GENERAL INFORMATION & FEATURES

Glossary .................................................................................................................. 1-1

Nameplate and Serial Number Locations .............................................. 1-5

Before Servicing LiftTrucks.................................................................................. 1-5

EV100ZX Motor Controller without SCR Hydraulics ........................ 1-6

EV100ZX Motor Controller with SCR Hydraulics ............................... 1-7

Basics of Circuit Operation ........................................................................... 1-8

Traction Control Logic Flow Chart ............................................................ 1-9

Console (Display) ............................................................................................... 1-10

Features of the EV100ZX Control System ............................................. 1-11

Creep Speed........................................................................................................ 1-11
Controlled Acceleration........................................................................................ 1-11
Current Limit ........................................................................................................ 1-11
Plugging ............................................................................................................... 1-11
Pedal Position Plug ............................................................................................. 1-11
Ramp Start........................................................................................................... 1-11
Full Power Transition ........................................................................................... 1-11
1A Current Drop Out............................................................................................ 1-11
Static Return to Off .............................................................................................. 1-11
Accelerator Volts Hold-Off ................................................................................... 1-12
Coil Drivers .......................................................................................................... 1-12
Thermal Cutback ................................................................................................. 1-12
Pulse Monitor Trip (PMT)..................................................................................... 1-12
Steer Pump Time Delay....................................................................................... 1-12
Internal Resistance Compensation...................................................................... 1-12
Hour Meter........................................................................................................... 1-12
Battery Discharge Indication................................................................................ 1-13
On Board Diagnostics.......................................................................................... 1-13
Reverse Battery Protection.................................................................................. 1-13
Shorted 3REC Protection .................................................................................... 1-13
Low Current Control Switches ............................................................................. 1-13
Regenerative Braking .......................................................................................... 1-13
Stored Status Codes ........................................................................................... 1-13
Four Speed Modes .............................................................................................. 1-13
Truck Management Module ................................................................................. 1-14
Maintenance Alert ................................................................................................ 1-14

General Maintenance for the SCR Control ............................................ 1-15

Trouble-shooting the EV100ZX Motor Controller .............................. 1-15

EV100ZX SCR Control Wiring Schematics............................................ 1-16

EV100ZX Wiring Schematics without SCR Hydraulics ....................................... 1-16
EV100ZX Wiring Schematics with SCR Hydraulics ............................................ 1-18
EV100ZX Wiring Schematics for Electrical Options ............................................ 1-20
 GENERAL INFORMATION & FEATURES

Glossary
Accelerator
A device that converts mechanical movement into
a voltage pattern to the logics for variable drive motor
speed.
Activate
A word used with a component or circuit. To change
from the normal condition to the “activated” condition
because of an application of force or electricity.
Circuit
A way for current to go from the positive (+) side of an
electrical power source to the negative (–) side of an
electrical power source. This can be through wires
and electrical components.
Coil
A component made from many circles or turns of wire
used to concentrate a magnetic field.

Ammeter Commutator
An electric meter used to measure current flow in An armature component used to transfer current from
amperes. the brushes to the armature windings.

Ampere (or Amp) Compound Motor

The unit of measure of current flow. The amount of A motor which has a field winding in series with the
current that one volt can push through a resistance of armature and a shunt field winding in parallel with the
one ohm. series winding and armature.

Anode Conduct
The positive (+) side of a diode. To allow the flow of current.

Armature Conductor
The rotating portion of an electric motor or generator. A material that provides a path for current flow.

Battery Connector
Two or more cells connected together for a supply of Part if a wire assembly or harness that connects with
electric current. another wire assembly or harness. Used for ease of
assembly and disassembly.
BDI (Battery Discharge Indicator)
An electrically controlled display showing the operator Contact Tips or Contacts
the state of battery charge. The portion of a switch, relay or contactor where the
circuit can be opened or closed.
Brush
A conductor, normally a block of carbon, that makes Contactor Assembly
sliding contact between the stationary and moving An electrical component consisting of an electro-
part of the motor or generator. magnetic coil and a set of heavy contact tips. Control
current passes through the coil, building a magnetic
Bus Bar field which closes or opens the contact tips.
A heavy electrical conductor to which other smaller
wires are connected. Contactor Coil
An electromagnet used to close or open contact tips
Capacitor in a contactor assembly.
Device used to store electrical energy for short periods
of time. Continuity
Having the ability to allow current flow.
Cathode
The negative (–) side of a diode.

