EV-100ZX™ SCR MOTOR

CONTROLLER
DESCRIPTION, ADJUSTMENTS,
TROUBLESHOOTING, REPAIRS,
AND THEORY
E1.50-1.75XM, E2.00XMS (E25-35XM, E40XMS) [D114];
E.200-3.20XM, E2.50-3.00XMS (E45-65XM, E45-50XMS) [F108];
E3.50-5.50XL (E70-120XL) [C098];
J2.00-3.20XM, J2.50XMS (J40/50/60/65XM, J50XM Short) [A216];
N30XMH [C210]

PART NO. 897636 2200 SRM 557

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have 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

on electric 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
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance 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 HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

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

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if 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
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

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

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

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
EV-100ZX™ SCR Motor Controller Table of Contents

TABLE OF CONTENTS

General ................................................................................................................................................................. 1
Model Number Data For EV-100ZX Controller ............................................................................................. 2
Register Parameters .......................................................................................................................................... 16
General ........................................................................................................................................................... 16
Function Numbers ......................................................................................................................................... 16
Control Card, Checks and Adjustments ........................................................................................................... 16
Handset .............................................................................................................................................................. 17
How to Check and Adjust Registers ............................................................................................................. 17
How to Scroll through Fault Codes and Clear Them................................................................................... 17
Checks and Adjustments on Workbench ...................................................................................................... 18
When Handset Is Connected to Control Card Installed In Lift Truck ....................................................... 19
Function Numbers 1 through 15................................................................................................................... 20
Function Numbers 16 through 30................................................................................................................. 20
Function Numbers 48 through 62................................................................................................................. 20
Control Cards ..................................................................................................................................................... 21
Function Number Descriptions..................................................................................................................... 21
Traction Control Cards (Label Letters - ZH and ZY)................................................................................... 21
Function Number 1 STORED STATUS CODE........................................................................................ 21
Function Number 2 CREEP SPEED........................................................................................................ 22
Function Number 3 CONTROLLED ACCELERATION AND 1A TIME ............................................... 22
Function Number 4 CURRENT LIMIT ................................................................................................... 22
Function Number 5 PLUGGING DISTANCE (CURRENT) ................................................................... 22
Function Number 6 1A DROP OUT CURRENT ..................................................................................... 22
Function Number 7 FIELD WEAKENING PICK UP............................................................................. 22
Function Number 8 FIELD WEAKENING DROP OUT......................................................................... 23
Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT ................................................. 23
Function Number 10 REGENERATIVE BRAKING START .................................................................. 23
Function Number 13 SPEED LIMIT 3 (SL3) .......................................................................................... 23
Function Number 14 INTERNAL RESISTANCE COMPENSATION ................................................... 24
Function Number 15 BATTERY VOLTS.................................................................................................. 24
Function Numbers GREATER THAN 15................................................................................................. 24
Function Number 16 PEDAL POSITION PLUG .................................................................................... 24
Function Number 17 CARD TYPE SELECTION.................................................................................... 25
Function Number 18 STEERING PUMP TIME DELAY ........................................................................ 25
Function Number 19 MAINTENANCE ALERT (Tens/Units) ................................................................ 25
Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds) .............................................. 25
Function Number 21 MAINTENANCE SPEED LIMIT ......................................................................... 25
Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS ................................................. 25
Function Number 29 HOURMETER (Tens/Units) .................................................................................. 26
Function Number 30 HOURMETER (Thousands/Hundreds) ................................................................ 26
Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE .............................................. 26
Function Number 48 CONTROLLED ACCELERATION AND 1A TIME ............................................. 26
Function Number 49 FIELD WEAKENING PICK UP........................................................................... 26
Function Number 50 SPEED LIMIT 1 .................................................................................................... 26
Function Number 52 CONTROLLED ACCELERATION AND 1A TIME ............................................. 27
Function Number 53 FIELD WEAKENING PICK UP........................................................................... 27
Function Number 54 SPEED LIMIT 1 .................................................................................................... 27
Function Number 56 CONTROLLED ACCELERATION AND 1A TIME ............................................. 27
Function Number 57 FIELD WEAKENING PICK UP........................................................................... 27
Function Number 58 SPEED LIMIT 1 .................................................................................................... 27
Function Number 60 CONTROLLED ACCELERATION AND 1A TIME ............................................. 28

©2003 HYSTER COMPANY i

Table of Contents EV-100ZX™ SCR Motor Controller

TABLE OF CONTENTS (Continued)

Function Number 61 FIELD WEAKENING PICK UP........................................................................... 28
Pump Control Card (Label Letter ZP).......................................................................................................... 28
Function Number 1 STORED STATUS CODE........................................................................................ 28
Function Number 2 INTERNAL RESISTANCE COMPENSATION START ........................................ 28
Function Number 3 CONTROLLED ACCELERATION ......................................................................... 28
Function Number 4 CURRENT LIMIT ................................................................................................... 28
Function Number 7 CONTROLLED ACCELERATION COMPENSATION ......................................... 28
Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and Slow Auxiliary (Auxiliary
and Slow Rotate for N30XMH) ................................................................................................................. 29
Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lift and Medium
Auxiliary (Slow Lift And Fast Rotate for N30XMH) ............................................................................... 29
Function Number 13 SPEED LIMIT 3 (SL3) .......................................................................................... 29
Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift........................................................................... 29
Function Numbers Greater Than 15........................................................................................................ 29
Function Number 16 INTERNAL RESISTANCE COMPENSATION ................................................... 29
Function Number 17 CARD TYPE SELECTION.................................................................................... 30
Function Numbers 18 through 28 TEMPORARY DATA REGISTERS .................................................. 30
Function Number 29 HOURMETER (Tens/Units) .................................................................................. 30
Function Number 30 HOURMETER (Thousands/Hundreds) ................................................................ 30
Function Number 48 CONTROLLED ACCELERATION ....................................................................... 30
Function Number 49 SPEED LIMIT 2 .................................................................................................... 30
Function Number 50 SPEED LIMIT 3 .................................................................................................... 30
Function Number 52 CONTROLLED ACCELERATION ....................................................................... 30
Function Number 53 SPEED LIMIT 2 .................................................................................................... 31
Function Number 54 SPEED LIMIT 3 .................................................................................................... 31
Function Number 56 CONTROLLED ACCELERATION ....................................................................... 31
Function Number 57 SPEED LIMIT 2 .................................................................................................... 31
Function Number 58 SPEED LIMIT 3 .................................................................................................... 31
Function Number 60 CONTROLLED ACCELERATION ....................................................................... 31
Function Number 61 SPEED LIMIT 2 .................................................................................................... 31
Function Number 62 SPEED LIMIT 3 .................................................................................................... 31
Register Parameters...................................................................................................................................... 31
Troubleshooting.................................................................................................................................................. 32
General ........................................................................................................................................................... 32
Status Codes .................................................................................................................................................. 33
Register Maps ................................................................................................................................................ 35
Status Code Charts ............................................................................................................................................ 46
EV-100ZX SCR Motor Controller Repair.......................................................................................................... 88
Fuses .............................................................................................................................................................. 90
SCR, Check .................................................................................................................................................... 90
SCR Assembly................................................................................................................................................ 90
Thermal Protector ......................................................................................................................................... 91
SCR 1 Assembly, Replace .............................................................................................................................. 91
OFF Circuit for SCR 1 ................................................................................................................................... 91
Reactor Assembly, Check .......................................................................................................................... 91
Suppressors for SCR 2 and SCR 5, Check ............................................................................................... 91
SCR 2 and SCR 5, Check .......................................................................................................................... 92
SCR 2 and SCR 5, Replace........................................................................................................................ 92
Capacitor C1, Check.................................................................................................................................. 92
Diodes D3 and D4 .......................................................................................................................................... 92
Diodes D3 and D4, Check ......................................................................................................................... 93

ii
EV-100ZX™ SCR Motor Controller Table of Contents

TABLE OF CONTENTS (Continued)

Diodes D3 and D4, Replace....................................................................................................................... 93
Motor Current Sensor ................................................................................................................................... 93
Contactors ...................................................................................................................................................... 93
Contactor, Repair....................................................................................................................................... 94
Control Card .................................................................................................................................................. 96
Control Card Plugs ........................................................................................................................................ 96
Brush Wear Indicators .............................................................................................................................. 97
Theory of Operation ........................................................................................................................................... 98
Electronic Speed Controls ............................................................................................................................. 98
Silicon Controlled Rectifier (SCR) ............................................................................................................ 98
Motor Circuit That Operates With Pulses ............................................................................................... 99
Traction Circuit ....................................................................................................................................... 101
Hydraulic Pump Motor ........................................................................................................................... 101
SCR 1 OFF Circuit .................................................................................................................................. 101
SCR 1 OFF Operation......................................................................................................................... 102
Induction Current from Motor .................................................................................................................... 104
Control Cards............................................................................................................................................... 105
Pulse Monitor Trip (PMT) (Traction Circuit Only)................................................................................ 105
SRO Circuit (Traction Circuit Only)....................................................................................................... 105
Sequence of Operation................................................................................................................................. 106
Control Card Adjustments (Traction Circuit) ........................................................................................ 107
Accelerator Control ................................................................................................................................. 110
SCR Control (Hydraulic Pump Motor) ....................................................................................................... 110
Contactors ..................................................................................................................................................... 111
Circuit Protection ......................................................................................................................................... 111
Traction Circuit Fuse ............................................................................................................................... 111
Current Limit ........................................................................................................................................... 111
Thermal Protection ................................................................................................................................. 112
Suppressors ............................................................................................................................................. 112
Truck Management Module (TMM1).......................................................................................................... 112
Display Panels ............................................................................................................................................. 113
Display Panel........................................................................................................................................... 113
Basic Display ........................................................................................................................................... 113
Early Display Panel ............................................................................................................................ 114
Later Display Panel ............................................................................................................................ 115
Performance Display ............................................................................................................................... 116
Brush Wear Indicators ............................................................................................................................ 119

This section is for the following models:

E1.50-1.75XM, E2.00XMS (E25-35XM, E40XMS) [D114];

E.200-3.20XM, E2.50-3.00XMS (E45-65XM, E45-50XMS) [F108];
E3.50-5.50XL (E70-120XL) [C098];
J2.00-3.20XM, J2.50XMS (J40/50/60/65XM, J50XM Short) [A216];
N30XMH [C210]

iii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 557
General
Four Service Manual sections are required for the
complete Description, Checks, Adjustments, Trou-
bleshooting, and Repairs of this motor controller:
• EV-100ZX SCR Motor Controller, Description,
Adjustments, Troubleshooting, Repairs, and
Theory 2200 SRM 557 (this section)
• Troubleshooting and Adjustments With a
Computer for EV-100ZX and EV-T100 Motor
Controllers 2200 SRM 597
• EV-100ZX SCR Motor Controller, Parameter
Tables 2200 SRM 595 and 2200 SRM 624
• Electrical System, Repairs, Checks, and Ad-
justments 2200 SRM 560
This section describes the operation and the func-
tions of the EV-100ZX motor controller. The EV-100
and the EV-200 series of motor controllers, used to
control the operation of electric lift trucks, are made
by the General Electric Company.
The EV-100 and the EV-200 series of motor con-
trollers are similar in design and function, but have
different control cards.
The ZX letters identify the controllers that have the
ZX series of diagnostic control cards. These control
cards can use an adapter for a serial cable that will
connect to a serial port on a personal computer for
checks, adjustments, and troubleshooting.
• A Cable Kit, Control Card to Computer, is required
(Hyster Part No. 1358471).
• The HYTECH™ software for a personal computer
is available on a 3.5-inch diskette (Hyster Part No.
1495217).
• The Cable Kit and the 3.5-inch diskette with
the HYTECH™ software are available from your
dealer for Hyster lift trucks.
These control cards have logic circuits and registers
that control and keep a record of the operations of the
motor controller. The registers also keep a record of
possible malfunctions of the motor controller that can
indicate the problems during troubleshooting.
This section has the following components:
• A Description for the EV-100ZX SCR Motor Con-
troller.
General
• A series of Status Code Charts that describe an
indication of a fault and its possible causes when
the code is shown on the instrument panel display.
• Checks and replacement of the components of the
motor controller are described in Repairs.
• A basic Theory Of Operation on how an SCR motor
controller operates.
An electronic diagnostic and adjustment device can
also be used to check and adjust the control cards.
This electronic diagnostic and adjustment device is
called a Handset and is described later in this sec-
tion. A computer with the control software installed
has access to 128 function registers on the control
cards. The Handset has access to less function regis-
ters on the control card and can only make changes
to a limited number of the registers on the ZX control
cards.
A description and the replacement of the instrument
panel display is also included in the repair section.
Most of the components of the EV-100ZX motor
controller cannot be repaired, but must be replaced.
This section describes the procedures for using the
electronic diagnostic and adjustment devices for
checking and adjusting the operation of the motor
controller.
There are electrical components that are not part
of the motor controller, but give input signals to it.
These components 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 SRM 560.
1
General 2200 SRM 557

MODEL NUMBER DATA FOR EV-100ZX
CONTROLLER
The model numbers for the EV-100ZX controller
indicate the following information:
Example:
IC3645EV 100 T1 ZH 1 operate a digital display with four digits. A digital
(01) (02) (03) (04) (05)
(01) The first series of letters and numbers indicate
the basic catalog number of the controller.
(02) The second set of numbers indicates the power
base rating of the controller:
100 = EV100 Power Base [lift trucks less than
3500 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
SCR 1 options:
T1 = Standard Current Limit for traction motor
T2 = High Performance Current Limit for traction
motor
P1 = Standard Current Limit for hydraulic pump
motor
P2 = High Performance Current Limit for hy-
draulic pump motor
(04) This set of letters indicate the control card op-
tions:
ZH = Traction Controller with three-wire poten-
tiometer and with Battery Discharge Indicator
(BDI)
ZP = Pump Motor Controller with Truck Manage-
ment Module (TMM1)
ZY = Traction Controller with three-wire poten-
tiometer and without Battery Discharge Indica-
tor (BDI)
(05) This number indicates the revision code:
1 = Active
The ZX series of motor controllers have an output to
display unit (instrument panel display) is available
for the instrument panel of some lift trucks. The ZX
control cards can use an adapter for a serial cable
that connects to a RS-232-C serial port on a personal
computer (PC) for checks and adjustments. A Hand-
set with a digital display is also available. All of the
control settings are set using a PC or the Handset.
The control card is a printed circuit board with elec-
tronic parts in a plastic case. The position of the con-
trol cards in the controllers can be seen in Figure 1,
Figure 2, and Figure 3. Two machine screws at the
bottom of the plastic case fasten the control card to
the mount plate.
The control card has two 6-pin plugs (PA and PB) that
connect the signal wires between the parts of the con-
troller and the control card. A terminal strip with
six screw connections are inputs from control compo-
nents of the lift truck. A 14-pin plug (PZ) connects
the control card to the functions for SCR 1, SCR 2,
and SCR 5. See Figure 4. Plug PY is a 14-pin plug
that connects the instrument panel display, PC, or
the Handset to the control card. Some pins of plug
PY are also used to connect to the control card for
the hydraulic pump motor. The functions of the of
the signal wires are described in Table 1, Table 2, Ta-
ble 3, and Table 4.

