph in Figure 23 shows the typical induction cur-rent during equal ON and OFF times of SCR 1.

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1. BATTERY2. SCR 1 (OFF)3. DIODE D34. MOTOR FIELD

5. MOTORARMATURE

6. MOTOR CURRENTSENSOR

Figure 23. Induction Current

CONTROL CARDS

The control cards for the traction circuit and the hy-draulic circuit are described separately in the followingparagraphs.

NOTE: The configuration of the controller divides thebase plate into three groups:1. Traction controller group2. Contactor group3. Controller group for the hydraulic pump motor

The three groups of components are fastened to therear plate of the battery compartment. Typical controllerconfigurations are shown in Figure 1. (If the SCR con-troller for the hydraulic pump motor is not used, a single

contactor for the hydraulic pump motor is installed inthat position.)

The control card makes checks as part of the logic se-quence. The control card only permits lift truck oper-ation during the correct conditions. The control cardchecks and controls the functions described in the fol-lowing paragraphs.

Pulse Monitor Trip (PMT) (Traction CircuitOnly)

The PMT circuit is part of the control card function.When the SRO checks are complete, the control cardsenses the voltage across SCR 1. If the voltage acrossSCR 1 stays at a low voltage, there is a fault in the trac-tion circuit. If the control card senses a short circuit(low voltage) across SCR 1, it does not permit a direc-tion contactor to close. The PMT circuit also checksthe traction circuit for faults during lift truck operation. IfSCR 1 stays ON for greater than 32 milliseconds, thePMT circuit opens the direction contactor. The controlcard immediately closes the contactor again. If the faultoccurs again, the control card opens the contactor untilthe fault is corrected or the PMT circuit is reset. The cir-cuit is reset when the key switch is turned to OFF andthen to ON again.

When the control card senses a fault across SCR 1, itremoves the signal that closes a direction contactor. Aloss of signal from the control card de-energizes andopens the direction contactors. A PMT occurs whenthe control card senses a malfunction in the operationof SCR 1 and stops sending a signal to the directioncontactors.

SRO Circuit (Traction Circuit Only)

The lift truck is equipped with a safety circuit, calledthe Static Return to OFF (SRO) circuit, that preventsthe operation of the lift truck if the starting sequence isnot correct. The function of the SRO circuit is to makesure the operator is in the seat and ready to operate thecontrols. The starting sequence:

1. The operator must be on the operator’s seat and theseat switch closed. (The seat switch closes whenthe weight of the operator is on the seat.)

2. Turn the key switch to the ON position. The keyswitch supplies the battery voltage to the controlcircuits.

3. Move the direction lever to FORWARD or RE-VERSE. Move the accelerator pedal to close the

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START switch after Step 1 and Step 2 are com-plete. The operator’s foot must be removed fromthe brake pedal so that the brake switch is closed.

If Step 3 is done before Step 1 and Step 2, the lift truckdoes not travel in either direction. The seat switch andkey switch each send a signal voltage to a timer circuit.Both voltages must be sent to the timer circuit beforethe timer sends a voltage signal to terminal TB3 on thecontrol card. The timer circuit has a 6-second delayif the seat switch is opened. This delay permits theoperator to change position in the seat without causingthe lift truck to stop. The voltages from the parts to the

SRO circuit are sent to the control card. The SRO circuitis reset when the START switch or a direction switch ismomentarily opened.

The control card must sense battery voltage at termi-nals TB4 and TB3, then at TB2, then at TB6 (seat switchclosed) or the control card will not permit a directioncontactor to close.

SEQUENCE OF OPERATION

The sequence of operation describes a complete cycleof the SCR traction circuit in Figure 24.

Figure 24. Sequence of Operation

Control Card Adjustments (TractionCircuit)

The control card checks the current in the traction circuitand controls the current to prevent damage. The controlcard has several control adjustments.

The control card for the traction circuit has a control ad-justment called CREEP. This adjustment controls the

minimum current level in the traction circuit when thedirection contactors are closed. This adjustment canbe changed to meet the needs of a specific application.The CREEP adjustment controls how far the acceler-ator pedal moves between the closing of the STARTswitch and the application of enough power to move the

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lift truck. This adjustment is only made after the adjust-ment between the accelerator pedal and the acceleratorpotentiometer is correct.

The C/A (Controlled Acceleration) adjustment con-trols the maximum rate that the average voltage is in-creased by the controller to accelerate the traction mo-tor. This maximum rate is not controlled by the ratethat the accelerator pedal is pushed down for maximumacceleration. A high rate of acceleration increases thewear on the brushes of the traction motor. The acceler-ation time can be adjusted for the operating conditionsof the user. The acceleration rate can be adjusted togive a smooth acceleration for better load handling.