1-1
 GENERAL INFORMATION & FEATURES
Glossary
Control Circuits
The wires and components carrying low current used
to signal the logics unit, turn on main components, or
support auxiliary circuits (indicated by thin lines on a
schematic).
Counter Electromotive
An opposing voltage set up by a collapsing or increas-
ing magnetic field within a Force (CEMF) coil.
Current
The movement or flow of electricity through a conductor.
A circuit must be complete for current to flow.
Current Limit
The maximum allowable armature current of a stalled
drive motor during pulsing.
Current Sensor
A hall-effect sensor in the drive motor circuit that
produces an increasing voltage output as the drive
motor current increases.
Current Shunt
A precision low-value resistor connected in series with
the armature of a motor. The logics uses the measured
voltage drop across the shunt to control maximum
current allowed in selected power circuits.
Deactivate
To change from the activated condition back to the
normal (deactivated) condition. It can be caused by
the application of force, the removal of force, or the
removal of electricity.
Digital Signal
A signal in which the elements may be either of two
distinct values. For example high voltage, low voltage.
Diode
A semiconductor device that allows current to flow in
one direction, from the anode to the cathode.
Display
An electrical device that converts voltage inputs to a
visual output.
1-2
Electric Motor
A device that changes electrical energy into
mechanical energy to do work.
Electrical Braking
Electrically trying to rotate the drive motor opposite to
the direction of truck movement.
Electromagnet
A coil of wire, most often wound on an iron core,
which produces a strong magnetic filed when current
is sent through the coil.
Electromotive Force (EMF)
The force that causes an electric current to flow in a
circuit. This force is measured in volts.
Field Windings
The stationary coils that produce a magnetic field in
motors and generators.
Filter
An electrical device or component for restriction or
suppression of undesired voltage spikes.
Fuse
A component in an electrical circuit that will open the
circuit if too much current goes through it.
Generator
A device that transforms non-electric energy (such as
mechanical, thermal, etc...) into electrical energy.
Grounded
A wire or wires that are in contact with the metal
chassis of the vehicle (ground). Can be caused by a
loss of insulation from the wire, or by connecting the
wire to the vehicle.
Harness
An assembly made of two or more wires that are held
together.
Heat Sink
A mounting frame used for semiconductor cooling.
 GENERAL INFORMATION & FEATURES

Glossary
Hour Meter Magnetic Field
An electrically activated device used to record the The area around a magnet where magnetic forces
amount of usage a truck receives. can be detected.

Horse Power Microprocessor

A measure of the time-rate of doing work. 1 HP is A small computer chip preprogrammed to control the
defined as the equivalent of raising 33,000 pounds, various electrical functions on a lift truck.
one foot, in one minute.
Normal Condition
Linear Measure:
Words used with a switch or relay. Their normal con-
HP = Force X Distance dition is their condition when they are not controlled
33,000 X Time by the application of force, temperature, pressure, or
electricity.
• Force in Pounds
• Distance in Feet
Normally Closed (N.C.)
• Time in Minutes
• 33,000 is a Constant A switch or relay whose contacts are closed in the
normal condition.
Rotational Measure:
Normally Open (N.O.)
HP = Torque X Speed
5250 A switch or relay whose contacts are open in the
normal condition.
• Torque in Foot - Pounds
• Speed in revolutions per minute (RMP) OFF-Time
• 5250 is a Constant
The amount of time a current does not flow through a
semiconductor.
Indicator
A lamp or LED that gives an indication of some
Ohm
vehicle condition when it turns on or flashes.
The unit of measurement of resistance. The amount
Input of resistance that will let one volt push only one
ampere of current through it.
A voltage change at the incoming connection of a
component.
ON-Time
Insulator The amount of time current flows through a transistor.
A material that has a very large resistance so that it
will not let current flow through it.
Open Circuit
Wiring or components of a circuit that have no
LED continuity.
Light Emitting Diode - a diode that emits light (lights)
when current flows in the forward direction. Optical Switch
An electronic device made up of an infrared light
Logics or Logic Unit signal generator and photosensitive signal receiver
The main printed circuit board containing a micro- that changes a digital voltage when the light pattern is
processor and circuits to condition the voltage signals conducting or blocked.
that go into or come out of the logics. It electronically
monitors and controls the truck’s functions. Output
The current flow from a component which initiated
from a voltage change at the component’s input.