2
2200 SRM 557 General

Figure 1. Typical Configurations of EV-100ZX Motor Controller in E-XM Model Lift Trucks

3
General
Legend for Figure 1
A. MOTOR CONTROLLER WITH REGENERATIVE
BRAKING, 1A BYPASS, AND SCR CONTROLLER
FOR HYDRAULIC PUMP
1. TRACTION CONTROLLER
2. SCR CONTROL FOR HYDRAULIC PUMP
MOTOR CONTROLLER
3. HYDRAULIC PUMP MOTOR CONTACTOR
4. FORWARD CONTACTOR
5. REVERSE CONTACTOR
6. 1A BYPASS CONTACTOR
7. REGENERATIVE BRAKING CONTACTOR
(OPTION ON SOME MODELS)
4
2200 SRM 557
B. MOTOR CONTROLLER WITH REGENERATIVE
BRAKING, 1A BYPASS, AND CONTACTOR
CONTROL FOR HYDRAULIC PUMP
8. FIELD WEAKENING CONTACTOR (OPTION ON
SOME MODELS)
9. FIELD WEAKENING RESISTOR (OPTION ON
SOME MODELS)
10. ELECTRONIC DRIVER
11. 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)
2200 SRM 557 General

A. MOTOR CONTROLLER WITH REGENERATIVE B. MOTOR CONTROLLER WITH REGENERATIVE

BRAKING, 1A BYPASS, AND SCR CONTROLLER BRAKING, 1A BYPASS, AND CONTACTOR
FOR HYDRAULIC PUMP CONTROL FOR HYDRAULIC PUMP
1. TRACTION CONTROLLER 9. FIELD WEAKENING RESISTOR
2. SCR CONTROL FOR HYDRAULIC PUMP 10. COUNTERWEIGHT
MOTOR CONTROLLER 11. ELECTRONIC DRIVER
3. HYDRAULIC PUMP MOTOR CONTACTOR 12. TRUCK MANAGEMENT MODULE (TMM1)
4. FORWARD CONTACTOR 13. FUSE 1 (TRACTION CIRCUIT)
5. REVERSE CONTACTOR 14. FUSE 2 (HYDRAULIC PUMP CIRCUIT)
6. 1A BYPASS CONTACTOR 15. FUSE PANEL (FU 7, FU 3, FU 5, FU 6)
7. REGENERATIVE BRAKING CONTACTOR 16. FUSE 4 (STEERING CIRCUIT)
8. FIELD WEAKENING CONTACTOR

Figure 2. Typical Configurations of EV-100ZX Motor Controller in J-XM Model Lift Trucks

5
General 2200 SRM 557

Figure 3. Configurations of EV-100ZX or EV-200ZX SCR Motor Controllers in E3.50/5.50XL

(E70/120XL) Lift Trucks

6
2200 SRM 557 General

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 HYDRAULIC C. EV-100ZX TRACTION AND SCR HYDRAULIC
CONTROLLERS CONTROLLERS
B. EV-100ZX OR EV-200ZX TRACTION AND DUAL D. EV-100ZX OR EV-200ZX TRACTION AND ONE
CONTACTOR HYDRAULIC CONTROLLERS CONTACTOR HYDRAULIC CONTROLLER
1. TRACTION MOTOR CONTROLLER 3. POWER STEERING CONTACTOR
2. MOTOR CONTROLLER(S) FOR LIFT PUMP
MOTOR

1. CONTROL CARD (TRACTION OR HYDRAULIC 4. PLUG PA (6-PIN) (WIDE GUIDES)

PUMP) 5. PLUG PB (6-PIN) (CLOSE GUIDES)
2. TB SCREW TERMINALS (6) 6. PLUG PY (14-PIN)
3. PLUG GUIDES 7. PLUG PZ (14-PIN)

Figure 4. Control Card Connections

7
General 2200 SRM 557

Table 1. Terminal and Plug Wire Connections for Control Card ZY, SCR Control of Traction
Circuit, Contactor Control of Hydraulic Pump, Standard or GE Panel Display, Without
Regenerative Braking, Without Brush Wear or Motor Temperature Indicators

Plug or Wire Color or

Terminal Wire Number Function
No.
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
equipped with 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.
PY3 WHT-2 Instrument panel display number 1 input.
PY4 BLK-1 Instrument panel display number 2 input.
PY5 WHT-1 Instrument panel display number 5 input.

8
2200 SRM 557 General

Table 1. Terminal and Plug Wire Connections for Control Card ZY, SCR Control of Traction Circuit,
Contactor Control of Hydraulic Pump, Standard or GE Panel Display, Without Regenerative
Braking, Without Brush Wear or Motor Temperature Indicators (Continued)

Plug or Wire Color or

Terminal Wire Number Function
No.
PY6 — Not Used.
PY7 — Not used.
PY8 BRN/WHT Signal wire between pump (or TMM1) and traction control card.
From pump card PY12.
PY9 BRN/PNK Signal wire between pump (or TMM1) and traction control card.
From pump card PY11.
PY10 BRN/ORN Signal wire between pump (or TMM1) and traction control card.
From pump 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.

9
General 2200 SRM 557

Table 2. Terminal and Plug Wire Connections for Control Card ZH, SCR Control of Traction
Circuit, Contactor Control of Hydraulic Pump, Enhanced Panel Display, With Regenerative
Braking, With Brush Wear and Motor Temperature Indicators

Plug or Wire Color or

Terminal Wire Number Function
No.
PA1 70 Signal connection for Reverse alarm.
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).
PB1 37 Electronic driver, Field Weakening contactor coil.
PB2 31 Electronic driver, Regenerative Braking contactor coil.
PB3 60 Electronic driver, steering pump motor coil. (Not used when
equipped with "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/BLU-L Key switch input. Battery voltage supply from key switch.
TB5 WHT-5 Forward direction switch input.
TB6 BLU-L Reverse direction switch input.
PY1 — Not used.
PY2 — Not used.
PY3 — Not used.
PY4 BLK-1 Instrument panel display number 9 input (ground).
PY5 WHT-1 Instrument panel display number 1 input.

10
2200 SRM 557 General

Table 2. Terminal and Plug Wire Connections for Control Card ZH, SCR Control of Traction
Circuit, Contactor Control of Hydraulic Pump, Enhanced Panel Display, With Regenerative
Braking, With Brush Wear and Motor Temperature Indicators (Continued)

Plug or Wire Color or

Terminal Wire Number Function
No.
PY6 — Not used.
PY7 — Not used.
PY8 BRN/WHT Signal wire between TMM1 and traction control card (temperature
switches, hydraulic pump motor and traction motor).
PY9 BRN/PNK Signal wire between TMM1 and traction control card (brush wear
indicators, all motors).
PY10 BRN/ORN Signal wire between TMM1 and traction control card (brush wear
indicators, all motors).
PY11 — Not used.
PY12 — Not used.
PY13 WHT-2 Instrument panel display number 5 input.
PY14 BLK-2 Instrument panel display number 4 input.
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.

11
General 2200 SRM 557

Table 3. Terminal and Plug Wire Connections for Control Card ZH, SCR Control of Traction
Circuit, SCR Control of Hydraulic Pump, Enhanced Panel Display, With Regenerative
Braking, With Brush Wear and Motor Temperature Indicators

Plug or Wire Color or

Terminal Wire Number Function
No.
PA1 70 Signal connection for Reverse alarm.
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).
PB1 37 Electronic driver, Field Weakening contactor coil.
PB2 31 Electronic driver, Regenerative Braking contactor coil.
PB3 60 Electronic driver, steering pump motor coil. (Not used when
equipped with 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/BLU-L Key switch input. Battery voltage supply from key switch.
TB5 WHT-5 Forward direction switch input.
TB6 BLU-L Reverse direction switch input.
PY1 — Not used.
PY2 — Not used.
PY3 — Not used.
PY4 BLK-1 Instrument panel display number 9 input (ground).
PY5 WHT-1 Instrument panel display number 1 input.

12
2200 SRM 557 General

Table 3. Terminal and Plug Wire Connections for Control Card ZH, SCR Control of Traction
Circuit, SCR Control of Hydraulic Pump, Enhanced Panel Display, With Regenerative
Braking, With Brush Wear and Motor Temperature Indicators (Continued)

Plug or Wire Color or

Terminal Wire Number Function
No.
PY6 — Not used.
PY7 — Not used.
PY8 BRN/WHT Signal wire between hydraulic pump control card and traction
control card (temperature switches, hydraulic pump motor and
traction motor).
PY9 BRN/PNK Signal wire between hydraulic pump control card and traction
control card (brush wear indicators, all motors).
PY10 BRN/ORN Signal wire between hydraulic pump control card and traction
control card (brush wear indicators, all motors).
PY11 — Not used.
PY12 — Not used.
PY13 WHT-2 Instrument panel display number 5 input.
PY14 BLK-2 Instrument panel display number 4 input.
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.

13
General 2200 SRM 557

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

Plug or Wire Color or

Terminal Wire Number Function
No.
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,
traction motor.
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
hydraulic pump motor.
PB1 DK-BLU/GRY Signal wire between hydraulic pump control card and brush wear
indicator, hydraulic pump motor.
PB2 GRN/PNK Signal wire between hydraulic pump control card and brush wear
indicator, 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 auxiliary
hydraulic 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.

14
2200 SRM 557 General

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

Plug or Wire Color or

Terminal Wire Number Function
No.
PY4 BLK-3 Instrument panel display/number 10 input (ground).
PY5 WHT-3 Instrument panel display number 2 input.
PY6 — Not used.
PY7 — Not used.
PY8 — Not used.
PY9 — Not used.
PY10 BRN/ORN Signal wire between hydraulic pump control card and traction
control card (brush wear indicators, all motors).
PY11 BRN/PNK Signal wire between hydraulic pump control card and traction
control card (brush wear indicators, all motors).
PY12 BRN/WHT Signal wire between hydraulic pump control card and traction
control card (temperature switches, hydraulic pump motor, and
traction motor).
PY13 WHT-4 Instrument panel display number 7 input.
PY14 BLK-4 Instrument panel display number 6 input.
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 — Not used.
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.

15
Control Card, Checks and Adjustments
Register Parameters
GENERAL
The ZX series of control cards have an electronic
device called an EEPROM (Electrically Erasable
Programmable Read Only Memory). The EEPROM
has a number of memory elements called registers.
These registers can have electronic data stored in
them to control an operation. The range of data that
can be stored in the registers is called a parameter.
A parameter is a measurement number that works
with other measurement numbers (parameters) to
define a system. The EEPROM in the control card is
a control system for the operation of the lift truck.
The EEPROM used in the ZX series of control cards
has 128 registers.
WARNING
Each register in each control card has a range
of numbers so the control card can be used on
different models of lift trucks. This variation
is needed for lift trucks of different sizes and
operating voltages. Adjustment of the register
to the wrong number for your lift truck model
can cause the truck to operate differently than
normal. This different operation of the truck
can cause an injury.
Do NOT adjust any of the registers without
using the parameters shown in EV-100ZX SCR
Control Card, Checks and Adjustments
A personal computer (PC) or a Handset is used to per-
mit Authorized Personnel to make the following
checks 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 cir-
cuit 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 in-
put (seat switch or directional switch)
16
2200 SRM 557
Motor Controller Parameter Tables 2200 SRM
595.
NOTE: The Parameter Tables show the permit-
ted ranges and the default setting for each control
function. The factory set parameters are the recom-
mended settings for new units. These settings give
satisfactory performance for most applications.
Some functions can be adjusted within the permit-
ted range to change the lift truck operation for a spe-
cific application. Adjustment of a register to a num-
ber that is different than the factory setting is al-
lowed, but follow the instructions carefully and stay
within the minimum and maximum limits. Adjust-
ments other than the factory settings cause the lift
truck to operate differently and can cause increased
wear of parts.
FUNCTION NUMBERS
The Function Numbers are code numbers for the dif-
ferent parameters that can be set for the ZX series
control cards. The personal computer or the Hand-
set must be used to adjust the parameters for the
control card. There is a description of the code num-
bers for the different control cards in the Parameter
Tables. These Parameter Tables have the correct
setting numbers for the parameters on each control
card.
– 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 func-
tions
2200 SRM 557 Handset

Handset
HOW TO CHECK AND ADJUST Legend for Figure 5
REGISTERS 1. ADJUSTMENT KNOB
2. LED DISPLAY
The Handset can be used with the EV-100ZX se- 3. KEYPAD
ries motor controllers. The Handset is used to 4. COIL CORD
access the registers for the traction or pump motor 5. PLUG PY (14 PIN)
functions, indicate status codes (possible faults), and 6. MODULAR PLUG (8-PIN HANDSET)
make adjustments to the operating limits set in the
NOTE: The vehicle operates with the Handset con-
control cards. Some of the registers in the ZX series
nected, however, the adjustment knob MUST be set
of control cards cannot be accessed with the Hand-
fully clockwise to make sure the control can oper-
set. The Handset can access the registers that con-
ate at maximum speed.
trol the operation of the lift truck. The values for the
limits on the control card functions must be set with This section has the control card checks and adjust-
either a PC or the Handset. The Handset has a Light ments that can be made using the Handset. The con-
Emitting Diode (LED) display, a keypad for data en- trol card checks and adjustments are usually made
try, and an adjustment knob for changing function with the control card installed in the lift truck. Bench
values. See Figure 5. checks and adjustments can also be made with the
control card connected as shown in Figure 7. The
checks show the stored setting numbers that have
been stored for the different control card functions.
This section also includes a description of each of
the different functions. Use the adjustment knob on
the Handset to adjust the function settings. See Fig-
ure 5.

HOW TO SCROLL THROUGH FAULT

CODES AND CLEAR THEM
The EV-100ZX controller has function registers (31
through 47) that store the last 16 status codes that
caused the operation of the lift truck to stop and the
battery charge at the time the fault occurred. A PMT
fault is reset by turning the key to the OFF position
and then to ON position. The first of the 16 status
codes is overwritten each time a new status code oc-
curs. The stored status can be cleared from the regis-
ter by using the Handset. The PC software program
clears the fault register automatically. Use the pro-
cedure in Figure 6 to access and clear the fault code
registers with the Handset.

Figure 5. Handset

17
Handset 2200 SRM 557

CAUTION
Prevent damage to the control card. The con-
trol card can be damaged if power is not cor-
rectly connected or disconnected. Always dis-
connect the battery connector before connect-
ing or disconnecting the control card plugs.

NOTE: The bench supply voltage does not need to be

the same as the voltage of the lift truck. A DC power
supply to a maximum of 84 volts can be used.

The Handset can also be used to check and adjust the

functions of the control card when it is connected to
a bench power supply for bench checks and adjust-
ments. 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 50
milliamperes can be used if a PC is used for checks
and adjustments. A Handset requires more power
for its operation and a power supply or two 12-volt
automotive batteries in series must be used.)
• An electrical adaptor to connect to the Plug Z con-
nector 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

a full bridge rectifier with a filter to give a good qual-
ity DC voltage. Make the following connections for
the bench checks and adjustments:

1. Connect the switch and a Plug Z to the power

source using the wire as shown in Figure 7.

2. Make sure the switch is in the OFF position and

connect the wire to TB4.

3. Connect Plug Z to the Plug PZ connector on the

Figure 6. How to Scroll Through Fault Codes control card and the PC or the Handset to the
and Clear Them Plug PY connector.

CHECKS AND ADJUSTMENTS ON NOTE: There are no connections to the Plug A or

Plug B connectors of the control card.
WORKBENCH
NOTE: The bench checks and adjustments are done
WARNING using the same procedures that follow.
NEVER adjust any of the parameters without
using the procedures and settings given in this
section.