The C/L (Current Limit) adjustment controls the pulserate if the current flow reaches the limit set by the ad-justment. The traction circuit has a current sensor inthe power circuit in series with the traction motor. All ofthe current that flows through the traction motor flowsthrough the current sensor. The current sensor is ashunt with two sensor wires connected. See Figure 25.The metal of the shunt has a small resistance betweenthe two sensor wires. This small resistance sends asignal voltage to the control card. This signal voltageincreases as the motor current increases. The controlcard compares the signal voltage with the C/L adjust-ment. When the signal voltage reaches the limit set onthe C/L, the control card reduces the pulse rate. Thecurrent sensor is connected between the heat sink forD3 and D4 and the terminal for a power cable.

1. SENSOR WIRES 2. SENSOR SHUNT

Figure 25. Motor Current Sensor

The 1A or Bypass Circuit permits the battery to beconnected directly to the traction motor. See Figure 26.This circuit disconnects the control of the SCR circuitand is used for maximum power from the traction mo-tor. When the battery is connected to the traction motorthrough the 1A circuit, the maximum voltage available

to the traction motor is increased by approximately 10percent.

1. BATTERY2. SCR 1 (OFF)3. DIODE D34. MOTOR FIELD

5. MOTORARMATURE


7. CONTACTOR 1A

Figure 26. 1A Bypass Circuit

The control card controls the operation of the 1A cir-cuit. A 1A TIME adjustment permits the SCR control tobegin the operation of the traction motor before the 1Acontactor closes. This time delay prevents full batterycurrent being applied across the traction motor when itis not rotating. (Full battery voltage applied across astalled traction motor causes a large current draw. Thislarge current draw causes a large amount of heat in themotor and wastes battery energy.) This adjustment alsopermits smoother operation of the lift truck. The controlcard begins 1A TIME when the accelerator voltage isdecreased to less than 1.0 volts. 1A TIME is normally 1to 3 seconds. The full battery power is available to thetraction motor through the 1A circuit after the time delay1A TIME.

PLUG. Plugging uses the traction motor as a braketo slow or stop a lift truck. When a lift truck is beingstopped, the motion of the lift truck causes the tractionmotor to rotate and operate like a generator. Plugginguses a current flow from the battery to be opposite thecurrent flow generated by the traction motor. Plugginggenerates heat in the traction motor. See Figure 27.

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1. BATTERY2. SCR 1 (OFF)3. DIODE D34. MOTOR FIELD5. MOTOR

ARMATURE


7. CONTACTOR 1A8. DIODE D4

Figure 27. Plugging Circuit

Plugging is energized when the direction switches inthe direction control lever are moved to the opposite di-rection from which the lift truck is traveling. The direc-tion contactors change to their opposite positions andreverse the current flow through the motor field. Theinduction current generated in the traction motor nowflows opposite to the current flow from the battery. Thelift truck stops very quickly if the induction current is notcontrolled. A diode D4 permits part of the induction cur-rent from the armature to flow with the battery currentthrough the armature again. This reduction of the oppo-site induction current permits the lift truck to stop moresmoothly.

The control card for the traction circuit has a PLUG ad-justment. This adjustment controls the maximum appli-cation of the plugging current. The position of the ac-celerator pedal controls the plugging distance up to themaximum application. This adjustment can be changedas needed for an operator. The shorter the pluggingdistance, the faster is the wear on the traction motorbrushes.

Regenerative Braking. When a lift truck is beingstopped, energy is generated by the traction motor.The lift truck causes the traction motor to rotate andoperate like a generator. Plugging uses battery energy

in opposition to the energy generated by the tractionmotor. This energy generates heat in the tractionmotor. Lift trucks used in heavy duty operations cangenerate enough heat to damage the traction motorsand cause the motor brushes to wear rapidly.

Regenerative braking returns the energy generated bythe traction motor to the battery. See Figure 28. Theregenerative braking contactor opens during regenera-tive braking. When the voltage generated by the trac-tion motor is less than the battery voltage, the lift truckmoves slowly. The contactor for regenerative brakingthen closes and plugging is used to stop the slowly mov-ing lift truck. Regenerative braking generates less heatin the traction motor and reduces brush wear. Anotherelectric circuit must be added to the motor controller tocontrol this operation. The energy generated during re-generative braking must be controlled within limits sothat the parts of the electric circuit are not damaged.The adjustments used to control regenerative brakingare:


ARMATURE6. MOTOR CURRENT

SENSOR7. CONTACTOR 1A

8. DIODE D49. REGENERATIVE

BRAKING (RB)CONTACTOR

10. DIODE D711. REGENERATIVE

BRAKINGCURRENTSENSOR

Figure 28. Regenerative Braking

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REGEN C/L (Regenerative Braking Current Limit)REGEN D.O. (Regenerative Braking Drop Out)

The regenerative braking current limit controls themaximum application of regenerative braking during op-eration. The position of the accelerator pedal by the op-erator controls the plugging distance up to the limit setby the REGEN C/L adjustment.