1-3
 GENERAL INFORMATION & FEATURES

Glossary
Resistance Wiring Diagram
Opposition to the flow of current in a circuit. The unit A drawing using visual representation of components
of electrical resistance is the OHM. The lower the the way they actually look. It is used to show the
resistance, the greater the current flow for a given locations of components and the connections between
voltage. them.

Silicon Controlled Rectifier (SCR) Zener Diode

An electrical switch; a solid-state device used to A special diode used to regulate voltage or as an
generate the rapid ON and OFF times. It has no moving overvoltage (too high a voltage) protector.
parts. See “Theory of Operation” Section.

Source
Terminal of a MOSFET through which the main current
flows (See MOSFET).

Terminal
An electrical connection point on an electrical
component.

Torque
The turning force or effect required to do work.
Torque = Force X Distance
• Force in Pounds
• Distance in Feet to center of rotation

Varistor
A component terminated across the horn connections
to eliminate voltage spikes when the horn is activated.

Volt
The unit of measurement of electromotive force. One
volt is the force needed to make one ampere of cur-
rent flow through one ohm of resistance in a circuit.

Watt
The unit of measurement of power. The amount of
power used when one volt pushes one ampere of
current through a resistance of one ohm. The result of
amperes (current) multiplied by volts (voltage) is watts
(power).

Wire
A conductor used to provide a path for current to flow
to and from electrical components.

1-4
 GENERAL INFORMATION & FEATURES

Nameplate and Serial Number Locations

Nameplate
Chassis
Serial
Number
Mast Serial Number

Hydraulic Motor Traction Motor

Serial Number Serial Number
Power Steering Motor
Serial Number

Before Servicing Lift Trucks

! WARNING
Before doing any maintenance or adjustments
on the Lift Truck, be sure to always use correct
blocks to prevent the unit from rolling or falling.
Raise the drive wheels off the ground. This can be
done by tilting the mast all the way back, placing
hard wood blocks under the mast then tilting
the mast forward. Securely support with blocks.

1-5
 GENERAL INFORMATION & FEATURES

EV-100ZX Motor Controller without SCR Hydraulics

6 5 3 4

7
9

12

2 8 (Under Fuses)
10 11 13

1. Controller, Traction 8. Electronic Driver

2. Contactor, Hydraulic Pump Motor 9. Truck Management Module (TMM1)
3. Forward Contactor 10. Fuse 1 (Traction Circuit)
4. Reverse Contactor 11. Fuse 2 (Hydraulic Pump Circuit)
5. Contactor, 1A By-Pass 12. Fuse Panel (FU 4, FU 5, FU 6)
6. Contactor, Regenerative Braking 13. Fuse 3 (Steering Circuit)
7. Contactor, Power Steering

TYPICAL CONFIGURATIONS OF THE EV-100ZX MOTOR CONTROLLER

1-6
 GENERAL INFORMATION & FEATURES

EV-100ZX Motor Controller with optional SCR Hydraulics

1 2

7 6
4 5

12

10

3
8 9 11

1. Controller, Traction 7. Contactor, Regenerative Braking

2. Controller, SCR Control for (Option on some models)
Hydraulic Pump Motor 8. Fuse 1 (Traction Circuit)
3. Contactor, Hydraulic Pump Motor 9. Fuse 2 (Hydraulic Pump Circuit)
4. Forward Contactor 10. Fuse Panel (FU 4, FU 5, FU 6)
5. Reverse Contactor 11. Fuse 3 (Steering Circuit)
6. Contactor, 1A By-Pass 12. Contactor, Power Steering