18
2200 SRM 557 Handset

NOTE: IF THE HANDSET IS USED WITH THIS POWER SUPPLY CONNECTIONS TO TB3 AND TB4 MUST BE
AVAILABLE SO ALL FUNCTION KEYS CAN BE USED.
1. CONTROL CARD 7. 24 VOLT DC 0.5 AMP POWER SUPPLY OR
2. PLUG A CONNECTOR BATTERIES
3. PLUG B CONNECTOR 8. PIN PZ7 (B+)
4. TB TERMINALS 9. PIN PZ2 (B )
5. PLUG Y CONNECTOR 10. TERMINAL TB4 (B+)
6. PLUG Z CONNECTOR

Figure 7. Bench Checks and Adjustments

WHEN HANDSET IS CONNECTED TO
CONTROL CARD INSTALLED IN LIFT
TRUCK
WARNING
Prevent movement of the lift truck when mak-
ing checks and adjustments. Before the Hand-
set is connected or disconnected to a control
card that is installed in a lift truck, raise the
drive wheels. Then turn the key to the OFF
position, disconnect the battery, and discharge
capacitor C1.
Make sure the power is off as described in the
WARNING. If the lift truck has an instrument
panel display connected, disconnect Plug Y at the
SCR control card (traction or hydraulic pump). Con-
nect the Handset plug at the connector for Plug Y
on the control card. Connect the battery and turn
the key to the ON position. The following display
sequence will occur:
• Display of 8888 for 1 second to check the display
segments.
• Status Code display of -01 if seat is in the UP po-
sition.
• 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.