The regenerative braking drop out adjusts the voltagelevel where the regenerative braking contactor closesduring regenerative braking. The regenerative brakingcontactor closes when the key switch is turned to ON.During regenerative braking, the contactor opens andthe energy generated by the traction circuit is sent tothe battery. When the voltage level is less than the levelset by the REGEN D.O., the regenerative braking con-tactor closes and the remainder of the lift truck speed isdecreased by plugging. When the plugging function isin operation, the voltage generated by the traction mo-tor is normally less than battery voltage.

Field Weakening. Some 36-48 volt lift trucks and some72-80 volt lift trucks have a field weakening circuit. Thefield weakening circuit permits a faster travel speed thanthe 1A circuit. The traction motor must be operating dur-ing 1A conditions of high speed and small load beforethe field weakening circuit is used.

The field weakening contactor connects a bypass shuntaround the motor field. This shunt gives a second pathfor the current flow and weakens the magnetic field inthe motor field. The increased current flow throughthe armature causes the motor to turn faster. SeeFigure 29. This increased speed caused by field weak-ening is only possible when the traction motor has asmall load, for example, high speed travel on a flatsurface. The field weakening decreases the poweravailable from the traction motor to increase the travelspeed.

The field weakening contactor is controlled by two ad-justments on the control card:

F.W.P.U. (Field Weakening Pick Up)F.W.D.O. (Field Weakening Drop Out)

When the lift truck is operating at high speed witha small load, the armature current decreases to aminimum current of approximately 185 amperes. The

F.W.P.U. is adjusted to close the field weakeningcontactor at approximately 1.3 times this minimumarmature current. The field weakening shunt is a stripof metal that connects the field weakening contactor tothe FORWARD and REVERSE contactors. The fieldweakening shunt is calibrated at less than 1.0 ohmand is parallel to the field of the traction motor in thecircuit. The field weakening contactor closes after the1A contactor closes. The 1A contactor closes after theaccelerator potentiometer voltage is less than 1.0 voltsand the 1A TIME function has occurred.

If the lift truck begins to travel up a ramp, the arma-ture current increases. When the armature current in-creases 2.75-3.0 times the minimum armature current,the F.W.D.O. opens the field weakening contactor. If theaccelerator pedal is moved to a slower speed, the con-trol card opens the field weakening contactor.


ARMATURE6. MOTOR CURRENT

SENSOR

7. CONTACTOR 1A8. FIELD

WEAKENING (FW)CONTACTOR

9. FIELDWEAKENING (FW)RESISTOR

Figure 29. Field Weakening Circuit

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RAMP START is a function of the EV-100LX controlcard for the traction circuit. This function permits anoperator to stop a lift truck with a load when going up aslope. If the operator does not change the direction con-trols, the lift truck can be started again on the slope. Alift truck often rolls backward a little distance when start-ing again on a slope. If the operator does not changethe direction controls, the control card does not sensethe reverse operation of the motor armature and appliesenough power to go up the slope. If the operator haschanged the direction controls, the control card sensesthat the expected operation is PLUGGING when the lifttruck rolls backward. The control card does not applyenough power during PLUGGING to make the lift truckgo up the slope.

Accelerator Control

The control card supplies approximately 5.0 volts at ter-minal TB1 of the control card. The accelerator poten-tiometer decreases the voltage between TB1 of the con-trol card and battery negative. This voltage controlsthe frequency of the oscillator which controls the SCRspeed of the lift truck.

The voltage signal from the accelerator potentiometeris 0-5 volts. The voltage is normally adjusted to 3.5-3.7volts. At 3.50-3.7 volts, the lift truck moves at CREEPspeed. The 1A TIME begins its cycle at 1.0 volts so thatthe 1A contactor can close. The maximum speed of thelift truck when operating in the SCR range occurs whenthe voltage is 0.0-0.2 volts. The 1A contactor appliesbattery voltage directly to the traction motor.

SCR CONTROL (HYDRAULIC PUMPMOTOR)

The control card for the hydraulic pump motor is not thesame as the control card for the traction circuit. Thiscontrol card has a different label. The SCR functionfor speed control is the same, but the many functionsnecessary for control of a traction circuit are not neededfor the hydraulic pump motor. A contactor is not used inthe power circuit. The 325-ampere fuse for the hydraulicpump circuit is found between the (+) bus bar and theSCR 1 anode of the controller.

This control card does not have an SRO check nor aPMT check. If SCR 1 has a short circuit, the hydraulicpump motor runs until the battery is disconnected. Themain control valve is an open center valve and the hy-draulic function stops when the hand lever is returned to

the NEUTRAL position. The SCR controller for the hy-draulic pump motor controls the motor at three speeds:

Speed 1 is for the TILT function and for optional func-tions that require the third or fourth spool of the maincontrol valve (slow speed for some attachments).

Speed 2 is for the low speed LIFT function and highspeed operation of an optional function that requires thethird spool of the main control valve.