TYPICAL CONFIGURATIONS OF THE EV-100ZX MOTOR CONTROLLER WITH

OPTIONAL SCR HYDRAULICS
1-7
 GENERAL INFORMATION & FEATURES

Basics of Circuit Operation

The control circuit is energized by closing the key During the off time, the energy stored in the motor, by
switch, seat switch, and moving the forward or reverse virtue of the motors inductance, will cause current to
lever to either position, and then depressing the circulate through the motor around the loop formed by
accelerator closing the start switch. This applies power 3REC. Thus, providing what is called “flyback current”.
to the control card which will close the selected The figure below shows the nature of the motor cur-
directional contactor and complete the circuits to the rent which is composed of both battery current and
drive motor. (See elementary drawings on page 6 & 7). the inductive flyback current.
The control card then supplies a gate pulse to 2REC
turning it on to a conducting state, allowing current to
flow from the battery through 1C, 1X, 2REC, motor
field, motor armature, sensor , and back to the battery.
After 1C charges, 2REC shuts off due to lack of holding
current. The control card checks that 1C is charged
and unlocks the gate to 1REC and 5REC,
The control card then supplies a gate pulse to 1REC
turning it on to a conducting state, allowing current to
flow from the battery through 1REC, motor field, motor
armature, sensor, and back to the battery. 5REC turns
on and allows current to flow T4-T3, 1C, 1REC, 5REC
to T4-T3. This current charges the bottom of 1C posi-
tive with respect to the battery positive bus. This
charging cycle occurs in less than 1 millisecond (.001
sec.) and 5REC shuts off. This charge is now stored
on the capacitor until it is time to turn off 1REC.
Current continues to flow in 1REC until the control
card fires 2REC. When 2REC conducts, capacitor 1C It should be noted that the average motor current mea-
discharges around the circuit composed of 1C, 1X, sured will be greater than the average battery current.
2REC, and 1REC. This discharge current opposes the The SCR control, in effect, converts battery current at
battery current through 1REC so that the resultant battery volts into a higher motor current and a lower
current is zero. With reverse voltage across 1REC,
motor volts.
1REC is turned off. Current continues to flow in the
2REC, 1C, motor and battery loop until the capacitor
(card terminal 14) is fully charged negative. This The time for the next ON and OFF cycle to start is
charge exceeds battery voltage by an amount which determined by the time that the control card takes to
is a function of peak motor current, and 2REC turns oscillate. This frequency of oscillation is controlled by
off. The figure below illustrates the pulsing of current the potentiometer in the accelerator and automatic cir-
from the battery. cuitry in the card. Slow speed is obtained by having
maximum ohms in the potentiometer. As the resistance
in the potentiometer decreases, the speed of the motor
increases. The SCR circuit is capable of delivering
approximately 95% speed. For full speed operation,
the 1A contactor is closed to apply full battery voltage
across the motor.

1-8
 GENERAL INFORMATION & FEATURES

Traction Control Logic Flow Chart

Circuit is energized
Connect
to allow the Direction
Battery
Contactor to Close when
a direction is selected

Close
was is
Key Switch YES YES
Truck in Truck in
Neutral? Neutral?

NO NO

Power is applied to
the Control Card The selected
Contactor closes

Regen Braking
is Contactor closes
Seat Switch NO
Closed?

YES are
Brake and
Accelerator NO
Switches
closed?
Battery
Positive NO
YES
at T2?

YES
PMT check INCORRECT PMT
completed Fault Sequence
CORRECT
PMT Fault Sequence

Accelerator Start Switch

closes and the
Accelerator moves retest T2
continue where to see if 1C is
you left welded or
1REC is
2REC is turned on on
by a signal from the
Control Card

Capacitor (C1)
open Forward and
charges up, and
Reverse Direction
turns off 2REC
Contactors

• Current flows through

1REC to the Motor and YES
back to the Battery
did
• Current flows through 1REC
5REC charging C1 to shut off? PMT Fault Sequence
reverse battery volts NO

the Control Card turns

on 2REC, 1C discharges
1REC shuts off
through 1REC to the
Motor 1REC shuts off when 1C is charged
when 1C is discharged