19
Handset
Turn the key to the OFF position. The following dis-
play sequence occurs:
• Display shows the hourmeter reading for the trac-
tion motor for 4 seconds.
• Display shows the hourmeter reading for the hy-
draulic pump motor for 4 seconds. If there is no
SCR control for the hydraulic pump, the display is
blank.
The registers can be set when the operator is on the
seat or when off the lift truck. Disconnect Plug Y
at the SCR control card (traction motor or hydraulic
pump motor) if the instrument panel display is con-
nected. See Figure 4. Connect the Handset plug at
connection PY on the control card. Connect the bat-
tery. Push and hold the CONT button of the Handset
so that it is depressed when power is applied. Turn
the key to the ON position or move the power switch
of the bench setup to the ON position. The display
shows 8888 to check that all segments of the display
are working. The register parameters can now be
checked or changed.
FUNCTION NUMBERS 1 THROUGH 15
Push the keypad numbers for the desired register.
The register and Handset numbers are shown in the
Parameter Tables.
FUNCTION NUMBERS 16 THROUGH 30
NOTE: The seat switch must be open.
1. Push the keypad numbers for the desired reg-
ister. Think of the CONT key equaling 15.
Push and hold the CONT key plus the addi-
tional key number above 15 to total the re-
quired Handset number.
Example: for Function Number 18, push the
CONT and key 3 (15+3=18). The display shows
the selected register. After 1 second, the display
shows the parameter that has been set in that
register.
2. Push and hold the CONT key for 1 second. The
display number blinks.
3. To change the parameter, check for the correct
parameter for that register in the Parame-
ter Tables. Change the parameter by turning
the adjustment knob on the Handset. The dis-
play continues to blink as the number changes.
20
2200 SRM 557
4. Push and hold the STORE key for 1 second.
When the new parameter is set (stored), the
display stops blinking.
5. Push and hold the ESC key for 1 second. The dis-
play shows 8888. To check or set another regis-
ter, do Step 1 through Step 3. To return to normal
operation (run mode), push and hold ESC again
for 1 second or longer. The display returns to the
status code mode or displays the state of battery
charge if the operator is in the seat. The display
can also be blank (if there are no status codes and
the battery indicator is not installed).
NOTE: Make sure the motor controller control is in
the run mode before disconnecting the Handset. If
the motor controller control is not in the run mode,
the battery must be disconnected and connected
again to reset the system.
The vehicle can now be operated with the Handset
connected or the Handset can be disconnected.
NOTE: If the vehicle is operated with the Handset
connected, make sure to set the adjustment knob
fully clockwise to make sure the control can oper-
ate at top speed.
Disconnect the plug at connection Y on the control
card to disconnect the Handset. Connect the plug for
the instrument panel display at connection Y.
FUNCTION NUMBERS 48 THROUGH 62
NOTE: The seat switch must be closed.
1. Turn the key to the ON position after the Hand-
set is connected to the traction card. Turn the
key to the OFF position after the Handset is con-
nected to the hydraulic pump card.
2. Push the keypad numbers for the desired reg-
ister. Think of the CONT key equaling 47.
Push and hold the CONT key plus the addi-
tional key number above 47 to total the re-
quired Handset number. Close the seat switch
and the key switch.
Example: for Function Number 48, push the
CONT and key 1 (47+1=48, 47+2=49, 47+3=50,
47+5=52, etc.). The display shows the selected
register. After 1 second, the display shows the
parameter that has been set in that register.
2200 SRM 557
NOTE: Handset Numbers 47, 51, 55, and 59 are the
registers for the MODE numbers and are not used.
Do not try to set these numbers with the Handset.
3. Push and hold the CONT key for 1 second. The
display number blinks.
4. To change the parameter, check for the correct
parameter for that register in the Parame-
ter Tables. Change the parameter by turning
the adjustment knob on the Handset. The dis-
play continues to blink as the setting changes.
Control Cards
FUNCTION NUMBER DESCRIPTIONS
The following pages have descriptions for the differ-
ent Function Numbers. The setting for each func-
tion is specific for each control card. To identify the
control card, check the label at the top edge of each
card case. There are some painted letters and num-
bers followed by letters on the lower part of the label.
The last two letters identify the type of card installed.
The following types of control cards are used:
ZH = Traction Controller with three-wire
potentiometer and with Battery Discharge
Indicator (BDI).
ZY = Traction Controller with three-wire
potentiometer and without Battery
Discharge Indicator (BDI)
ZP = Pump Motor Controller with Truck
Management Module (TMM1)
These same letters are also shown in the Parame-
ter Tables and in the section headings for the con-
trol cards for the traction motor and hydraulic pump
motor.
TRACTION CONTROL CARDS (LABEL
LETTERS - ZH AND ZY)
NOTE: These control cards are used with the motor
controllers that control the speed of the traction mo-
tor.
Control Cards
5. Push and hold the STORE key for 1 second.
When the new parameter is set (stored), the
display stops blinking.
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
1 second or longer.
Function Number 1 STORED STATUS
CODE
(Push 1)
WARNING
If any of the parameters are changed, the oper-
ators must be told that the lift truck will oper-
ate differently.
Do not adjust the parameters outside of the
range of numbers shown in the Tables. Pa-
rameters set outside of the ranges can cause
damage to the components of the traction
system and can cause the lift truck to operate
differently than normal. This different oper-
ation of the lift truck can result in personal
injury.
This register contains the last status code of a possi-
ble PMT fault that caused the lift truck to stop oper-
ation. These codes can be removed from the display
by turning the key to the OFF position. The code
is stored in registers in the control card. This sta-
tus code will be replaced with the same status code if
another possible PMT fault occurs. The status code
can be cleared from memory by adjusting the setting
number to zero. The number must be stored by push-
ing the STORE key for 1 second. Adjustment of the
values in this register does not change the operation
of the lift truck. This register is cleared when the
battery is disconnected.
21
Control Cards
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. A
constant creep speed frequency is maintained when
the accelerator input voltage is between 3.7 and 3.5
volts (a potentiometer resistance value between 6K
and 4.7K ohms).
Function Number 3 CONTROLLED
ACCELERATION AND 1A TIME
(Push 3)
This register adjusts the maximum rate of acceler-
ation. The setting determines the time allowed to
reach maximum SCR speed after the accelerator is
set for maximum speed from stop. The control stays
in SCR acceleration for between 0.77 second (setting
8) and 21.5 seconds (setting 255) before the 1A con-
tactor closes. The numbers in parenthesis are the
parameters for the times shown. The 1A contactor
automatically closes 0.2 second after the controlled
acceleration stops. The speed control input is less
than 0.5 volt (accelerator potentiometer set at less
than 50 ohms). Do not adjust the number in the reg-
ister to less than the minimum setting of 8.
Function Number 4 CURRENT LIMIT
(Push 4)
This register adjusts the current limit of the motor
controller. The current rating of the motor controller
determines the range of adjustment for this register.
See the Tables for the Parameter Registers. Do not
adjust the register to any number other than the fac-
tory setting.
Function Number 5 PLUGGING DISTANCE
(CURRENT)
(Push 5)
This register adjusts the distance it takes to stop the
lift truck when plugging. A parameter set to higher
numbers makes the lift truck stop faster. Lower
numbers decrease the plugging for a longer stopping
distance.
22
2200 SRM 557
CAUTION
Traction motor or controller damage occurs
if the parameter is set above the maximum
shown in the Tables for the Parameter Regis-
ters.
The number for this parameter, for the current value
of this register, must be found if the Pedal Posi-
tion Plug (Function Number 16 PEDAL POSITION
PLUG is not used). To find the number for the cur-
rent value, use the following 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 OUT
CURRENT
(Push 6)
This register adjusts the parameter for the current
value at which the 1A contactor de-energizes (opens).
The 1A contactor opens and the motor torque is lim-
ited 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 WEAKENING
PICK UP
(Push 7)
CAUTION
A setting HIGHER than the setting shown in
the Tables for the Parameter Registers will
make the Field Weakening Contactor energize
too soon. This operation can damage the trac-
tion motor.
This register adjusts the current value at which the
FW contactor energizes (closes). This parameter per-
mits the FW contactor to close when the lift truck has
returned to approximately 150 percent of its running
current with a full load on a level surface.
2200 SRM 557
Do NOT set this register to a number greater
than the number set by Function Number 8. If
this register is set to a number less than 5, the
Field Weakening function is de-energized.
Function Number 8 FIELD WEAKENING
DROP OUT
(Push 8)
CAUTION
A parameter set HIGHER than the number
shown in the Tables for the Parameter Regis-
ters will make the Field Weakening Contactor
remain energized at high currents. This oper-
ation can cause motor heating and damage the
traction motor.
This register adjusts the current value at which the
FW contactor de-energizes (opens). This parameter
permits the FW contactor to open when the lift truck
requires more than 300 percent of the running cur-
rent with a full load on a level surface.
Function Number 9 REGENERATIVE
BRAKING CURRENT LIMIT
(Push 9)
WARNING
A parameter set greater than the number
shown in the Tables for the Parameter Regis-
ters will make the lift truck slow at a rate faster
than normal. A parameter set at less than the
number shown will make the lift truck have
a slower regenerative braking effect. This
different operation of the truck can result in
personal injury. A faster regenerative braking
rate can also damage the control system or the
traction motor.
This register adjusts the Regenerative Braking cur-
rent limit. The higher the current limit setting, the
shorter the stopping distance. The shorter stopping
distance causes faster wear on the drive train and
brushes of the traction motor.
Control Cards
Function Number 10 REGENERATIVE
BRAKING START
(Push 10)
CAUTION
A parameter set greater than the number
shown in the Tables for the Parameter Regis-
ters can prevent regenerative braking. The lift
truck will remain in the plugging mode longer
and increase brush wear in the traction motor.
This parameter adjusts the percent ON time at
which the control starts to energize the regenera-
tive braking circuit. The percent ON time can be
between 0 and 95 percent. This adjustment sets
the speed where regenerative braking starts. This
parameter prevents the controller from energizing
the regenerative braking circuit when motor current
is too low.
Function Number 13 SPEED LIMIT 3 (SL3)
(Push 13)
This parameter adjusts the speed limit (maximum
battery volts to the motor). The range is 0 percent
to 96 percent. The adjustment sets the speed limit
for the time when the input signal from the SL3 limit
switch is received by the control card. This signal can
be from the sensor in the traction motor or the hy-
draulic pump motor. If the sensor shows that a motor
is too hot, the control decreases the maximum motor
speed to this speed setting. The SL3 limit switch is
a normally closed switch connected to battery neg-
ative. When the switch opens, it enables the speed
limit function. A setting of 0 disables the speed limit
function. This zero setting permits top speed when
no limit switch is connected. A zero setting does not
slow the motor with an input from the sensor and can
damage the motor. Some models of lift trucks do not
use this function. This function is activated by Sta-
tus Codes -90 and -93.
23
Control Cards
Function Number 14 INTERNAL
RESISTANCE COMPENSATION
(Push 14)
CAUTION
Adjusting this function setting to the wrong
number can cause battery damage.
This register is used when the control card has the
Battery Discharge Indicator (BDI) function. Control
cards that have BDI are type ZH control cards. The
Tables for the Parameter Registers show the param-
eters for a battery in average condition.
For the best use of your battery energy, the register
can be adjusted using the following procedure. How-
ever, you must use the procedure to change the pa-
rameter in the register as the battery changes during
months the battery is used or battery damage can oc-
cur. Setting the parameter too low for your battery
can allow the battery to discharge below the mini-
mum specific gravity value. This minimum specific
gravity is the specification given by the battery man-
ufacturer to prevent battery damage.
Use the following procedure to adjust the parameter:
1. Operate the lift truck on a normal work cycle.
Travel at medium speeds.
2. When lift interrupt occurs, stop the lift truck and
wait for approximately 10 minutes.
3. Check the specific gravity of several battery cells.
If the specific gravity is between 1.140 and 1.150,
the setting is correct for that battery. If the spe-
cific gravity reading is high, adjust the parame-
ter in the register to a lower number. If the spe-
cific gravity reading is low, adjust the parameter
to a higher number.
NOTE: It may be necessary to charge the battery and
do Step 1 through Step 3 again to get an accurate
number for your battery.
Function Number 15 BATTERY VOLTS
(Push 15)
This register adjusts the operating voltage of the
lift truck. The adjustment also controls the Battery
Discharge Indicator function for lift trucks equipped
with BDI. For the controller and BDI to operate
correctly, the parameter shown in the Tables for the
Register Parameters must be entered.
24
2200 SRM 557
Battery Volts Parameter
36 volts Between 32 and 44
48 volts Between 45 and 69
72 volts Between 70 and 80
80 volts Between 81 and 183
36/48 volts Between 184 and 250
No BDI Between 251 and 255
NOTE: If the parameter is set to a number other
than the number shown for your lift truck in Tables
for the Register Parameters, a status code of -15 or
-16 occurs. Make sure the battery is fully charged
and battery connector has good connections before
making this adjustment. This check is especially
important when adjusting for 36/48 volt operation
(numbers 184 to 250).
Function Numbers GREATER THAN 15
NOTE: For registers greater than 15, think of
the CONT key as equal to 15. Push and hold
the CONT key plus the additional key number
above 15 to total the required register num-
ber. Example: for Function 18, push the CONT key
and key 3 (15+3=18). The display shows the selected
function. After 1 second, the display shows the set-
ting number that has been set for that register.
NOTE: The Seat Switch must be OPEN for
Function Numbers 16 through 30.
Function Number 16 PEDAL POSITION
PLUG
(Push CONT and 1)
This register adjusts the range for pedal position
plugging. The parameter in this register permits
the pedal position to control the plugging current
and the plugging distance. The current value set
by this register is enabled as the accelerator is
returned to the creep speed position. There is max-
imum plugging current when the accelerator is in
the maximum speed position. To disable the pedal
position plugging function, adjust the current value
to the same current value as the plugging distance
current. See the description in Function Number 5
PLUGGING DISTANCE (CURRENT).
Example: If Plugging Distance Current (Function
Number 5 PLUGGING DISTANCE (CURRENT)) is
set at 500 amps, then set pedal plugging current to
2200 SRM 557
500 amps. The pedal position has no effect on the
plugging distance 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 TYPE
SELECTION
(Push CONT and 2)
WARNING
Wrong parameters entered into the register in
Function Number 17 CARD TYPE SELECTION
can cause the truck to operate differently than
normal. This different operation of the truck
can cause an injury. NEVER set Function Num-
ber to a parameter that is not shown for your
lift truck.
This register permits the selection of the card type
used for your lift truck application.
Function Number 18 STEERING PUMP
TIME DELAY
(Push CONT and 3)
WARNING
A parameter set lower than the number shown
in the Tables for the Parameter Registers can
permit the steering pump to stop if the seat
switch opens momentarily during normal oper-
ation. There is no power steering if the steer-
ing pump stops. The sudden and difficult steer-
ing effort that is not expected can cause injury
or property damage.
This register selects input for the steering pump
contactor. Closing the seat switch or the FWD/REV
switch can be the input. The parameter also sets the
time delay for the contactor to open after the switch
opens.
Control Cards
NOTE: There is no delay time for the contactor to
close after receiving the input signal from the seat
switch or the FWD/REV switch. Parameters in the
0-128 range adjust the delay after the seat switch
opens. Parameters in the 129-255 range adjust the
delay after the FWD/REV switch opens. Adjust the
setting to the number shown in Tables for the
Register Parameters.
Function Number 19 MAINTENANCE
ALERT (Tens/Units)
(Push CONT and 4)
This register can be set by the service person to give
a Status Code -99 when scheduled maintenance is
required. The range for this register is 0 to 99 hours.
Function Number 20 MAINTENANCE
ALERT (Thousands/Hundreds)
(Push CONT and 5)
This register can be set by the service person to give
a Status Code -99 when scheduled maintenance is
required. The range for this register is 100 to 9900
hours.
Function Number 21 MAINTENANCE
SPEED 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 activated by the control card. The range for
this register is 0 to 180.
Function Numbers 22 Through 28
TEMPORARY DATA REGISTERS
CAUTION
Function Number 25 (temporary storage reg-
ister for fault data) and Function Number 26
(temporary storage register for battery charge
data) must not be changed by the user to any
number above zero. Any number above zero
can cause the instrument panel display to not
operate correctly and the lift truck can become
disabled.
These registers can be read with the Handset, but the
data in them changes during lift truck operation. Do
not change the parameters in registers for Function
25
Control Cards
numbers 22 through 27. Function Number 28 is
the fault indicator pointer and must be set to
zero when all faults or malfunctions have been
fixed or removed from the controller.
Function Number 29 HOURMETER
(Tens/Units)
(Push CONT and 14)
This register has the data for the accumulated oper-
ating hours of the lift truck. This register is not nor-
mally changed unless a new control card is installed.
If a new control card is installed, the total hours from
the old control card must be entered so that the total
operating 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 oper-
ating hours of the lift truck. This register is not nor-
mally changed unless a new control card is installed.
If a new control card is installed, the total hours from
the old control card must be entered so that the total
operating hours of the lift truck is correctly recorded.
Function Number 48 Through 62 SET LIFT
TRUCK PERFORMANCE
If the lift truck is equipped with a Premium instru-
ment panel, the lift truck can be set to four perfor-
mance levels by the operator. (If the customer does
not want this function available to the operator, a ser-
vice person can set all four levels to the same setting.)
Each time the operator pushes the button on the in-
strument panel, the performance level will increase
by one step. At the maximum (rabbit) level, the per-
formance levels will begin at the lowest (turtle) level
again. The four performance levels set by the manu-
facturer are:
1. Low performance for handling fragile loads.
2. Medium speed for less consumption of battery
charge during a work shift.
3. Higher performance with higher consumption of
battery charge during a work shift.
4. Maximum lift truck performance with higher
consumption of battery charge.
26
2200 SRM 557
The four performance levels can be set to any level up
to the maximum limits. Two or more adjacent per-
formance levels can be set to the same limits. The
performance levels must be set at the same or in as-
cending order (from turtle to rabbit). The register
interlocks will not permit a higher performance level
setting toward the turtle than the adjacent registers
toward the rabbit.
NOTE: The Seat Switch must be CLOSED for
Function Numbers 48 through 62.
Function Number 48 CONTROLLED
ACCELERATION AND 1A TIME
(Push CONT and 1 while the key switch and
seat switch are closed)
This register adjusts the maximum rate of accelera-
tion in MODE 1 (Turtle). The parameter determines
the time allowed to reach maximum SCR speed after
the accelerator is set for maximum speed from stop.
The control stays in SCR acceleration for 3.5 seconds
(setting 40) before the 1A contactor closes. The num-
bers in parenthesas are the parameters for the times
shown. The 1A contactor automatically closes 0.2
seconds after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator
potentiometer set at less than 50 ohms). Do not set
the register to less than Function Number 52 CON-
TROLLED ACCELERATION AND 1A TIME.
Function Number 49 FIELD WEAKENING
PICK UP
(Push CONT and 2 while the key switch and
seat switch are closed)
This register adjusts the current value at which the
FW contactor energizes (closes). This parameter per-
mits the FW contactor to close when the lift truck
has returned to approximately 150 percent of its run-
ning current with a full load on a level surface. The
minimum parameter is zero. Do not set the register
greater than Function Number 53 FIELD WEAKEN-
ING PICK UP.
Function Number 50 SPEED LIMIT 1
(Push CONT and 3 while the key switch and
seat switch are closed)
This parameter adjusts the speed limit (maximum
battery volts to the motor). The range is 0 percent
to 96 percent. There is no speed limit switch for this
2200 SRM 557
function. This function is disabled if the parameter
in the register is set to zero. Do not set the register
to less than Function Number 54 SPEED LIMIT 1.
Do not set the register greater than 180.
Function Number 52 CONTROLLED
ACCELERATION AND 1A TIME
(Push CONT and 5 while the key switch and
seat switch are closed)
This register adjusts the maximum rate of accelera-
tion in MODE 2. The parameter determines the time
allowed to reach maximum SCR speed after the ac-
celerator is set for maximum speed from stop. The
control stays in SCR acceleration for 2.6 seconds (set-
ting 30) before the 1A contactor closes. The num-
bers in parenthesis are the parameters for the times
shown. The 1A contactor automatically closes 0.2
seconds after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator
potentiometer set at less than 50 ohms). Do not set
the register to less than Function Number 56 CON-
TROLLED ACCELERATION AND 1A TIME. Do not
set the register greater than Function Number 48
CONTROLLED ACCELERATION AND 1A TIME.
Function Number 53 FIELD WEAKENING
PICK UP
(Push CONT and 6 while the key switch and
seat switch are closed)
This register adjusts the current value at which the
FW contactor energizes (closes). This parameter per-
mits the FW contactor to close when the lift truck
has returned to approximately 150 percent of its run-
ning current with a full load on a level surface. Do
not set the register to less than Function Number 49
FIELD WEAKENING PICK UP. Do not set the regis-
ter greater than Function Number 57 FIELD WEAK-
ENING PICK UP.
Function Number 54 SPEED LIMIT 1
(Push CONT and 7 while the key switch and
seat switch are closed)
This parameter adjusts the speed limit (maximum
battery volts 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 reg-
ister is set to zero. Do not set the register to less than
Control Cards
Function Number 58 SPEED LIMIT 1. Do not set the
register greater than Function Number 50 SPEED
LIMIT 1.
Function Number 56 CONTROLLED
ACCELERATION AND 1A TIME
(Push CONT and 9 while the key switch and
seat switch are closed)
This register adjusts the maximum rate of accelera-
tion in MODE 3. The parameter determines the time
allowed to reach maximum SCR speed after the ac-
celerator is set for maximum speed from stop. The
control stays in SCR acceleration for 1.8 seconds (set-
ting 20) before the 1A contactor closes. The num-
bers in parenthesis are the parameters for the times
shown. The 1A contactor automatically closes 0.2
seconds after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator
potentiometer set at less than 50 ohms). Do not set
the register to less than Function Number 60 CON-
TROLLED ACCELERATION AND 1A TIME. Do not
set the register greater than Function Number 52
CONTROLLED ACCELERATION AND 1A TIME.
Function Number 57 FIELD WEAKENING
PICK UP
(Push CONT and 10 while the key switch and
seat switch are closed)
This register adjusts the current value at which the
FW contactor energizes (closes). This parameter per-
mits the FW contactor to close when the lift truck
has returned to approximately 150 percent of its run-
ning current with a full load on a level surface. Do
not set the register to less than Function Number 53
FIELD WEAKENING PICK UP. Do not set the regis-
ter greater than Function Number 61 FIELD WEAK-
ENING PICK UP.
Function Number 58 SPEED LIMIT 1
(Push CONT and 11 while the key switch and
seat switch are closed)
This parameter adjusts the speed limit (maximum
battery volts 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 reg-
ister is set to zero. Do not set the register greater
than Function Number 58 SPEED LIMIT 1.
27
Control Cards
Function Number 60 CONTROLLED
ACCELERATION AND 1A TIME
(Push CONT and 13 while the key switch and
seat switch are closed)
This register adjusts the maximum rate of accelera-
tion in MODE 4 (Rabbit). The parameter determines
the time allowed to reach maximum SCR speed after
the accelerator is set for maximum speed from stop.
The control stays in SCR acceleration for 0.94 sec-
onds (setting 10) before the 1A contactor closes. The
numbers in parenthesis are the parameters for the
times shown. The 1A contactor automatically closes
0.2 seconds after the controlled acceleration stops.
The speed control input is less than 0.5 volt (acceler-
ator potentiometer set at less than 50 ohms). Do not
set the register to less than 8. Do not set the register
greater than Function Number 56 CONTROLLED
ACCELERATION AND 1A TIME.
Function Number 61 FIELD WEAKENING
PICK UP
(Push CONT and 14 while the key switch and
seat switch are closed)
This register adjusts the current value at which the
FW contactor energizes (closes). This parameter per-
mits the FW contactor to close when the lift truck
has returned to approximately 150 percent of its run-
ning current with a full load on a level surface. Do
not set the register to less than Function Number 57
FIELD WEAKENING PICK UP. Do not set the reg-
ister greater than 110.
PUMP CONTROL CARD (LABEL LETTER
ZP)
NOTE: This control card is used with the motor con-
troller that controls the speed of the motor for the
hydraulic pump.
Function Number 1 STORED STATUS
CODE
(Push 1)
WARNING
If any of the register parameters are changed,
the operators must be told that the lift truck
will operate differently. Do not adjust the reg-
ister parameters outside of the range shown in
28
2200 SRM 557
the Parameter Tables for the register param-
eters. Settings outside the ranges can cause
damage to the components of the hydraulic sys-
tem and different truck operation. This differ-
ent operation of the truck can cause personal
injury.
This register contains the last status code of a
possible fault that caused the pump motor to run
continuously. The battery must be disconnected to
stop the motor if it runs continuously. This status
code is replaced with the same status code if another
possible fault occurs. The status code can be cleared
from memory by adjusting the setting number to
zero. Any new number (including zero) must be
stored by pushing the STORE key for 1 second. Ad-
justment of this register does not change operation
of the hydraulic system.
Function Number 2 INTERNAL
RESISTANCE COMPENSATION START
(Push 2)
This register adjusts the current level required to
start the internal resistance compensation (Function
Number 16 INTERNAL RESISTANCE COMPEN-
SATION).
Function Number 3 CONTROLLED
ACCELERATION
(Push 3)
This register adjusts the maximum rate of accelera-
tion. The parameter determines the time allowed to
reach maximum SCR speed after the switch closes.
This parameter determines how fast the hydraulic
functions begin to operate. The control stays in SCR
operation for 0.1 to 22 seconds after the switch closes.
Function Number 4 CURRENT LIMIT
(Push 4)
This register adjusts the current limit of the control.
The current limit is normally set at the maximum
(255).
Function Number 7 CONTROLLED
ACCELERATION COMPENSATION
(Push 7)
This register adjusts the rate (in seconds) for the con-
troller to add the internal resistance compensation
2200 SRM 557
voltage that is applied to motor. This function adds
0.375 volts to the motor at the rate of time set in the
register until the total (current × resistance) compen-
sation voltage 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
and added to the motor, this example would require
0.18 seconds to add a total of 2.08 volts.
(2.08 volts/0.375 volts per unit) 0.032 seconds =
0.1775 or 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 bat-
tery voltage applied to the motor). When switch SL-1
is closed, the signal to TB2 on the controller card
causes the controller to apply the limit on battery
voltage to the motor.
Function Number 12 SPEED LIMIT 2 (SL2)
(Medium Speed) - Slow Lift and Medium
Auxiliary (Slow Lift And Fast Rotate for
N30XMH)
(Push 12)
This register adjusts the speed limit (maximum bat-
tery voltage applied to the motor). When switch SL-2
is closed, the signal to TB3 on the controller card
causes the controller to apply the limit on battery
voltage to the motor.
Function Number 13 SPEED LIMIT 3 (SL3)
(Push 13)
Not Connected.
Control Cards
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 (maxi-
mum battery voltage the motor). The range is 0 to
96 percent. A parameter set over the maximum pa-
rameter shown in the Parameter Table can cause
the motor or controller to become too hot.
Function Numbers Greater Than 15
NOTE: For registers greater than 15, push and
HOLD the CONT key and the additional key
number above 15 to total the required regis-
ter number. Example: for Function Number 18,
push CONT key and key 3 (15+3=18). The display
shows the selected register. After 1 second, the dis-
play shows the parameter that has been set in that
register.
NOTE: The Seat Switch must be OPEN for
Function Numbers 16 through 30.
Function Number 16 INTERNAL
RESISTANCE COMPENSATION
(Push CONT and 1)
This register gives the pump speed better stability
by increasing the motor voltage during heavy loads.
This parameter is set using the information from the
speed torque curve of the motor used.
The voltage selected is added to the motor for each
100 ampere increment starting with the parameter
set in Function Number 2 INTERNAL RESIS-
TANCE COMPENSATION START. The voltage
selected is added in steps of 0.375 volts until the
entire voltage is added. For example, a parameter of
10 is adds 2.28 volts in six steps of 0.375 volts each.
29
Control Cards
Function Number 17 CARD TYPE
SELECTION
(Push CONT and 2)
WARNING
Wrong parameters entered into the register in
Function Number 17 CARD TYPE SELECTION
can cause the truck to operate differently than
normal or cause damage to the controller. This
different operation of the truck can result in
personal injury. NEVER set Function Number
17 CARD TYPE SELECTION to a parameter
that is not shown for your lift truck.
This register selects the card type used for your lift
truck application. See the correct setting in the Pa-
rameter Tables.
Function Numbers 18 through 28
TEMPORARY DATA REGISTERS
CAUTION
Function 25 (temporary storage register for
fault data) and Function 26 (temporary storage
register for battery charge data) must not be
changed by the user to any number above zero.
Any number above zero can cause the instru-
ment panel display to not operate correctly
and the lift truck can become disabled.
These registers can be read with the Handset, but the
data in them changes during lift truck operation. Do
not change the parameters in registers for Handset
numbers 21 through 27. Handset number 28 is the
fault indicator pointer and must be set to zero
when all faults or malfunctions have been fixed
or removed from the controller.
Function Number 29 HOURMETER
(Tens/Units)
(Push CONT and 14)
This register has the data for the accumulated op-
erating hours of the hydraulic system. This register
is not normally changed unless a new control card is
installed. If a new control card is installed, the total
hours from the old control card must be entered so
the total operating hours of the hydraulic system is
correctly recorded.
30
2200 SRM 557
Function Number 30 HOURMETER
(Thousands/Hundreds)
(Push CONT and 15)
This register has the data for the accumulated oper-
ating hours of the lift truck. This register is not nor-
mally changed unless a new control card is installed.
If a new control card is installed, the total hours from
the old control card must be entered so the total op-
erating hours of the lift truck is correctly recorded.
Function Number 48 CONTROLLED
ACCELERATION
(Push CONT and 1 while the key switch and
seat switch are closed)
This register adjusts the maximum rate of accelera-
tion in MODE 1 (Turtle). The parameter determines
the time allowed to reach maximum SCR speed from
stop. Do not set the register to less than Function
Number 52 CONTROLLED ACCELERATION.
Function Number 49 SPEED LIMIT 2
(Push CONT and 2 while the key switch and
seat switch are closed)
This register adjusts the speed limit for the hydraulic
pump in MODE 1. The minimum parameter is zero.
Do not set the register greater than Function Num-
ber 53 SPEED LIMIT 2.
Function Number 50 SPEED LIMIT 3
(Push CONT and 3 while the key switch and
seat switch are closed)
This parameter permits adjustment of the speed
limit (maximum battery voltage to the motor). The
range is 0 to 96 percent. There is no speed limit
switch for this function. This function is disabled if
the parameter is set to zero. Do not set the register
to less than Function Number 54 SPEED LIMIT 3.
The maximum number in the register is 255.
Function Number 52 CONTROLLED
ACCELERATION
(Push CONT and 5 while the key switch and
seat switch are closed)
This register adjusts the maximum rate of accelera-
tion in MODE 2. The parameter determines the time
allowed to reach maximum SCR speed from stop. Do
2200 SRM 557
not set the number in the register to less than the
parameter for Function Number 56 CONTROLLED
ACCELERATION. Do not set the register greater
than Function Number 48 CONTROLLED ACCEL-
ERATION.
Function Number 53 SPEED LIMIT 2
(Push CONT and 6 while the key switch and
seat switch are closed)
This register adjusts the speed limit for the hydraulic
pump in MODE 2. Do not set the register to less than
Function Number 49 SPEED LIMIT 2. Do not set the
register greater than Function Number 57 SPEED
LIMIT 2.
Function Number 54 SPEED LIMIT 3
(Push CONT and 7 while the key switch and
seat switch are closed)
This parameter adjusts the speed limit (maximum
battery voltage to the motor). The range is 0 to 96
percent. There is no speed limit switch for this func-
tion. This function is disabled if the parameter in
the register is set to zero. Do not set the register to
less than Function Number 58 SPEED LIMIT 3. Do
not set the register greater than Function Number
50 SPEED LIMIT 3.
Function Number 56 CONTROLLED
ACCELERATION
(Push CONT and 9 while the key switch and
seat switch are closed)
This register adjusts the maximum rate of acceler-
ation in MODE 3. The parameter determines the
time allowed to reach maximum SCR speed from
stop. Do not set the register to less than Function
Number 60 CONTROLLED ACCELERATION. Do
not set the register greater than Function Number
52 CONTROLLED ACCELERATION.
Function Number 57 SPEED LIMIT 2
(Push CONT and 10 while the key switch and
seat switch are closed)
This register adjusts the speed limit for the hydraulic
pump in MODE 3. Do not set the register to less than
Function Number 53 SPEED LIMIT 2. Do not set the
register greater than Function Number 61 SPEED
LIMIT 2.
Control Cards
Function Number 58 SPEED LIMIT 3
(Push CONT and 11 while the key switch and
seat switch are closed)
This parameter adjusts the speed limit (maximum
battery voltage to the motor). The range is 0 to 96
percent. There is no speed limit switch for this func-
tion. This function is disabled if the parameter in the
register is set to zero. The maximum number in the
register is 255.
Function Number 60 CONTROLLED
ACCELERATION
(Push CONT and 13 while the key switch and
seat switch are closed)
This register adjusts the maximum rate of accelera-
tion in MODE 4 (Rabbit). The parameter determines
the time allowed to reach maximum SCR speed from
stop. Do not set the number in the register to less
than 8. Do not set the register greater than Func-
tion Number 56 CONTROLLED ACCELERATION.
Function Number 61 SPEED LIMIT 2
(Push CONT and 14 while the key switch and
seat switch are closed)
This register adjusts the speed limit for the hydraulic
pump in MODE 4. Do not set the number in the reg-
ister to less than Function Number 57 SPEED LIMIT
2. Do not set the register greater than 110.
Function Number 62 SPEED LIMIT 3
(Push CONT and 14 while the key switch and
seat switch are closed)
This parameter adjusts the speed limit (maximum
battery voltage to the motor). The range is 0 to 96
percent. There is no speed limit switch for this func-
tion. This function is disabled if the parameter in the
register is set to zero. The maximum number in the
register is 255.
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 for
your lift truck model. Do NOT adjust a parameter
to a number that is NOT SHOWN in the correct ta-
ble. Make sure you use the correct table when
you make adjustments. It is a good procedure to
31
Troubleshooting
check the parameter and compare the parameter to
the number in the table before making the adjust-
ment. The factory parameter, and the value (cur-
rent, time, etc.) for that parameter, are shown in the
columns indicated as Default. The minimum and
maximum parameters and their values are shown in
the columns indicated as Permitted Range.
NOTE: Check the label at the top edge of each card
case to identify the control card on your lift truck.
There are some painted letters and numbers followed
by other numbers and letters on the lower part of the
label. The last two letters on the lower part iden-
tify theTYPE of card installed. The table titles show
these card types for the EV-100ZX motor controllers.
Troubleshooting
GENERAL
Many electrical malfunctions of the lift truck are
shown in the status code number on the digital
display. There is a digital display on the Handset
or instrument panel display (optional on some lift
trucks). There is a table, in this Troubleshooting
section, for each status code with a description of the
malfunction, the circuit that has the incorrect input,
and the possible causes.
NOTE: Make sure the parameters are correct for your
lift truck to make sure the trouble is not just a
wrong setting. See the Parameter Tables to set
the parameters for the correct values. If there is no
status code display and the lift truck does not operate
correctly, there can be a fault in the control card.
See the procedures to connect and use the Handset.
The following Status Codes indicate possible faults
in these 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
32
2200 SRM 557
CAUTION
Do not set the Field Weakening functions with-
out checking to make sure the traction motor
is designed for Field Weakening. There can be
traction motor damage if Field Weakening is
used with motors that are not designed for it.
NOTE: A control card that has the Field Weakening
functions can be installed on lift trucks that have
traction motors that are not designed for Field Weak-
ening. The Field Weakening functions are set to not
operate on these lift trucks.
Make sure to read the WARNINGS and CAUTIONS
under each parameter description and in the section
Parameters, Checks, and Adjustments.
NOTE: A blank display on the instrument panel
display or the Handset, during operation, can
mean that the diode D7 for regenerative braking has
a short circuit. The indication for this malfunction
is an open traction power fuse. If D7 has a short
circuit, there is a short circuit across the battery as
soon as the regenerative braking contactor closes
and will cause the power fuse to open. If D7 is open,
the regenerative braking does not operate and the
plugging is too quick.
NOTE: A short circuit in the 1A contactor coil causes
the lift truck to suddenly stop when operating at the
higher speeds. The lift truck operates correctly until
the 1A contactor is energized. When the 1A contactor
is energized, the traction motor then stops and the
direction contactors open.
NOTE: If the coil of the Field Weakening contactor
has a short circuit, the lift truck will operate nor-
mally until the FW contactor is energized. Then the
lift truck loses power and the direction contactors
open.
The control card in the motor controller has a trou-
bleshooting system that continuously checks the
static and operating conditions of the control and
power circuits for the motor. If the troubleshooting
circuits find a condition that is not normal, the
control card indicates a status code on a display
connected to plug PY. Some lift trucks can have an
instrument panel display that indicates the status
codes from the control cards for the traction motor
and hydraulic pump motor.
2200 SRM 557 Troubleshooting