Speed 4 is only for the high speed LIFT function. Thisspeed applies full battery voltage across the hydraulicpump motor. The SPD 3 adjustment is not used.

The control card sends three reference voltages to theswitches controlled by the linkage to the main controlvalve. When a contact on a switch is closed, the ref-erence voltage is connected with battery negative andthe control card senses the change in the reference volt-age. The voltage controlled oscillator in the control cardcauses SCR 1 to operate at a certain frequency (see theparagraphs that describe Electronic Speed Controls).The speeds of operation can be adjusted for an operat-ing application.

CONTACTORS

Contactors are switches, controlled by electromagnets,that close and open a power circuit. The control cardhas internal electronic drivers and the electronic driverscontrol the current to the coils of the electromagnetsfor the contactors. The electromagnetic field in the coilmoves the armature against spring pressure to closethe contact. When the coil is de-energized, the springpressure moves the armature and opens the contacts.When a spring holds the contacts of a switch open, theswitch is called normally open (NO). If a spring holds thecontacts of a switch closed, the switch is called normallyclosed (NC).

Some lift trucks have an SCR control for the hydraulicpump motor. Some lift trucks also have an electronicdriver that energizes the coil for the hydraulic pump con-tactor.

Lift trucks equipped with regenerative braking, 1A, andfield weakening circuits have contactors with one setof NO contacts. See Figure 30. When the lift truckdoes not have an SCR controller for the hydraulic pumpmotor, the hydraulic pump contactor also has one set ofNO contacts.

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1. POWERTERMINALS

2. CONTACTS3. SUPPRESSOR


Figure 30. Typical Contactor Assembly(Regenerative Braking Shown)

1. POWERTERMINALS

2. NC CONTACTS3. NO CONTACTS4. COIL TERMINALS

5. MOUNT BRACKET6. COIL

(SUPPRESSORIS ADDED TOOUTSIDE OF COIL)


A typical set of direction contactors is shown in Fig-ure 31. The direction contactors (FORWARD and RE-VERSE) each have two sets of NC and NO contacts.When a coil for a direction contactor is energized, theNO contacts close and the NC contacts open. Thisdesign prevents the contacts from being closed in thewrong sequence.

CIRCUIT PROTECTION

Traction Circuit Fuse

The 500 ampere fuse for the traction circuit is found onthe motor controller between the (+) bus bar and the an-ode of SCR 1. If the current flow becomes great enoughto damage the traction circuit because of a short circuitor electrical overload, the fuse fails.

Current Limit

SCR 1 becomes damaged from heat unless the currentflow has limits. A current sensor is installed in the trac-tion circuit between the armature and battery negative.The current sensor sends a voltage signal to the con-trol card. The control card compares the adjustmentC/L with the signal from the current sensor. If the cur-rent flow reaches the limit, the control card overrides theother signals to the oscillator. The pulse width and fre-quency are decreased to decrease the average motorcurrent.

Thermal Protection

The parts of the traction circuit can be damaged by toomuch heat. A heat sensor is connected to the SCR 1heat sink. When the temperature increases toward thedesign limit [85 C (185 F)], the resistance in the sen-sor increases. This increase in resistance decreasesthe SCR 1 ON time by decreasing the pulse width andfrequency to SCR 1. The average motor current is de-creased to prevent damage. When the heat sink cools,the thermal protection returns the control to normal op-eration. This input signal overrides all other input sig-nals (except the 1A signal) to the oscillator during lifttruck operation.

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Suppressors

Electrical noise is high voltage pulses caused by otherelectric parts operating momentarily. Electrical noisecan damage SCRs and diodes. Suppressors are in-cluded in the controller to prevent electrical noise fromentering SCRs and the control card and damaging theelectronic parts. The suppressors are one or more re-sistors and capacitors in a small plastic block. They areinstalled on a mount as shown in Figure 32.

NOTE: DOTTED LINES INDICATE INTERNAL CON-NECTIONS.

Figure 32. Suppressor Mount

TRUCK MANAGEMENT MODULE (TMM1)

The Truck Management Module is a multifunction ac-cessory card that can be used to give additional statuscodes or operator warnings on the display panel dis-play. If a lift truck has brush wear indicators and mo-tor temperature switches and does not have an SCRcontroller for the hydraulic pump motor, a TMM1 cardis added to the controller. The TMM1 receives the sig-nals from the brush wear sensors and motor tempera-ture switches and sends the signals through the tractioncontroller to the display panel. See Figure 33 and Ta-ble 8.

Figure 33. Truck Management Module (TMM1)

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Table 8. Terminal and Plug Wire Connections for TMM1 Module

InputTerminal No.

Function OutputTerminal No.

Actuation OutputVoltage

Fault Code

TB1 Signal wire for temperature switch,traction motor.

TB7 Battery - 0.6 volts 90

TB2 Not Used. — — — —

TB3 Signal wire for temperature switch,hydraulic pump motor.