1-9

Console (Display)
Mode
Change
Mode Change: The ZX control allows the operator to
select from 4 different speed ranges by use of this
button on the console. Each speed from 1 to 4 provides
increasing acceleration rates as well as top speed.
These are preset by the technician through the
Handset Functions 48 through 60.
Mode Check: The console will display the speed
range currently selected when this button is pressed
in the event the operator is uncertain. The operator
may complain that a truck is running too slow or fast if
unaware of how to check the speed.
Fault Code: When the ! is lit the number being
displayed on the dash gauge is a fault code indicating
a problem.
Park Brake: This will warn the operator the park brake
is applied.
1-10
GENERAL INFORMATION & FEATURES
P Mode Check
Fault Code
Park Brake
Brake Fluid
Battery Low
Over Temp
BWI
Service Due
Brake Fluid: This lamp will light when the brake fluid
is low in the reservoir.
Battery Low: When the battery state of charge gets
to 20 on the meter this light comes on to give the
operator advance warning that the lift will soon reach
cut out.
Over Temp: This light will come on when either drive
or pump motor thermostat switches close. The truck
will also slow down.
BWI: This light will come on when the brushes in
either the drive or pump motor wear to the point that
they require maintenance. The truck will also slow
down.
Service Due: This is the wrench light that will come
on when the Maintenance Hour Meter reading
programmed into the card is reached.
 GENERAL INFORMATION & FEATURES
Features of the EV100ZX Control Systems
The EV100ZX Control System uses a microprocessor
in the main card. This microprocessor is programmable
in the field allowing for more features to be adjustable
and there is a greater range over which they can be
set. This allows us to fine tune the control for a
customers specific needs.
Creep Speed
This is the rate at which the Main SCR is turned on and
off when the accelerator is at it’s slowest speed posi-
tion. This is adjustable to meet the individual needs of
each customer. It can be set from 5% to 15% on time.
Controlled Acceleration
This is the pace at which the oscillator increases the
percent of on time of the Main SCR. It allows for
adjustments in the time required to go from creep
speed to 96% applied battery voltage to the motor on
hard acceleration. It can be set from 0.1 seconds to
22.0 seconds. The 1A bypass contactor will then close
.2 seconds after top control speed is reached and
controlled acceleration stops.
Current Limit
This feature monitors the current through the motor
circuit. It looks at actual motor current where older
controls were only able to look at battery current. This
is important since motor current includes flyback (*)
current and can be 2 to 3 times battery current. When
heavy motor loading takes place this feature overrides
the oscillator and limits the average current to the
value at which it is set. The factory setting should be
adhered to for this adjustment.
(*) flyback - When the Main SCR shuts off and stops
conducting the magnetic field in the drive motor field
collapses. This collapsing of a magnetic field moving
across a set of windings induces a current of opposite
polarity voltage. We then use this voltage to continue
driving the armature during the off time of the Main
SCR. The average motor current then is the sum of
the flyback and the amount conducted by the Main
SCR. We will see exactly how this works later.
Plugging
This feature allows the operator to change the direc-
tion the truck is traveling without coming to a stop
first. When the direction lever is reversed the truck
comes to a smooth stop and gradually accelerates in
the other direction. The severity of this feature is
adjustable for individual customer preferences. We
will cover this in more detail later.
1-11
Pedal Position Plug
This feature allows the operator to control the severity
of the stopping and acceleration during a plug. The
operator simply positions the accelerator for the plug-
ging severity desired. Letting up on the accelerator
during the plug reduces the severity (increasing the
stopping distance) and pushing down increases the
severity (reducing the stopping distance). This feature
is adjustable, however it should be noted that it
interacts with the plugging adjustment and if changed
the plugging adjustment may also have to be reset.
This feature is new with the programmable ZX control
system.
Ramp Start
This feature allows the operator to stop on an incline
and restart without the truck rolling. The control
remembers if the directional switch has changed posi-
tion. If it has it assumes the operator is in a plugging
mode, if not it assumes they have stopped on a ramp.
Full Power Transition
This feature prevents arcing and burning of the 1A
bypass contactor tips. It keeps the Main SCR pulsing
during the pick-up and drop out of the 1A bypass
contactor. This is helpful to keep in mind when
troubleshooting.
1A Current Drop Out
This feature will open the 1A bypass contactor under
excessive motor currents. This puts the truck back in
control range where the currents are limited as preset.
In certain operations this can protect the motor from
damage. The control does not utilize full power transi-
tion when the feature is operational and therefore
some burning of the 1A tips will take place.
Static Return To Off
This is a safety feature to assure that the operator
cannot accidentally make the truck drive when climbing
on. If the key switch is left on and the directional
switch is left with either forward or reverse selected
the truck could drive, if the operator accidentally
depressed the accelerator while climbing on the truck.
This is done through the installation of a seat switch
which opens when the operator exits the seat of the
vehicle. There is a time delay built in of approximately
1.5 seconds to allow for momentary opening of the
seat switch in the event of a bump. This feature is not
adjustable.