Different control cards are used in the electric lift Table 5. Status Codes List
trucks. A replacement control card must have the
same part number as the control card that is re- Status
Description
moved. A bad control card cannot be repaired by Code
service persons and must be replaced.
CARD INPUTS
STATUS CODES BLANK No input voltage to control card or
display
The status codes are code numbers for malfunctions
that the control card can sense. The control card in- -01 No input signal from seat switch
dicates this code number on the digital display of the -02 FWD switch closed on initial start
instrument panel display (optional on some units) or
the display on a Handset. The control card illumi- -03 REV switch closed on initial start
nate the numbers of the status code on the display. -04 Start switch, low voltage after start
The status codes are twice illuminated flash on the
display approximately every 2seconds. Every third -05 Start or brake switch did not close
flash of the display indicates the battery charge in- -06 Accelerator depressed, no direction
stead of the status code. selected
The control card senses the following malfunctions: -07 Accelerator input voltage too high
• Input voltages that are too high or too low
-08 Accelerator input voltage too low or
• Input voltages that have the wrong polarity
power to control card after key in ON
• Input voltages in the wrong sequence
position
• Correct input voltages that occur at the wrong
time. -09 Both FWD and REV switches closed
at same time
NOTE: A status code display does not always mean
that there is a malfunction. A temporary operating -11 The START switch is closed when the
condition can cause a status code display. key switch is closed and voltage is
applied to the control card
The status codes all have a dash (-) before the num- -15 Battery volts too low
bers. If the battery is disconnected, the dash (-) is
missing on the display of the Handset when a bat- -16 Battery volts too high
tery is connected again. If a status code number is -17 Wrong control card installed
indicated on the digital display, checks and adjust-
ments cannot be done. See Table 5 and the following -21 Accelerator input is less than 0.25
Status Code Charts to find and correct the malfunc- volts
tion. There are no checks or adjustments for the sta- CONTACTOR PANEL, TRACTION
tus codes. These code numbers are only codes to help CIRCUIT
identify a possible malfunction. Table 5 has a short
description of the different status codes. -23 Coil current low, Forward or
Reverse contactor
There is a Status Code Chart in this section for each
-24 Voltage at T2 too high
status code. These charts have a more complete de-
scription of the status code, the circuit that generated -25 1A contactor does not open or opens
the input for the status code, the symptom, and the too slowly
possible causes.
-26 Short circuit in electronic driver for
RB, SP or FW contactor
* Not used on all models of lift trucks. Status
Codes in this group will flash on the display.
NOTE: Motor speed is decreased when a status
code -41 is indicated.

33
Troubleshooting 2200 SRM 557

Table 5. Status Codes List (Continued) Table 5. Status Codes List (Continued)

Status Status
Description Description
Code Code
SCR CONTROL, TRACTION -74 Regenerative braking contactor
CIRCUIT energizes too slowly
-41 Open thermal protector or motor -75 SCR 1 does not go OFF during
control temperature too high regenerative braking
-42 Motor sensor input missing (green -76 C1 voltage too high during
wire) regenerative braking
-43 Motor sensor input missing (yellow LIFT TRUCK MANAGEMENT*
wire)
-90 Temperature too high, traction motor*
-44 SCR 1 did not go OFF correctly
-91 Temperature too high, hydraulic
-45 SCR 1 did not go ON correctly pump motor*
-46 T2 voltage too high -93 Brush wear, steering pump motor*
-47 SCR 2 does not go ON correctly -94 Brush wear, traction motor*
-48 T2 voltage too low -95 Brush wear, hydraulic pump motor*
-49 SCR 5 does not go ON correctly -99 Maintenance Alert Code.
-50 C1 voltage too low SCR CONTROL, HYDRAULIC
PUMP
-51 C1 voltage too high with high motor
current -117 Wrong control card installed
-52 C1 voltage too high with low motor -123 Pump PMT contactor coil current is
current too low
-53 SCR 1 does not go OFF during -124 Voltage at T2 too high.
plugging
-125 1A contactor does not de-energize or
-54 Short circuit, FWD, REV or 1A opens too slowly
electronic driver
-141 Open thermal protector or motor
-57 Polarity check, current sensor output control temperature too high
voltage
-142 Motor sensor input missing (green
REGENERATIVE BRAKING wire)
-70 Current sensor input missing (yellow -143 Motor sensor input missing (yellow
wire) wire)
-71 Current sensor input missing (green -144 SCR 1 did not go OFF correctly
wire)
-145 SCR 1 did not go ON correctly
-72 Regenerative braking contactor does
-146 T2 voltage too high
not energize
-147 SCR 2 does not go ON correctly
-73 Regenerative braking contactor does
not de-energize or de-energizes slowly -148 T2 voltage too low
* Not used on all models of lift trucks. Status * Not used on all models of lift trucks. Status
Codes in this group will flash on the display. Codes in this group will flash on the display.
NOTE: Motor speed is decreased when a status NOTE: Motor speed is decreased when a status
code -41 is indicated. code -41 is indicated.

34
2200 SRM 557 Troubleshooting

Table 5. Status Codes List (Continued) REGISTER MAPS

The information in the Register Maps shown in Ta-
Status ble 6 and Table 7 is not needed by most service peo-
Description
Code ple. This additional technical information is for ser-
-149 SCR 5 does not go ON correctly vice engineers who have special troubleshooting re-
quirements. These registers and their descriptions
-150 C1 volts low are designed by the General Electric Company. Many
-151 C1 volts high with high motor current of these registers are programmed by Hyster Com-
pany to do certain functions. These register maps as
-152 C1 volts high with low motor current programmed by Hyster Company are shown in the
-154 Short circuit in electronic driver for Parameter Tables.
the hydraulic pump contactor or 1A
NOTE: The number of the EEPROM register is off-
contactor
set by one from the PC Register Number and the
-157 Polarity check, current sensor output Function Number in the Register Map Tables. The
voltage EEPROM begins its count from zero (0) while the PC
and Handset count from one (1).
* Not used on all models of lift trucks. Status
Codes in this group will flash on the display. NOTE: EEPROM = Electrically Erasable Pro-
NOTE: Motor speed is decreased when a status grammable Read Only Memory
code -41 is indicated.