TB5 Signal wire for brush wear indicator,steering pump.


TB6 Signal wire for brush wear indicator,steering pump.



TB8 Signal wire for brush wear indicator,traction motor.



TB10 Signal wire for brush wear indicator,traction motor.


TB11 Signal wire for brush wear indicator,hydraulic pump motor.


TB12 Signal wire for brush wear indicator,hydraulic pump motor.


TB13 5-volt supply.

TB15 Battery negative.

DISPLAY PANELS

Display Panel

WARNINGSome adjustments can cause the lift truck to oper-ate differently than normal. This different operationof the truck can result in personal injury or damage.Do NOT try to make adjustments for the instrumentpanel display without using the procedures in thesection EV-100/200ZX Motor Controller ParameterTables 2200 YRM 595.

The electric lift trucks covered in this section can haveone of three instrument cluster display panels:• Optional Basic Display Panel• Standard Display Panel

• Premium Display Panel

Optional Basic Display Panel

Features of the Optional Basic Display Panel

NOTE: The Optional Basic Display Panel is availableonly on ERC/P16-20AAF (ERC030-040AF) lift truckmodels. See Figure 34.

The Optional Basic Display Panel contains the followingindicators:• Voltmeter• Parking brake indicator• Brake fluid low indicator• Hourmeter• Fasten seat belt indicator

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1. VOLTMETER2. PARKING BRAKE INDICATOR3. BRAKE FLUID LOW INDICATOR

4. HOURMETER5. FASTEN SEAT BELT INDICATOR

Figure 34. Optional Basic Display Panel

Description of Features on the Optional BasicDisplay Panel

Voltmeter

The voltmeter indicates the voltage of the battery. Thevoltage is indicated when the key and seat switches areON. The battery must have a current draw to accuratelycheck the condition of the battery. Hold the tilt lever inthe tilt BACKWARD position and look at the voltmeter.If the needle is at the left side, charge the battery. Op-erating the lift truck with the needle in the last part ofthe band can decrease battery life. Continued opera-tion with a discharged battery can damage the battery,motors, or the contactors.

Parking Brake Indicator

This red indicator is ON for 1 second after the key ismoved to the ON position. This on-time checks thatthe indicator is operating. The indicator will also be ONwhen the parking brake is applied and the seat switchis closed. The indicator will go OFF when the parkingbrake is released.

Brake Fluid Low Indicator

The red brake fluid low indicator is ON for 1 secondafter the key is moved to the ON position. This on-timechecks that the indicator is operating. If the indicatoris ON during operation, the fluid level in the brake fluidreservoir is low and must be filled.

Hourmeter

The hours and tenths of hours of traction operation areon the hourmeter display whenever the key and seatswitches are ON.

Fasten Seat Belt Indicator

This red indicator is ON for 8 to 10 seconds after thekey is moved to the ON position. This on-time checksthat the indicator is operating and reminds the operatorto fasten the seat belt.

Standard Display Panel

Features of the Standard Display Panel

The Standard Display Panel contains the following indi-cators: See Figure 35.• A Curtis or optional GE meter• Parking brake indicator• Brake fluid low indicator• Fasten seat belt indicator

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A. CURTIS METER B. GE METER (OPTIONAL)

1. HOURMETER2. BATTERY INDICATOR3. PARKING BRAKE INDICATOR4. BRAKE FLUID LOW INDICATOR5. FASTEN SEAT BELT INDICATOR

6. LIQUID CRYSTAL DISPLAY (LCD)7. FUNCTION INDICATORS8. STATUS CODES FUNCTION SYMBOL9. BATTERY INDICATOR FUNCTION SYMBOL10. HOURMETER FUNCTION SYMBOL

Figure 35. Standard Display Panel (With Curtis or GE Meter)

Description of Features on the Standard DisplayPanel

Curtis Meter

The Curtis meter has two functions in one meter case.See Figure 35. The battery meter is a bar of 10 LightEmitting Diodes (LEDs). If the LED at the far right is theonly LED illuminated, the battery has a full charge. Asthe battery discharges, the next LED to the left will goON and the previous LED will go OFF. When the batteryneeds charging, the next-to-last LED will flash. Whenthis LED is flashing, you must CHARGE THE BATTERYNOW. If the last two LEDs are flashing alternately, thebattery is discharged to the point where damage canoccur.

The last two LEDs begin to flash just before the lift in-terrupt is enabled. When the last two LEDs are illu-minated continuously, the controller for the battery dis-charge indicator will disable the lift pump circuit. Thebattery MUST be charged or changed after the circuithas disabled the lift pump motor. Enough battery poweris normally available to move the lift truck to a battery

charger or to a place where a charged battery can beinstalled. DO NOT continue to operate the truck withthese LEDs flashing alternately. Battery, motor, or con-tactor damage can occur if truck operation continues.

The hourmeter has a Liquid Crystal Display (LCD)and can show up to 100,000 hours of operation.The hourmeter operates whenever the key and seatswitches are ON.