Features of the EV100ZX Control Systems
Accelerator Volts Hold-Off
The EV100 control checks the accelerator circuit to
assure that the voltage is above 2.5 before the control
will start. This is to assure that in the event of an
accelerator related failure the truck will not start up at
full speed immediately when the accelerator is first
depressed. It is not adjustable.
Coil Drivers
The early EV100 utilized drivers to actuate and carry
the current load of the contactors. These helped
reduce the need for coil filters in spike suppression.
Drivers also eliminated any need to incorporate inter-
lock switches. Advancing technology has allowed
these drivers to be incorporated within the main solid
state card on the ZX system. The contactors on the
early EV100 had a compromise 42 volt coil which
would work on either 36 or 48 volt systems. The
contactors on the ZX are 24 volt which reduces current.
Battery voltage for the coils is reduced by a chopper
circuit in the card. The card has internal spike sup-
pressions which eliminates the need for external
suppressors. This reduction of components improves
reliability and reduces maintenance costs.
Thermal Cutback
Heat is the primary cause of failure for electrical com-
ponents. If the control should be subjected to excessive
loading for a lengthy time period it will cause the
control to overheat. When this occurs the control will
gradually cut back the current allowed to flow through
the system to the motor. This will reduce the vehicle
speed as the system cools due to handling less
current. If the overheating is severe the control will
also not be allowed to close the 1A bypass contactor.
This is to prevent the truck from lurching as a result of
the lower control range speed and the transition to full
bypass speed.
Pulse Monitor Trip (PMT)
This feature will prevent the control from operating if a
condition exists which would result in the truck operat-
ing in an uncontrolled (run away) condition.
Understanding the three separate aspects will assist
you in proper troubleshooting and repairing any failures.
1. The PMT circuit will check ahead to see if certain
faults exist prior to start up. If found the control
will be prevented from starting. The items checked
include a shorted Main SCR, welded 1A contactor
tips, shorted Forward or Reverse contactors coil
drivers, or a shorted 3 REC.
1-12
GENERAL INFORMATION & FEATURES
2. The PMT circuit will shut down the control during
operation if certain faults occur. These include
failure of the Main SCR to turn off or for the 1A
contactor to remain closed when it is supposed
to be open. The control will then open the
Forward or Reverse contactor.
3. After opening the contactor the PMT circuit closes
the contactor and checks again to see if the fault
still exists. If so it opens the contactor again and
will not allow it to close until the key switch is
cycled. At that time depending on the fault the
look ahead PMT circuit may refuse to let the
control start up.
Steer Pump Time Delay
Actuation of the steering pump contactor on the ZX
system is done through the Main Control Card. This
allows the time delay for opening of the contactor to
be adjustable. These controls are usually set to open
the steer sump contactor after the directional switch
has been returned to neutral for 3.5 seconds. There is
also an override feature which will drop the steer
contactor out after the seat switch has been opened
for 1.5 seconds.
Internal Resistance Compensation
All batteries have a small amount of internal resistance
and this value varies significantly. Likewise the internal
resistance of individual trucks will vary depending on
size of power cables, length of power cables, routing
of cables, etc. This feature allows the adjustment of
the control to compensate for these varying resis-
tances. This will allow the Battery Discharge Indicator
feature to be considerably more accurate than on
earlier control systems. This adjustable feature
became available with the LX and ZX controls.
Hour Meter
The truck hour meter is built into the card and will
automatically record control hours on the ZX controls.
Each time the key switch is turned on the display will
show 8 8 8 8 briefly so that the LED’s can be checked
to prevent possible erroneous readings if one of them
fails. When the key switch is turned off the hours will
display briefly. The hour meter display is a four digit
display.