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

EEPROM PC Handset
Register Register (HS) Description Access By: Restrictions
Number Number Number
0 1 1 Fault Code HS or PC Erases when battery
is disconnected
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 Braking HS or PC None
Current Limit
9 10 10 Regenerative Start HS or PC None
10 11 11 Speed Limit 1 HS or PC None
11 12 12 Speed Limit 2 HS or PC None
12 13 13 Speed Limit 3 HS or PC None
13 14 14 Battery Voltage HS or PC None
Compensation
14 15 15 Battery Voltage Selection HS or PC None

35
Troubleshooting 2200 SRM 557

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

EEPROM PC Handset
Register Register (HS) Description Access By: Restrictions
Number Number Number
15 16 16 Pedal Position Plugging HS or PC None
16 17 17 Type of Control Card HS or PC None
Selection
17 18 18 Steering Pump Time HS or PC None
Delay
18 19 19 Maintenance Alert HS or PC None
(Tens/Units)
19 20 20 Maintenance Alert HS or PC None
(Thousands/Hundreds)
20 21 21 Maintenance Speed HS or PC None
Limit
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
27 28 28 Fault Count Pointer HS or PC None (Location of last
fault recorded)
28 29 29 Hourmeter (Tens/Units) HS or PC None
29 30 30 Hourmeter (Thousands/ HS or PC None
Hundreds)
30 31 Auxiliary Hourmeter PC Only Reset to Zero only
(Tens/Units)
31 32 Auxiliary Hourmeter PC Only Reset to Zero only
(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/ PC Only Reset to Zero only
Hundreds) 1
36 37 Fault 2 PC Only Reset to Zero only
37 38 BDI 2 PC Only Reset to Zero only

36
2200 SRM 557 Troubleshooting

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

EEPROM PC Handset
Register Register (HS) Description Access By: Restrictions
Number Number Number
38 39 Hours (Tens/Units) 2 PC Only Reset to Zero only
39 40 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 2
40 41 Fault 3 PC Only Reset to Zero only
41 42 BDI 3 PC Only Reset to Zero only
42 43 Hours (Tens/Units) 3 PC Only Reset to Zero only
43 44 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 3
44 45 Fault 4 PC Only Reset to Zero only
45 46 BDI 4 PC Only Reset to Zero only
46 47 Hours (Tens/Units) 4 PC Only Reset to Zero only
47 48 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 4
48 49 Fault 5 PC Only Reset to Zero only
49 50 BDI 5 PC Only Reset to Zero only
50 51 Hours (Tens/Units) 5 PC Only Reset to Zero only
51 52 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 5
52 53 Fault 6 PC Only Reset to Zero only
53 54 BDI 6 PC Only Reset to Zero only
54 55 Hours (Tens/Units) 6 PC Only Reset to Zero only
55 56 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 6
56 57 Fault 7 PC Only Reset to Zero only
57 58 BDI 7 PC Only Reset to Zero only
58 59 Hours (Tens/Units) 7 PC Only Reset to Zero only
59 60 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 7
60 61 Fault 8 PC Only Reset to Zero only
61 62 BDI 8 PC Only Reset to Zero only
62 63 Hours (Tens/Units) 8 PC Only Reset to Zero only
63 64 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 8
64 65 Fault 9 PC Only Reset to Zero only

37
Troubleshooting 2200 SRM 557

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

EEPROM PC Handset
Register Register (HS) Description Access By: Restrictions
Number Number Number
65 66 BDI 9 PC Only Reset to Zero only
66 67 Hours (Tens/Units) 9 PC Only Reset to Zero only
67 68 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 9
68 69 Fault 10 PC Only Reset to Zero only
69 70 BDI 10 PC Only Reset to Zero only
70 71 Hours (Tens/Units) 10 PC Only Reset to Zero only
71 72 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 10
72 73 Fault 11 PC Only Reset to Zero only
73 74 BDI 11 PC Only Reset to Zero only
74 75 Hours (Tens/Units) 11 PC Only Reset to Zero only
75 76 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 11
76 77 Fault 12 PC Only Reset to Zero only
77 78 BDI 12 PC Only Reset to Zero only
78 79 Hours (Tens/Units) 12 PC Only Reset to Zero only
79 80 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 12
80 81 Fault 13 PC Only Reset to Zero only
81 82 BDI 13 PC Only Reset to Zero only
82 83 Hours (Tens/Units) 13 PC Only Reset to Zero only
83 84 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 13
84 85 Fault 14 PC Only Reset to Zero only
85 86 BDI 14 PC Only Reset to Zero only
86 87 Hours (Tens/Units) 14 PC Only Reset to Zero only
87 88 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 14
88 89 Fault 15 PC Only Reset to Zero only
89 90 BDI 15 PC Only Reset to Zero only
90 91 Hours (Tens/Units) 15 PC Only Reset to Zero only
91 92 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 15

38
2200 SRM 557 Troubleshooting

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

EEPROM PC Handset
Register Register (HS) Description Access By: Restrictions
Number Number Number
92 93 Fault 16 PC Only Reset to Zero only
93 94 BDI 16 PC Only Reset to Zero only
94 95 Hours (Tens/Units) 16 PC Only Reset to Zero only
95 96 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 16
96 97 48 Instrument Panel HS or PC None
Display CA-1
97 98 49 Instrument Panel HS or PC None
Display FWPU-1
98 99 50 Instrument Panel HS or PC None
Display SL1-1
99 100 51 NOT USED HS or PC None
100 101 52 Instrument Panel HS or PC None
Display CA-2
101 102 53 Instrument Panel HS or PC None
Display FWPU-2
102 103 54 Instrument Panel HS or PC None
Display SL1-2
103 104 55 NOT USED HS or PC None
104 105 56 Instrument Panel HS or PC None
Display CA-3
105 106 57 Instrument Panel HS or PC None
Display FWPU-3
106 107 58 Instrument Panel HS or PC None
Display SL1-3
107 108 59 NOT USED HS or PC None
108 109 60 Instrument Panel HS or PC None
Display CA-4
109 110 61 Instrument Panel HS or PC None
Display FWPU-4
110 111 62 Instrument Panel HS or PC None
Display SL1-4
111 112 NOT USED PC Only
112 113 Secure Hourmeter PC Only Read Only
(Tens/Units)
113 114 Secure Hourmeter PC Only Read Only
(Thousands/Hundreds)

39
Troubleshooting 2200 SRM 557

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

EEPROM PC Handset
Register Register (HS) Description Access By: Restrictions
Number Number Number
114 115 Secure Auxiliary PC Only Read Only
Hourmeter (Thousands/
Hundreds)
115 116 Secure Auxiliary PC Only Read Only
Hourmeter (Thousands/
Hundreds)
116 117 PC Only GE Use Only
117 118 PC Only GE Use Only
118 119 PC Only GE Use Only
119 120 PC Only GE Use Only
120 121 PC Only None
121 122 PC Only None
122 123 PC Only None
123 124 PC Only None
124 125 PC Only None
125 126 PC Only None
126 127 PC Only None
127 128 PC Only None

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

Handset
EEPROM PC
(HS)
Register Function Function Access By: Restrictions
Function
Number Number
Number
0 1 1 Fault Code HS or PC Erases when battery
is disconnected
1 2 2 Internal Resistance HS or PC None
Compensation Start
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 Resistance HS or PC None
Compensation Rate
7 8 8 NOT USED
8 9 9 NOT USED

40
2200 SRM 557 Troubleshooting

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

Handset
EEPROM PC
(HS)
Register Function Function Access By: Restrictions
Function
Number Number
Number
9 10 10 NOT USED
10 11 11 Speed Limit (SL1) HS or PC None
11 12 12 Speed Limit (SL2) HS or PC None
12 13 13 Speed Limit (SL3) HS or PC None
13 14 14 Speed Limit (SL4) HS or PC None
14 15 15
15 16 16 Speed and Torque HS or PC None
Compensation
16 17 17 Type of Control Card HS or PC None
Selection
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 for
instrument panel
display when battery
power 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
26 27 27 NOT USED
27 28 28 Fault Count Pointer HS or PC None (Location of last
fault recorded)
28 29 29 Hourmeter (Tens/Units) HS or PC None
29 30 30 Hourmeter (Thousands/ PC Only None
Hundreds)
30 31 Auxiliary Hourmeter PC Only None
(Tens/Units)
31 32 Auxiliary Hourmeter PC Only None
(Thousands/Hundreds)
32 33 Fault 1 PC Only Reset to Zero only
33 34 NOT USED

41
Troubleshooting 2200 SRM 557

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

Handset
EEPROM PC
(HS)
Register Function Function Access By: Restrictions
Function
Number Number
Number
34 35 Hours (Tens/Units) 1 PC Only Reset to Zero only
35 36 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 1
36 37 Fault 2 PC Only Reset to Zero only
37 38 NOT USED
38 39 Hours (Tens/Units) 2 PC Only Reset to Zero only
39 40 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 2
40 41 Fault 3 PC Only Reset to Zero only
41 42 NOT USED
42 43 Hours (Tens/Units) 3 PC Only Reset to Zero only
43 44 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 3
44 45 Fault 4 PC Only Reset to Zero only
45 46 NOT USED
46 47 Hours (Tens/Units) 4 PC Only Reset to Zero only
47 48 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 4
48 49 Fault 5 PC Only Reset to Zero only
49 50 NOT USED
50 51 Hours (Tens/Units) 5 PC Only Reset to Zero only
51 52 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 5
52 53 Fault 6 PC Only Reset to Zero only
53 54 NOT USED
54 55 Hours (Tens/Units) 6 PC Only Reset to Zero only
55 56 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 6
56 57 Fault 7 PC Only Reset to Zero only
57 58 NOT USED
58 59 Hours (Tens/Units) 7 PC Only Reset to Zero only
59 60 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 7
60 61 Fault 8 PC Only Reset to Zero only

42
2200 SRM 557 Troubleshooting

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

Handset
EEPROM PC
(HS)
Register Function Function Access By: Restrictions
Function
Number Number
Number
61 62 NOT USED
62 63 Hours (Tens/Units) 8 PC Only Reset to Zero only
63 64 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 8
64 65 Fault 9 PC Only Reset to Zero only
65 66 NOT USED
66 67 Hours (Tens/Units) 9 PC Only Reset to Zero only
67 68 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 9
68 69 Fault 10 PC Only Reset to Zero only
69 70 NOT USED
70 71 Hours (Tens/Units) 10 PC Only Reset to Zero only
71 72 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 10
72 73 Fault 11 PC Only Reset to Zero only
73 74 NOT USED
74 75 Hours (Tens/Units) 11 PC Only Reset to Zero only
75 76 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 11
76 77 Fault 12 PC Only Reset to Zero only
77 78 NOT USED
78 79 Hours (Tens/Units) 12 PC Only Reset to Zero only
79 80 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 12
80 81 Fault 13 PC Only Reset to Zero only
81 82 NOT USED
82 83 Hours (Tens/Units) 13 PC Only Reset to Zero only
83 84 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 13
84 85 Fault 14 PC Only Reset to Zero only
85 86 NOT USED
86 87 Hours (Tens/Units) 14 PC Only Reset to Zero only
87 88 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 14

43
Troubleshooting 2200 SRM 557

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

Handset
EEPROM PC
(HS)
Register Function Function Access By: Restrictions
Function
Number Number
Number
88 89 Fault 15 PC Only Reset to Zero only
89 90 NOT USED
90 91 Hours (Tens/Units) 15 PC Only Reset to Zero only
91 92 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 15
92 93 Fault 16 PC Only Reset to Zero only
93 94 NOT USED
94 95 Hours (Tens/Units) 16 PC Only Reset to Zero only
95 96 Hours (Thousands/ PC Only Reset to Zero only
Hundreds) 16
96 97 48 Instrument Panel HS or PC None
Display CA-1
97 98 49 Instrument Panel HS or PC None
Display SL2-1
98 99 50 Instrument Panel HS or PC None
Display SL4-1
99 100 51 NOT USED HS or PC None
100 101 52 Instrument Panel HS or PC None
Display CA-2
101 102 53 Instrument Panel HS or PC None
Display SL2-2
102 103 64 Instrument Panel HS or PC None
Display SL4-2
103 104 55 NOT USED HS or PC None
104 105 56 Instrument Panel HS or PC None
Display CA-3
105 106 57 Instrument Panel HS or PC None
Display SL2-3
106 107 58 Instrument Panel HS or PC None
Display SL4-3
107 108 59 NOT USED HS or PC None
108 109 60 Instrument Panel HS or PC None
Display CA-4
109 110 61 Instrument Panel HS or PC None
Display SL2-4

44
2200 SRM 557 Troubleshooting

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

Handset
EEPROM PC
(HS)
Register Function Function Access By: Restrictions
Function
Number Number
Number
110 111 62 Instrument Panel HS or PC None
Display SL4-4
111 112 NOT USED PC Only
112 113 Secure Hourmeter PC Only Read Only
(Tens/Units)
113 114 Secure Hourmeter PC Only Read Only
(Thousands/Hundreds)
114 115 Secure Auxiliary PC Only Read Only
Hourmeter (Thousands/
Hundreds)
115 116 Secure Auxiliary PC Only Read Only
Hourmeter (Thousands/
Hundreds)
116 117 PC Only GE Use Only
117 118 PC Only GE Use Only
118 119 PC Only GE Use Only
119 120 PC Only GE Use Only
120 121 PC Only None
121 122 PC Only None
122 123 PC Only None
123 124 PC Only None
124 125 PC Only None
125 126 PC Only None
126 127 PC Only None
127 128 PC Only None

45
Status Code Charts 2200 SRM 557

Status Code Charts

Status Code Description Cause of Status Indication
No display on the instrument panel No input voltage to the control card
NONE display or the Handset or the display unit.
Memory Recall Indication of Fault
No
No display on the instrument panel
display or the Handset
Possible Cause
No control voltage
Make sure the key switch is ON and there
is voltage between PZ7 and PZ3 (battery
negative). Check that there is voltage
between TB4 and PZ3.
Circuit Open circuit between control card
Traction and plug Y and the instrument panel
Hydraulic Pump display or the Handset:
Check for an open circuit or loose
connections between each wire going
to the plug on the control card and the
instrument panel display or the Handset.
Malfunction of the instrument panel
display or the Handset:
Replace the instrument panel display.
NOTE: A blank display, during operation,
can indicate that the regenerative braking
diode has a short circuit. The symptom
for this malfunction is: no operation and
traction power fuse open. If the diode
has a short circuit, there is a short circuit
across the battery as soon as the regenera-
tive braking contactor closes and the fuse
opens. If the regenerative braking diode is
open, there is no indicated fault except that
there is stiff plugging and no regenerative
braking.

46
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

No voltage from seat switch This Status Code is indicated when TB3 is
-01 less than 50% of battery voltage.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
Seat switch malfunction or needs
adjustment.
Check that the seat switch closes correctly.
Circuit Open circuit between battery
Traction positive and TB3
Check for loose connections or broken
wires between the seat switch and TB3,
between the key switch and the battery
positive side of the seat switch, between
the seat switch and TB4.

Status Code Description Cause of Status Indication

FORWARD direction switch is closed when This Status Code is indicated when TB5 is
-02 the key switch is turned on ON. greater than 60% of battery voltage when
the key switch is turned to ON.
Memory Recall Indication of Fault
No Forward contactor does not close. Static
Return to OFF (SRO) circuit activated.
Possible Cause
FORWARD direction switch is closed when
the key switch is turned to ON.
Move the direction control lever to
NEUTRAL and then select a direction.
Circuit FORWARD direction switch has
Traction a short circuit.
Replace or adjust the direction switch so
that it opens when the direction control
lever is in NEUTRAL.
Short circuit between TB2 and TB5.
Disconnect the wire from TB5 and check
for a short circuit between TB2 and the
wire.
Malfunction of the control card.
Disconnect the wire from TB5. Check for
less than 60% of battery voltage at TB5.

47
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

REVERSE direction switch is closed when This Status Code is indicated when TB6 is
-03 the key switch is turned to ON. greater than 60% of battery voltage when
the key switch is turned to ON.
Memory Recall Indication of Fault
No Reverse contactor does not close. Static
Return to OFF (SRO) circuit activated.
Possible Cause
REVERSE direction switch is closed when
the key switch is turned to ON.
Move the direction control lever to
NEUTRAL and then select a direction.

Circuit REVERSE direction switch has

Traction a short circuit.
Replace or adjust the direction switch so
that it opens when the direction control
lever is in NEUTRAL.
Short circuit between TB2 and TB6.
Disconnect the wire from TB6 and check
for a short circuit between TB2 and the
wire.
Malfunction of the control card.
Disconnect the wire from TB6. Check for
less than 60% of battery voltage at TB6.