GE Meter

Your lift truck may be equipped with an optional GE me-ter in place of the Curtis meter. See Figure 35. TheGeneral Electric meter has three functions in one case.The three functions have one Liquid Crystal Display(LCD) with four digits. Three function Light EmittingDiode (LED) indicators show which function is on thedisplay. These indicators are green LEDs. Functionsymbols below the indicators show the three functions.The three function symbols are described below:• HOURMETER - The hours of traction operation are

on the display when the hourmeter indicator is ON.

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The hourmeter operates whenever the key and seatswitches are ON.

NOTE: On some units, there can also be a display forthe operating time of the lift circuit. On these units,the traction time is shown for 4 seconds after the lifttruck has been operating and the key is turned to theOFF position. The lift pump time will now be shownfor another 4 seconds.

• BATTERY INDICATOR - The four digit LCD shows thebattery charge when the indicator above the batterysymbol is ON. The battery indicator shows the bat-tery charge represented by the numbers between 0and 100. A display of 100 shows a fully charged bat-tery. The digital display will flash when it reads 19.When the number 19 is flashing, CHARGE THE BAT-TERY NOW. At a display of 9, the control will disablethe lift pump circuit. The battery MUST be charged orchanged after the circuit has disabled the lift pump, orbattery, motor, or contactor damage can occur. A sta-tus code of -16 shows that a battery with a high volt-age has been installed. A status code of -15 showsthat a battery with a low voltage has been installed.See the section Battery Indicators 2260 YRM 138for a more complete description of the operation, ad-justment, and repair procedures.

NOTE: Not all lift trucks with this meter have all thefunctions for the flashing status codes.

• STATUS CODES - The display shows the status codewhen the indicator above the wrench symbol is ON.Status codes are code numbers for different symp-toms that the control card can sense. Status codesall have a minus sign ( ) before the numbers. Thesecodes help identify a possible malfunction. A sta-tus code display does not always mean that there isa malfunction. A temporary operating condition cancause a status code to display. See Figure 35.The following status codes will flash to get the oper-ator’s attention:• 90 Traction motor hot• 93 Lift pump motor hot• 94 Traction motor brushes worn• 95 Lift pump motor brushes worn


The red parking brake indicator is ON for 1 second af-ter the key is moved to the ON position. This on-timechecks that the indicator is operating. The indicator willalso be ON when the parking brake is applied and theseat switch is closed. The indicator will go OFF whenthe parking brake is released.


This red indicator is ON for 1 second after the key ismoved to the ON position. This on-time checks thatthe indicator is operating. If the indicator is ON duringoperation, the fluid level in the brake fluid reservoir islow and must be filled.

Fasten Seat Belt Indicator

This red indicator is ON for 8 to 10 seconds after the keyis moved to the ON position. This on-time checks thatthe indicator is operating and to remind the operator tofasten the seat belt. See Figure 35.

Premium Display Panel

Features on the Premium Display Panel

The Premium Display Panel includes the following fea-tures: See Figure 36.• Battery indicator• Parking brake indicator• Brake fluid low indicator• Fasten seat belt indicator• Hourmeter function indicator• Status code function indicator• Motor temperature indicator• Lift pump motor indicator• Traction motor indicator• Brush wear indicator• Steering pump motor indicator• Digital display• Status codes push button• Performance level indicators• Performance level push button

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1. BATTERY INDICATOR2. PARKING BRAKE INDICATOR3. BRAKE FLUID LOW INDICATOR4. FASTEN SEAT BELT INDICATOR5. HOURMETER FUNCTION INDICATOR6. STATUS CODE FUNCTION INDICATOR7. MOTOR TEMPERATURE INDICATOR8. LIFT PUMP MOTOR INDICATOR

9. TRACTION MOTOR INDICATOR10. BRUSH WEAR INDICATOR11. STEERING PUMP MOTOR INDICATOR12. DIGITAL DISPLAY13. STATUS CODES PUSH BUTTON14. PERFORMANCE LEVEL INDICATORS15. PERFORMANCE LEVEL PUSH BUTTON

Figure 36. Premium Display Panel

Description of Features on the Premium DisplayPanel

Battery Indicator

The battery indicator is a scale with a series of 10 LightEmitting Diodes (LEDs) in three colors (green, orange,and red). As the battery voltage decreases during oper-ation, different LEDs illuminate to indicate a dischargedbattery. No more than two LEDs are illuminated at onetime. When the battery is fully charged, the two greenLEDs at the end of the scale are illuminated. When thebattery discharges during operation, the LEDs illumi-nate from top to bottom (green to red). See Figure 36.See the section Battery Indicators 2260 YRM 138 fora more complete description of the operation, adjust-ment, and repair procedures.