Features of the EV100ZX Control Systems
Battery Discharge Indication
During the normal run mode the Display indicates the
state of battery charge. It has a range of from 0% to
100% of charge state. When properly adjusted the
gauge will read 10% when the battery has reached an
80% discharge state. Battery manufacturers recom-
mend this to be the maximum amount of discharge
prior to recharging. When the gauge reads 20% the
display will start to blink as an early operator alert. Lift
interrupt is incorporated in the ZX card. When the
gauge reads 10 the control will disable the pump
contactor. This feature is adjustable but should not be
set so that it will allow over discharging of the battery.
The BDI display is a three digit display.
On Board Diagnostics
The ZX Control includes diagnostic readouts of fault
codes on the battery indicator gauge. Readouts make
it possible for technicians to take advantage of the
fault codes displayed prior to going out to work on the
truck. This may prove helpful in knowing what parts,
tools, etc. to take with them. The fault code is a two
digit number preceded by a dash for the traction control.
With the optional SCR hydraulic control this will be a
three digit number preceded by a dash if the problem
is in the pump control. In the event that the fault is
intermittent the last code will not be displayed, however
it will be maintained in the cards memory and can be
accessed through the use of the Hand Set. The ZX
control stores up to 16 of the most recent fault codes.
We will discuss how to access these later.
Reverse Battery Protection
If the battery connections are reversed, the control will
not operate.
Shorted 3REC Protection
This feature prevents the control from operating if the
flyback diode (3REC) is in a shorted condition.
Low Current Control Switches
This feature is used for the directional input switches.
The only coil current carrying switches are the key,
brake, seat and start switches.
1-13
GENERAL INFORMATION & FEATURES
Regenerative Braking
This feature is activated when the vehicle is moving
and the directional lever is moved from one direction to
the other. This initiates a plugging signal by reversing
the motor field. Once the generated current reaches a
particular current level, the plugging mode transitions to
regenerative braking mode. The major advantage is
longer motor life due to reduced motor heating.
Stored Status Codes
This feature furnishes a function register that contains
the last fault that shut down truck operation (PMT type
fault that is reset by cycling the key switch). This status
code will be overwritten each time a new status code
occurs and can be cleared from memory by adjusting
the value to zero.
Four Speed Modes
There is a button on the dash console which allows the
operator to select 4 different speed modes of control
operation. This will allow the operator to select the best
control operating characteristics for individual plant
operating conditions. The ranges effect acceleration
and top speed. Each speed mode number increase
gives an increase in acceleration and/or top speed.
With factory settings the following ranges may be
selected:
Speed #1 – 10.9 seconds to accelerate to top possible
speed. No 1A available.
Speed #2 – 2.6 seconds to accelerate to top possible
speed. No 1A available.
Speed #3 – 2.6 seconds to accelerate to top possible
speed. 1A is available.
Speed #4 – No minimum time to accelerate to top
possible speed. 1A is available.
The preset speeds can be changed only with the
Handset and the operator can only select one of the
four possible preset speeds. In this way, if desired, the
amount of difference in these speed settings can be
minimized or eliminated. Each speed, however, must be
equal to or more aggressive than the one preceding it.
 GENERAL INFORMATION & FEATURES

Features of the EV100ZX Control Systems

Truck Management Module
This feature slows the truck down should certain con-
ditions arise. This will occur anytime we have overheating
of either the pump or the drive motor. It also happens
if either the pump or drive motor brush wear indicators
actuate. In these situations truck speed will be
reduced to half SCR range speed and 1A will be held
off. When the situation is rectified, the truck will return
to full speed. A 90 series status (fault) code will be
displayed on the dash gauge but will not be retained
in memory. These speed reductions may be disabled
or changed as a customer may require. When the
truck is equipped with SCR hydraulics this function is
done in the hydraulic SCR card and we do not need
the TMM card.
Maintenance Alert
The main card can be programmed to illuminate a
wrench shaped light on the dash when the truck is due
for Planned Maintenance. The time interval can be
programmed into the card. The factory setting will turn
the light on at 200 hours. The factory setting will not
effect the truck speed but if desirable this can be done
with the proper programming. The light will stay on until
a new hour meter reading is programmed into the card.