48
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Low voltage when the START switch This Status Code is indicated when the voltage
-04 is closed after the key switch and the at TB2 is less than 60% of battery voltage
seat switch are closed. when the START switch is closed after the key
switch and the seat switch are closed.
Memory Recall Indication of Fault
Yes Forward or Reverse contactor does
not close.
Possible Cause
FORWARD or REVERSE direction
switch is closed when the key switch
is turned to ON.
Push on the accelerator to close the START
switch. The Status Code changes to -03
if the REVERSE direction switch or to
-02 if the FORWARD direction switch is
closed. Move the direction control lever to
NEUTRAL and then select a direction.
Circuit Short circuit between TB2 and
Traction battery negative.
Check the voltage at TB2 when the key
switch and seat switch are closed and the
direction control lever is in NEUTRAL.
The correct voltage is greater than 60% of
battery voltage.
If the voltage is less than 60% of battery
voltage, disconnect the wire from TB2.
Measure the resistance between the end
of the wire and the negative side of SCR
1. The correct resistance is less than 22k
ohms.

49
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

START switch or brake switch This Status Code is indicated when TB1
-05 does not close is less than 2.5 volts and TB2 is less than
60% of battery voltage.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
Malfunction of the brake switch circuit.
Check the brake switch to make sure it
closed when the brake pedal is released.
Circuit Check for an open circuit loose connections
Traction in the wires from the brake switch to the
seat switch, to TB3, and from the brake
switch to the START switch.
Malfunction of the START switch circuit.
Check the START switch to make sure it
closed when the accelerator is actuated.
Check for an open circuit or loose
connections in the wires from the brake
switch to the START switch and from TB2
to the START switch.

50
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Accelerator actuated and no direction This Status Code is indicated when TB5 and
-06 switch is selected. TB6 are less than 60% of battery voltage
and TB1 is less than 2.5 volts.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
Accelerator pedal is actuated before a
direction switch is closed.
The Status Code is cleared when a
direction switch is closed or the accelerator
pedal is released.
Circuit Malfunction of the circuit for the
Traction FORWARD or REVERSE switches.
Check the direction switches to make sure
they close when the direction control lever
is moved to that position.
Open circuit between the direction
switches and TB5 or TB6.
Check for an open circuit or loose
connections in the wires for the direction
control circuits to TB5 or TB6.

51
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Accelerator input voltage is too high. This Status Code is indicated when the
-07 accelerator input voltage of TB1 is higher than
3.7 volts and a direction contactor is closed.
Memory Recall Indication of Fault
No Forward or Reverse contactor closes, but
the motor controller does not operate
when the accelerator pedal is actuated
or the -07 Status Code clears when the
lift truck begins to accelerate.
Possible Cause
Accelerator potentiometer has a
malfunction or needs adjustment.
The correct output voltage of TB1 is
more than 3.0 volts. Repair or adjust
the accelerator potentiometer so that it
correctly changes from 3.5 to less than
0.5 volts (minimum 0.30 volts) when the
accelerator pedal is actuated.
Circuit Open circuit between battery negative and
Traction TB1 in the accelerator input circuit.
Check for broken wires or loose connections
in the accelerator potentiometer circuit.
Short circuit from battery positive to a
wire in the accelerator input circuit.
Disconnect the wire from TB1 and
measure the voltage between the end of
the wire and battery negative. The correct
voltage is zero for an accelerator with a
potentiometer.

52
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Accelerator input voltage is too low This Status Code is indicated when the
-08 after the key switch is closed. accelerator input voltage at TB1 is less than
3.0 volts and the battery connector, or the seat
switch, or the key switch is opened and closed.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
Accelerator potentiometer has a
malfunction or needs adjustment.
The correct output voltage at TB1 is
more than 3.0 volts. Repair or adjust
the accelerator potentiometer so that it
correctly changes from 3.5 to less than
0.5 volts (minimum 0.30 volts) when the
accelerator pedal is actuated.
Circuit Short circuit between battery negative and
Traction TB1 in the accelerator input circuit.
Disconnect wire from TB1. Check for short
circuit from the end of the wire to battery
negative. The correct resistance is greater
than 4.7k ohms.
Control card malfunction.
Disconnect the wire from TB1 and measure
the voltage between TB1 and battery
negative. The correct voltage is greater
than 4.5 volts. If the voltage is wrong,
replace the control card.

53
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Both FORWARD and REVERSE direction This Status Code is indicated when TB5
-09 switches are closed at the same time. and TB6 are greater than 60% of battery
voltage at the same time.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
FORWARD or REVERSE direction
switches are welded closed or need
adjustment.
Replace or adjust the direction switches to
make sure that they are both open when
the direction control lever is in NEUTRAL.
Circuit Short circuit between battery positive
Traction and TB5 or TB6.
Disconnect the wires from TB5 and TB6
and check for a short circuit between the
end of the wire and the battery positive
side of the direction switch.
Control card malfunction.
Disconnect the wires and measure the
voltage at TB5 and TB6. The correct
voltage is less than 60% of battery voltage.

54
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

The START switch is closed when the This Status Code is indicated when TB2
-11 key switch is closed and voltage is is greater than 60% of battery voltage
applied to the control card. when the key switch is closed.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
START switch needs adjustment
or is damaged.
Input voltage must be less than 60% of
battery voltage when the key switch is
closed. Replace or adjust the START
switch.
Circuit Short circuit between battery positive
Traction (ZX and TB2 in START switch circuit.
Control Card
Disconnect the wire from TB2. Check for
Only)
a short circuit between the end of the wire
and the battery positive. Resistance must
be greater than 4.7 kohms.
Control card malfunction.
Disconnect the wire from TB3 and measure
the voltage from TB3 to battery negative.
If the voltage is not zero, replace the
control card.

55
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Battery voltage is too low. This Status Code is indicated when the battery
-15 voltage is less than 1.95 volts per cell when
the key switch is turned to ON.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
Discharged battery.
Check the battery for the correct open
circuit voltage as shown in the illustration
at the right and charge the battery as
required.
Circuit Bad connection of battery connector or
Traction short in the power cables.
Check the power cables and the battery
connector.
Battery malfunction.
Check each battery cell for the correct
voltage (greater than 1.95 volts per cell).
Replace or repair the battery.
Control card needs adjustment.
Check Function Number 15 BATTERY
VOLTS for the correct adjustment for
the battery that is being used. See the
instructions for the Handset. Make the
correct adjustments.

56
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Battery voltage is too high. This Status Code is indicated when the battery
-16 volts are greater than 2.40 volts per cell when
the key switch is turned to ON.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
Control card needs adjustment.
Check Function Number 15 BATTERY
VOLTS for the correct adjustment for
the battery that is being used. See the
instructions for the Handset. Make the
correct adjustments.
Circuit Open circuit in current sensor circuit
Traction for the regenerative braking.
Check for a broken yellow wire from the
current RB sensor to PA4. Check for
loose connections or a broken weld at the
current sensor. Check PA4 for a loose plug
or pin connection.
Battery is charged wrong or wrong
battery is installed.
Check the battery for the correct open
circuit voltage (see the table in the
illustration at the right). If the battery
voltage is too high, check the battery
charger for the correct output voltage.
48-volt battery is too low (between
WHT and BRN in Plug Z).
Function Number 15 is set for 36/48
volt operation (184 to 250).
The controller has determined that a 36
volt battery is installed that has a voltage
too high.
If the battery voltage at the battery
connector is greater than 46.8 volts,
check for a bad connector or other bad
connections.

57
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Selection for type of control card is wrong. This Status Code is indicated when the control
-17 card type selection is set to a wrong number.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
Control card type selection is wrong.
Circuit Check Function Number 17 CARD TYPE
Traction SELECTION in the instructions for the
Handset. Make the correct adjustments
for the type of control card.

Status Code Description Cause of Status Indication

Accelerator input is less than 0.25 volts. This Status Code is indicated when the control
-21 card type selection is set to a wrong number.
Memory Recall Indication of Fault
No Controller does not operate.
Possible Cause
Accelerator potentiometer needs
adjustment or is damaged.
Input voltage of TB1 must be greater
than 0.25 volts when the accelerator pedal
is fully released. Adjust or replace the
accelerator potentiometer.
Circuit Short circuit between battery negative
Traction (ZX and TB1 in accelerator input circuit.
Control Card
Disconnect wire from TB1 and check for
Only)
short circuit from end of wire to battery
negative. Resistance must be greater than
4.7k ohms.
Open circuit between accelerator
potentiometer and PZ6.
Make sure 5 volts is present from PZ6 to
accelerator potentiometer.
Control card malfunction.
Disconnect the wire from TB1 and measure
the voltage between TB1 and battery
negative. If the voltage is not greater than
4.5 volts, replace the control card.

58
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Forward or Reverse contactor or any This Status Code is indicated when
-23 other contactor has a short circuit or there is a current draw in a contactor
low current to the coil. coil of less than 100 ma.
Memory Recall Indication of Fault
No Forward or Reverse contactor does not
close. The Status Code can change
between code -23 and code -24. Do all of
the Possible Cause checks for this Status
Code. If the problem is not found, do
the checks in Status Code -24.
Possible Cause
Malfunction of the coil circuit for Forward
and Reverse contactors.
Circuit Check for open circuit or loose connection
Traction between PB4 and the positive side of
the Forward contactor coil and between
PB5 and the positive side of the Reverse
contactor coil.
Remove Plug B. Check the resistance in
the wire from PB4 to the positive side of
the Forward contactor coil. The correct
value is 10 to 14 ohms. Do the same check
for the Reverse contactor coil.
Check for an open Forward-Reverse
control fuse.
Malfunction of the coil circuit for 1A,
RB, PS, or FW contactors.
Remove Plug B. Check the resistance in
the wire from the positive side of each
contactor coil to its plug connection. The
correct value is 10 to 14 ohms. The coil
resistance for the power steering contactor
is 52 ohms.

59
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

T2 voltage is greater than 12% of This Status Code is indicated when T2 voltage
-24 battery voltage. is greater than 12% of battery voltage and the
circuit for the direction contactors is energized.
Memory Recall Indication of Fault
No The motor controller does not operate.
The Status Code can change between
code -23 and code -24. Do all of the
Possible Cause checks for this Status
Code. If the problem is not found, do
the checks in Status Code -23.
Possible Cause
Most common cause is that the contacts
on one of the direction contactors or the
RB contactor does not close correctly to
make an electrical connection.
Circuit Clean the contact of the direction
Traction contactors and the RB contactor with
alcohol. New contacts can have a surface
condition that prevents conducting electric
current. Check that the contacts close
correctly.
Malfunction of coil circuit for Forward
and Reverse.
Check for welded contacts or contactors
that do not close correctly.
Malfunction of RB contactor.
Check that the contacts and contactor
close correctly.
Check for an open circuit or loose
connections between the positive side of
the RB contactor coil and PB2.
Open motor circuit.
Check for an open circuit or loose
connections in the motor circuit from the
A1 connection to the A2 connection on the
SCR control panel.
Malfunction of the 1A, RB, PS, or
FW contactors.
Do the checks described in Status Code
-23.

60
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

1A Contactor does not open or opens slowly. This Status Code is indicated when the 1A
-25 Contactor opens in greater than 0.060 seconds.
Memory Recall Indication of Fault
Yes Forward and Reverse, and 1A contacts
wear rapidly. Status Code -46 can be
indicated and no fault is found.
Possible Cause
NOTE: This Status Code can only be found
when the Handset is connected. This Sta-
tus Code is shown here as additional infor-
mation for Status Code -46.
Circuit Malfunction of 1A Contactor.
Traction
Check 1A Contactor for slow operation
when it opens.

Status Code Description Cause of Status Indication

Electronic driver in control card for the RB, This Status Code is indicated when there
-26 PS, or FW contactor has a short circuit. is a short circuit in the electronic driver for
the 1A, RB, or PS contactor coil.
Memory Recall Indication of Fault
No The 1A, RB, or PS contactor closed
immediately when the key switch is closed.
Possible Cause
Malfunction of an electronic driver
in the control card.
Circuit Replace the control card.
Traction

61
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Open thermal protector or motor This Status Code is indicated when the voltage
-41 controller is too hot. between PZ1 and PZ5 is greater than 1.8 volts.
Memory Recall Indication of Fault
No The traction motor has reduced power
on no power in the SCR range.
Possible Cause
Open circuit, thermal protector.
Check for a loose or broken wire between
the following points:
Black wire between thermal protector and
PZ1.
Gray wire between thermal protector and
PZ5.
Circuit Malfunction of thermal protector.
Traction
Disconnect the wires from PZ1 and PZ5.
When the temperature is approximately
25 C (77 F), measure the resistance
between the black and gray wire. The
correct resistance is approximately 300
ohms.
Thermal protector is operating because
motor controller is too hot.
Permit the motor controller to cool.

Status Code Description Cause of Status Indication

Input missing from motor current sensor. This Status Code is indicated when the voltage
-42 between PY7 and battery negative is greater
than 1.6 volts and no current is flowing
through the traction motor circuit.
Memory Recall Indication of Fault
No No power to the traction motor in
the SCR range.
Possible Cause
Open sensor wire circuit to PZ4.
Circuit Check for a loose or broken wire (green
Traction wire) between the current sensor and PZ4
on the control card.

62
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Input missing from motor current sensor. This Status Code is indicated when the voltage
-43 between PY7 and battery negative is less
than 0.84 volts and no current is flowing
through the traction motor circuit.
Memory Recall Indication of Fault
No Stall currents in the SCR range are higher
than normal and cannot be controlled
with the current link adjustment.
Possible Cause
Open sensor wire circuit to PZ3.
Circuit Check for a loose or broken wire (yellow
Traction wire) between the current sensor and PZ3
on the control card.

Status Code Description Cause of Status Indication

SCR 1 does not go to OFF correctly. This Status Code is indicated when SCR 1 does
-44 not go to OFF correctly during operation.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch 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 the
suppressor for SCR 5.
Check for an open circuit across SCR 2 or
an open gate lead to SCR 5.
Circuit Malfunction of SCR 2 circuit.
Traction
Check for a short circuit across SCR 2.
Check for a short circuit across the
suppressor for SCR 2.
Check for an open circuit across SCR 5 or
an open gate lead to SCR 2.
Open Inductor 1X.
Check for an open circuit between T5 and
T3. The correct resistance is zero ohms.
Malfunction of SCR 1.
The OFF time for SCR 1 is not within
specifications. No easy test is possible.
Replace SCR 1 after the other checks have
been done and no other problem is found.

63
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

SCR 1 does not go to ON correctly. This Status Code is indicated when SCR 1
-45 does not go ON correctly during operation.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
Malfunction of SCR 2 circuit.
Check for a short circuit across SCR 2.
Check for a short circuit across the
suppressor for SCR 2.
Check for an open circuit across SCR 2 or
an open gate lead to SCR 2.
Circuit Malfunction of SCR 1 circuit.
Traction
Check for an open circuit or loose
connections between SCR 1 and PZ8
(white/blue wire).
Check for an open circuit or loose
connections between SCR 1 and D3
suppressor and PZ9 (blue wire).
Malfunction of SCR 1.
An open or bad gate circuit to SCR 1. No
easy test is possible. Replace SCR 1 after
the other checks have been done and no
other problem is found.