All lift trucks with this type of warning indicator displayhave a lift interrupt. When the battery is discharged tothe red section of the battery discharge indicator, thelast two LEDs begin to flash just before the lift interrupt

is enabled. When the last two LEDs are illuminated con-tinuously, the controller for the battery discharge indica-tor stops the power to the hydraulic pump motor. Thisaction prevents the lift truck from lifting. Enough bat-tery power is normally available to move the lift truck toa battery charger or to a place where a charged batterycan be installed.


This red indicator is ON for 1 second after the key ismoved to the ON position. This on-time checks thatthe indicator is operating. The indicator will also be ONwhen the parking brake is applied and the seat switchis closed. The indicator will go OFF when the parkingbrake is released.

If the parking brake is NOT applied and the operatorleaves the seat or turns the key to the OFF position, awarning buzzer will make a noise for approximately 10seconds.

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This red indicator is ON for 1 second after the key ismoved to the ON position. This on-time checks thatthe indicator is operating. If the indicator is ON duringoperation, the fluid level in the brake fluid reservoir islow and must be filled. See Figure 36.

Fasten Seat Indicator

The red fasten seat belt indicator is ON for 8 to 10 sec-onds after the key is moved to the ON position. Thison-time checks that the indicator is operating and to re-mind the operator to fasten the seat belt.

Hourmeter Function Indicator

The hourmeter function shows the operating time of thetraction circuit. There also is a display for the operatingtime of the circuit for the lift pump motor.

The hourmeter indicator is illuminated for 4 seconds af-ter the lift truck has been operating and the key is movedto the OFF position. During this time the operating timeof the traction system is displayed on the four digits ofthe digital display. The traction motor indicator is alsoON at this time. The hourmeter indicator is illuminatedfor another 4 seconds and the operating time for the liftpump motor will be displayed during these 4 seconds.The lift pump motor indicator will also be ON during thistime.

Status Code Function Indicator

The status codes are numbers for different symptomsor malfunctions that the control card can sense. Thecontrol card will show this code number for the symptomor malfunction on the digital display.

The indicator will flash if the control card senses asymptom or malfunction. The status code number willbe displayed on the digits of the digital display. Allstatus code numbers have a minus sign ( ) before thefirst digit. Every third display shows the battery charge.

Have authorized service personnel check and repair thelift truck if a status code appears.

The status code function indicator will also be ON whenit is time for periodic maintenance. A status code of 99will show on the digital display. Have the maintenancedone by authorized maintenance personnel. The ser-vice personnel must also reset the register to turn theindicator OFF.

Motor Temperature Indicator

The traction motor and lift pump motor have thermalswitches inside the motors. When the temperatureexceeds the switch temperature setting, the thermalswitch closes and the indicator of the display illumi-nates. The motor indicator (traction or lift pump) willalso illuminate. This temperature is set by the manu-facturer of the motor and is less than the temperaturewhere the insulation in the motor can be damaged.Travel speed is slower if either motor is hot. See Fig-ure 36.

Lift Pump Motor Indicator

This indicator is ON for 1 second after the key is movedto the ON position. This on-time checks that the indica-tor is operating. If the indicator is ON during operation,it will illuminate with either the brush wear indicator orthe motor temperature indicator. If the brush wear indi-cator is also ON, the lift pump motor brushes are wornand must be replaced. If the motor temperature indica-tor is also ON, the lift pump motor is hot and must beallowed to cool before further operation.

Traction Motor Indicator

This indicator is ON for 1 second after the key is movedto the ON position. This on-time checks that the indica-tor is operating. If the indicator is ON during operation,it will illuminate with either the brush wear indicator orthe motor temperature indicator. If the brush wear indi-cator is also ON, the traction motor brushes are wornand must be replaced. If the motor temperature indi-cator is also ON, the traction motor is hot and must beallowed to cool before further operation.

Brush Wear Indicator

The brush wear indicator illuminates when the motorbrushes of one of the three motors are worn and mustbe replaced. The motor indicator (steering pump, trac-tion or lift pump) will also illuminate.

Steering Pump Motor Indicator

This indicator is ON for 1 second after the key is movedto the ON position. This on-time checks that the indica-tor is operating. If the indicator is ON during operation,it will illuminate with the brush wear indicator to showthat the brushes for the steering pump motor are wornand must be replaced.

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Digital Display

The four-digit, digital display on the right side of the in-strument panel is the display for the traction hourmeter,lift pump hourmeter, and the status codes. The hourme-ter and traction motor indicators will be ON when thedisplay shows hours of operation of the traction sys-tem. The hourmeter and lift pump motor indicators willbe ON when the display shows hours of operation of thehydraulic system. The status code indicator will be ONwhen the display shows status codes.

Status Codes Push Button

Push and hold the push button to display all the sta-tus codes in the memory for detected faults of the trac-tion system. The traction motor indicator will be ONto show that the status codes are for the traction sys-tem. If the push button is released and then pushedand held again, the digital display will start over show-ing all the status codes for the traction system. Pushthe button twice and hold the push button to display allthe status codes in the memory for detected faults ofthe lift system. The lift pump motor indicator will be ONto show that the status codes are for the lift system. Ifthe push button is released and then pushed twice andheld again, the digital display will start over, showing allthe status codes for the lift system.