Notes

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General Maintenance for the
SCR Control
The SCR control, like all electrical apparatus, does
have some thermal losses. The semiconductor junc-
tions have finite temperature limits above which these
devices may be damaged. For these reasons, normal
maintenance should guard against any action which
will expose the components to excessive heat, such
as steam cleaning; or which will reduce heat dissipating
ability of the control, such as restricting air flow.
The following DO’S and DON’TS should be observed:
Any controls that will be used in ambients of 100° F
(40° C) or over should be brought to the attention of
the truck manufacturer.
All external components having inductive coils must be
filtered. Refer to vehicle manufacturer for specifications.
The control should not be steam cleaned. In dusty areas,
use low-pressure air to blow off the control. In oily or
greasy areas, a mild solution of detergent or denatured
alcohol can be used to wash off the control and then
blow completely dry with low-pressure air.
For the SCR panel to be most effective, it must be
mounted against the frame of the truck. The truck frame,
acting as an additional heat sink, will give improved
truck performance by keeping the SCR control package
cooler. The use of a heat-transfer grease (Dow
Corning 340) is recommended.
Terminal boards and other exposed SCR control parts
should be kept free of dirt and paint that might
change the effective resistance between
points.
! CAUTION
The truck should not be plugged when the truck
is jacked up and the drive wheels are in a free
wheeling position. The higher motor speeds
can create excessive voltages that can be
harmful to the control.
Do not hipot (or megger) the control. Unless the termi-
nals of each semiconductor and card are connected
together, the control may be damaged. Refer to control
manufacturer before hipotting.
Use a lead-acid battery with the voltage and ampere
hour rating specified for the vehicle. Follow normal
battery maintenance procedures, recharging before 80
percent discharged and with periodic equalizing charges.
1-15
GENERAL INFORMATION & FEATURES
Trouble-shooting the
EV100ZX Motor Controller
If mis-operation of the vehicle occurs, a Status Code
will be displayed on the Dash Display (for trucks
equipped with a Dash Display) or by plugging a Handset
into the Logic Card’s plug “Y” location and then reading
the status code. With the Status Code Number, follow
the procedures outlined in the Status Code Section of
this manual. to determine the problem.
Checking and replacement of components are also
outlined in this manual. Please refer to this section as
needed.
Important Note: Due to the interaction of the logic
card with all vehicle functions, almost any status code
or control fail could be caused by the Logic Card. After
all other status code procedures have been followed
and no problem is found the logic card should then be
replaced as the last option to correct the problem.
The same device designations have been maintained
on different controls but the wire numbers may vary.
Refer to the elementary and wiring diagrams for your
specific control. The wire number shown on the ele-
mentary diagram will have identical numbers on the
corresponding wiring diagrams for a specific truck.
! WARNING
Before trouble-shooting, jack up wheels, discon-
nect the battery and discharge the capacitor
1C. Reconnect the battery as needed for the
specific check.
If capacitor 1C terminals are not accessible, discharge
capacitor by connecting from SCR POS terminal to 2
REC anode. Check resistance on RX1000 scale from
frame to SCR power and control terminals. A resis-
tance of less than 20,000 ohms can cause misleading
symptoms. Resistance less than 1000 ohms should
be corrected first.
Before proceeding visually check for loose wiring,
maladjusted linkage to the accelerator switch, signs of
overheating of components, etc.
Tools and test equipment required are: (a) 6-volt lamp,
6-volt battery, two A14 diodes (1Amp 400V), clip
leads, volt-ohm meter (20,000 ohms per volt) and
general hand tools.
 GENERAL INFORMATION & FEATURES

EV100ZX SCR Control Wiring Schematic

Optional Equipment

1-20