Performance Level Indicators

These indicators show the performance level set by theoperator by the push button under them. There are fourpossible performance levels available from the slowest(left indicator - turtle) to the fastest (right indicator - rab-bit). See Figure 36.

Performance Level Push Button

This push button sets the performance level of the lifttruck as follows:• Level 1 - Low performance for handling fragile loads.• Level 2 - Medium level for more economy of battery

charge.• Level 3 - Higher level for faster load handling, but less

economy.• Level 4 - Maximum level for maximum performance

operation.

A service person can set all four levels to the same levelsetting.

CURTIS 1215 DISPLAY PANEL

Description and Features

NOTE: See the section Battery Indicators 2260 YRM138 for a more complete description of the operationand the adjustment and repair procedures.

The Curtis 1215 display panel is a rectangular displayunit that operates with the main interface board and thetraction motor controller. See Figure 37. It is used ex-clusively with the Curtis 1215 traction motor controller.For additional information, see the section Traction Mo-tor Controller and Handset - Curtis 1215-9102 2200YRM 608.

1. BATTERY FUEL GAUGE INDICATOR2. LOW BATTERY INDICATOR3. LCD SCREEN4. DISPLAY MODE (SWITCH 1)5. HYDRAULIC FUNCTION INDICATORS6. DRIVE MODE (SWITCH 2)

Figure 37. Curtis 1215 Display Panel

Two different versions of the display panel are available,depending on ambient temperature.

Standard models 25 to 70 C( 13 to 158 F)

Freezer models 40 to 70 C( 40 to 158 F)

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The Curtis 1215 Display Panel contains the followingfeatures:• 10-bar LED battery state of charge indication• 16-character English messages for status, warnings,

and faults• Three-button, selectable hourmeters (traction, lift,

and total hours)• Three-button, selectable drive modes• Four-hydraulic function indicator lights• Low-battery lift interrupt indication and permissive

output

Operation

1. The battery indicator has a 10-bar multicolor diode(LED) to indicate battery charge status. The barsare green, yellow, and red. As power is used, theLEDs will turn off, starting with green, then yellow,then red. The red LED, second from the bottom,will flash indicating a nearly discharged battery.The bottom red LED will alternately flash with theLO-Battery LED indicator, indicating a dischargedbattery. The lift function will be disallowed at thispoint. Continued operation with a dischargedbattery can damage the battery, motor, or thecontactors. See Figure 37.

2. The message center is a 16-character, dot matrix,liquid crystal display (LCD) with green backlighting.The 16-character, alphanumeric display shows thehourmeter readings, lift truck performance status,and warning or fault conditions. When a warningmessage is received, the warning/fault indicator willblink as a yellow light. When a fault message isreceived, the warning/fault indicator will blink as ared light.

3. The instrument display hourmeter switch is con-trolled by the operator and is used for on-demanddisplay of hourmeter information. The hourmeterdata can be displayed at any time by pressing thehourmeter switch. The switch is marked with anhourglass symbol. Press the hourmeter switch toget the following:• Press once to display truck hours to 1/10 of an

hour.

• Press twice to display drive motor hours.• Press three times to display the lift motor hours.• Press four times to return to the normal display

mode.

After 30 seconds, the display will return to the nor-mal display mode, which indicates the current op-erational status of the truck.

4. The drive mode display allows the operator to selectthe level of traction motor controller performancemost suited to the application. Operation of thedrive mode switch will cause the green indicatorsand corresponding drive modes to increase fromTurtle to Mid to Rabbit. The following describesthese modes as programmed from the factory:• Turtle mode provides slower acceleration, re-

duced top speed, and maximized energy effi-ciency. It is also a valuable setting when trainingnew operators.

• Mid mode reduces acceleration with full travelspeed.

• Rabbit mode provides maximum accelerationand travel speed. When the key switch is turnedto OFF, the selected drive mode is retained.When the battery is disconnected, the drivemode returns to the Rabbit mode.

The rates of acceleration and travel speeds are pro-grammable and can be adjusted by a qualified ser-vice technician. See the section Traction MotorController and Handset - Curtis 1215-9102 2200YRM 608 for additional information.

5. The LED function selection lights display the se-lected hydraulic function. Status messages will bedisplayed for lift, tilt, reach, and sideshift. The func-tion selection lights will display the current hydraulicfunction, independent of the present LCD display.

The instrument display is powered when the keyswitch is ON. The instrument panel contains an in-ternal backup battery that is capable of memory re-tention of the battery indicator and hourmeter read-ings when the battery is disconnected.

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NOTES

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Yale Materials Handling Corp.1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 557 7/03 Printed in U.S.A.

ev-100zx™ scr motor controller

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