Status Code Description Cause of Status Indication

Short circuit across SCR 1. This Status Code is indicated when the voltage
-46 (Also see Status Code -25). at T2 is greater than 85% of battery voltage.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors do not close.
Possible Cause
Malfunction of SCR 1 circuit.
Check for a short circuit across SCR 1.
Check for a short circuit across the
insulator between the heat sink for SCR 1
and the base plate.

Circuit Malfunction of Contactor 1A.

Traction
Check for welded contacts on Contactor 1A
that hold the contactor closed.

64
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

SCR 2 does not go to ON correctly. This Status Code is indicated when SCR 2
-47 (Also see Status Code -25). has a failure and does not go ON.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
Malfunction of SCR 2 circuit.
Check that SCR 2 goes ON with a gate
signal.
Circuit Check for an open circuit or loose
Traction connection between SCR 2 gate and PZ10
(white/red wire).
Check for an open circuit or loose
connection between SCR 1 and C1 and
through the SCR 2 circuit.
Malfunction of Forward or Reverse
contactors.
Check for Forward or Reverse contactors
momentarily opening and closing during
operation when traveling over bumps and
dock plates.

Status Code Description Cause of Status Indication

Voltage check at T2 is less than 12% This Status Code is indicated when a voltage
-48 of battery voltage. check at T2 is less than 12% of battery voltage.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors do not close.
Possible Cause
Malfunction of Forward or Reverse
contactors.
Check for welded contacts that hold a
Forward or Reverse contactor closed.
Check for slow operation of a Forward or
Reverse contactor.
Circuit Malfunction of diode D3 circuit.
Traction
Check for a short circuit across D3.
Check for a short circuit across the
suppressor for D3.

65
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

SCR 5 does not go ON correctly. This Status Code is indicated when SCR
-49 5 does not go ON correctly.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch 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 the
suppressor for SCR 5.
Check for an open circuit across SCR 2 or
an open gate lead to SCR 5.
Circuit Check for an open circuit or a loose
Traction connection between SCR 5 and PZ12
(white/purple wire).
Malfunction of SCR 2 circuit.
Check for a short circuit across SCR 2.
Check for a short circuit across the
suppressor for SCR 2.
Check for an open circuit across SCR 5 or
an open gate lead to SCR 2.
Malfunction of C1.
Check for an open capacitor C1.
Check for loose connections at capacitor
terminals.

66
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Low voltage on capacitor C1. This Status Code is indicated when SCR 2
-50 has a failure and does not go ON.
Memory Recall Indication of Fault
No Forward or Reverse contactor closes, but
motor controller does not operate.
Possible Cause
Malfunction of SCR 2 circuit.
Check for an open circuit or loose
connection between spider assembly and
SCR 5.
Check for an open circuit or loose
connection between SCR 5 and SCR 2.
Circuit Check for an open circuit or loose
Traction connection between SCR 2 and PZ11 (red
wire) and between SCR 2 gate connection
and PZ10 (white/red wire).
Check that SCR 2 goes ON with a gate
signal.

Status Code Description Cause of Status Indication

Voltage on C1 too high when motor This Status Code is indicated when the voltage
-51 current is high. on C1 is greater than 225 volts and the motor
current is greater than 300 amps.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
Too much inductance from cables.
Check that the battery cables are too long.
Circuit Check that additional cables for other
Traction equipment have been added.
Motor current too high.
Check for a short circuit at a field winding.
Check for a short circuit across an
armature winding.

67
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Voltage on C1 too high when motor This Status Code is indicated when the voltage
-52 current is low. on C1 is greater than 225 volts and the motor
current is less than 200 amps.
Memory Recall Indication of Fault
No Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
Too much inductance from cables.
Check that the battery cables are too long.
Circuit Check that additional cables for other
Traction equipment have been added.
Malfunction of diode D4 circuit.
Check for a short circuit across D4.
Check for an open circuit or loose
connection in the D4 circuit.
Malfunction of diode D3 circuit.
Check for an open circuit or loose
connection in the D3 circuit.

68
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

SCR 1 does not go OFF correctly This Status Code is indicated when any failure
-53 during plugging cycle. of SCR 1 to go OFF during the plugging cycle.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
SCR 1 failure is not caused by plugging.
Cause the traction motor to stall in both
directions and check for a new status
code that also indicates the failure. Do
Troubleshooting for the new or additional
Status Code.
Circuit SCR 1 failure is caused by plugging.
Traction
Check for an open circuit across D4.
Check for an open circuit or loose
connection in the D4 circuit.
Check current sensor for loose or open
connections. Check the yellow and green
wire from the current sensor to the control
card for open or loose connections.
Malfunction in motor circuit.
Check motor circuit for open or loose
connections.
Check motor brushes for wear and correct
installation.
Malfunction of Forward or Reverse
contactors.
Check for Forward or Reverse contactors
momentarily opening and closing during
operation when traveling over bumps and
dock plates.

69
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Short circuit in an electronic driver for the This Status Code is indicated when the
-54 Forward, or Reverse, or 1A contactor. control card has a short circuit in one of
the electronic drivers for the Forward or
Reverse, or 1A contactor.
Memory Recall Indication of Fault
Yes Motor controller does not operate.
Possible Cause
Fuse 7 is open.
Check for a short circuit that can cause
Fuse 7 to open. Replace Fuse 7.
Circuit Control card malfunction.
Traction
Replace the control card.

Status Code Description Cause of Status Indication

Polarity check of the output voltage This Status Code is indicated when the input
-57 from the current sensor. voltage to PZ4 and PZ3 is the wrong polarity.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
The yellow and green wires from the
current sensor to the control card
are connected wrong.
Check the yellow wire is connected to PZ3
and the green wire is connected to PZ4.
Circuit Check from the current sensor to the
Traction control card for open or loose connections.
Power cables are connected wrong
in motor circuit.
Check that the power cables are connected
correctly in the motor circuit.

70
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

No voltage input from current sensor for This Status Code is indicated when the
-70 regenerative braking (yellow wire). input signal to PA4 is missing.
Memory Recall Indication of Fault
No Motor controller does not operate.
Possible Cause
Open circuit in current sensor circuit
for the regenerative braking.
Circuit Check for a broken yellow wire from the
Traction current RB sensor to PA4. Check for loose
connections or a broken wire at the current
sensor. Check PA4 for a loose plug or pin
connection. Check that the control card
type is set correctly.

Status Code Description Cause of Status Indication

No voltage input from current sensor for This Status Code is indicated when the
-71 regenerative braking (green wire). input signal to PA5 is missing.
Memory Recall Indication of Fault
No Motor controller does not operate.
Possible Cause
Open circuit in current sensor circuit
for the regenerative braking.
Circuit Check for a broken green wire from the
Traction current RB sensor to PA5. Check for loose
connections or a broken wire at the current
sensor. Check PA5 for a loose plug or pin
connection. Check that the control card
type is set correctly.

71
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Regenerative braking contactor This Status Code is indicated when the control
-72 does not close. card is ready to operate and the voltage
at PA6 is 2.5 volts or greater.
Memory Recall Indication of Fault
No Regenerative braking control does
not operate.
Possible Cause
Open circuit in the PA6 circuit.
Check for open circuit or loose connections
between PA6 and the A2 connection
(positive connection) of the RB contactor.
Circuit Check for open circuit or loose connections
Traction between D7 and the A2 connection
(positive connection) of the RB contactor.

Status Code Description Cause of Status Indication

Regenerative braking contactor does This Status Code is indicated when the
-73 not open or opens slowly. RB contacts do not open within 100
milliseconds after power is removed from
the RB contactor coil.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
RB contactor malfunction.
Check the RB contactor for smooth
operation and wear on the moving parts.
Circuit Input signal to PA6 is not regular.
Traction
Check for open circuit or loose connections
in the PA6 circuit from PA6 to the A2
connection (positive connection) of the RB
contactor.

72
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Regenerative braking contactor This Status Code is indicated when the RB
-74 closes slowly. contacts do not close within 100 milliseconds
after power is applied to the RB contactor coil.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
RB contactor malfunction.
Check the RB contactor for smooth
operation and wear on the moving parts.
Circuit Input signal to PA6 is not regular.
Traction
Check for open circuit or loose connections
in the 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 contactor
coil. The correct resistance is 10 to 14
ohms.
Check for loose connections from PB2 to
the negative side of the RB coil.
Check for loose connections from battery
positive to the positive side of the RB coil.

73
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

SCR 1 does not go OFF during This Status Code is indicated when SCR 1 fails
-75 regenerative braking. to go OFF during regenerative braking.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
To find if SCR 1 fault is caused by
regenerative braking:
Cause the traction motor to stall in both
directions and check for a new status
code that also indicates the failure. Do
Troubleshooting for the new or additional
Status Code.
Circuit If Status Code 75 continues:
Traction
Check for loose connections on all power
circuits for regenerative braking.
Check for an open circuit or loose
connection in the following input circuits
for regenerative braking:
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 loose
connections.
Check motor brushes for wear and correct
installation.
Malfunction of Forward or Reverse
contactors.
Check for Forward or Reverse contactors
momentarily opening and closing during
operation when traveling over bumps and
dock plates.

74
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Voltage on C1 too high during This Status Code is indicated when the
-76 regenerative braking. voltage on C1 is greater than 225 volts
during regenerative braking.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
Bad connection or irregular connection
in battery power circuit.
Check battery power circuit for loose
connections.
Circuit Check the power fuse and battery
Traction connections that can open during
regenerative braking.
Too much inductance from cables.
Check that battery cables are too long.

Status Code Description Cause of Status Indication

Traction motor temperature too high. This Status Code is indicated when the
-90 voltage at terminal PA3 of the hydraulic
pump control card is at zero volts.
Memory Recall Indication of Fault
No Status 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 the
traction motor are too hot.
Possible Cause
Traction motor is too hot. Temperature
sensor has closed battery negative.
Permit traction motor to cool.
Circuit Other causes.
Traction and
PA3 has a short circuit to battery negative.
Hydraulic Pump
There is a short circuit in the sensor wires.
There is a short circuit or other
malfunction in the sensor.

75
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Hydraulic pump motor temperature This Status Code is indicated when the
-91 is too high. voltage at terminal PA6 of the hydraulic
pump control card is at zero volts.
Memory Recall Indication of Fault
No Status 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 the
traction motor is too hot.
Possible Cause
Hydraulic pump motor is too hot.
Temperature sensor has closed to
battery negative.
Permit the hydraulic pump motor to cool.
Circuit Other causes.
Hydraulic Pump
PA2 has a short circuit to battery negative.
There is a short circuit in the sensor wires.
There is a short circuit or other
malfunction in the sensor.

Status Code Description Cause of Status Indication

Steering pump motor brushes are worn This Status Code is indicated when the voltage
-93 and must be replaced. at terminal PA1 or PA2 of the hydraulic
pump control card is at zero volts.
Memory Recall Indication of Fault
No Status Code is indicated as a flashing
number on the instrument panel display.
Possible Cause
Steering pump motor brushes are
worn. The sensor has closed circuit
to battery negative.
Replace the brushes.
Circuit Other causes.
Steering Pump
PA* or PA* has a short circuit to battery
negative.
There is a short circuit in the sensor wires.
There is a short circuit or other
malfunction in the sensor.

76
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Traction motor brushes are worn This Status Code is indicated when the voltage
-94 and must be replaced. at terminal PA4 or PA5 of the hydraulic
pump control card is at zero volts.
Memory Recall Indication of Fault
No Status Code is indicated as a flashing
number on the instrument panel display.
Possible Cause
Traction motor brushes are worn. The
sensor has closed to battery negative.
Replace the brushes.
Circuit Other causes.
Traction and
PA4 or PA5 has a short circuit to battery
Hydraulic Pump
negative.
There is a short circuit in the sensor wires.
There is a short circuit or other
malfunction in the sensor.

Status Code Description Cause of Status Indication

Hydraulic pump motor brushes are This Status Code is indicated when the voltage
-95 worn and must be replaced. at terminal PB1 or PB2 of the hydraulic
pump control card is at zero volts.
Memory Recall Indication of Fault
No Status Code is indicated as a flashing
number on the instrument panel display.
Possible Cause
Hydraulic pump motor brushes are worn.
The sensor has closed to battery negative.
Replace the brushes.
Circuit Other causes.
Hydraulic Pump
PA2 has a short circuit to battery negative.
There is a short circuit in the sensor wire.
There is a short circuit or other
malfunction in the sensor.

77
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Maintenance Alert Code. This Status Code is indicated when the
-99 maintenance alert hours are reached.
Memory Recall Indication of Fault
No Status Code flashes ON and OFF.
Possible Cause
Circuit Maintenance Alert Hours have been
Traction (ZX reached. Do the scheduled maintenance
Control Card and reset the Maintenance Alert hours.
Only) See Function Number 19 MAINTENANCE
ALERT (Tens/Units) and Function
Number 20 MAINTENANCE ALERT
(Thousands/Hundreds) in the Handset
instructions.

Status Code Description Cause of Status Indication

Wrong control card type is selected. This Status Code is indicated when the wrong
-117 number for the control card is selected.
Memory Recall Indication of Fault
No Hydraulic motor controller does
not operate.
Possible Cause
Wrong control card type is selected.
Circuit See Function Number 17 CARD TYPE
Hydraulic Pump SELECTION in the instructions for
the Handset. Set the control card type
correctly.

78
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Low voltage to hydraulic pump This Status Code is indicated when the current
-123 contactor coil. to the coil circuit of the hydraulic pump
contactor is less than 100 milliamps.
Memory Recall Indication of Fault
No The contactor for the hydraulic pump does
not close. Status code can change between
code -123 and code -124. Do the checks for
Status Code -123 first. If the problem not
found, do the checks for Status Code -124.
Possible Cause
Malfunction in coil circuit of hydraulic
pump contactor.
Check for open circuit or loose connections
between PB4 and the battery positive side
of contactor coil.
Circuit Disconnect Plug A and check the resistance
Hydraulic Pump between PB4 and the battery positive side
of contactor coil.
Coil for contactor 1A is damaged.
Disconnect Plug A and check the resistance
between the battery positive side of the
contactor coil and its Plug A connection.
The normal resistance is 10 to 14 ohms.

79
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

T2 voltage is greater than 12% of This Status Code is indicated when T2
-124 battery voltage. voltage is greater than 12% of battery
voltage and the electronic driver for the
hydraulic pump is energized.
Memory Recall Indication of Fault
No The motor controller does not operate. The
Status Code can change between code -123
and code -124. Do the checks for Status
Code -124 first. If the problem is not
found, do the checks for Status Code -123.
Possible Cause
Malfunction of hydraulic pump contactor.
Check for welded contacts or contactors
that do not close correctly.
Circuit Check that the armature assembly moves
Hydraulic Pump freely.
Check the contactor coil. (See Status Code
-123.)
Open motor circuit.
Check for an open circuit or loose
connections in the motor circuit from the
A1 connection to the A2 connection on the
SCR control panel.
Coil for contactor 1A is damaged.
Do the checks in Status Code -123.

Status Code Description Cause of Status Indication

Hydraulic pump contactor does not This Status Code is indicated when T2
-125 open or opens slowly. voltage is greater than 12% of battery
voltage and the electronic driver for the
hydraulic pump is energized.
Memory Recall Indication of Fault
No Contacts wear quickly on contactor 1A
or the hydraulic pump contactor.
Possible Cause
NOTE: This status code can only be seen
by using the Handset or a PC and looking
at Function 1. This status code is added
as help when troubleshooting Status Code
-146.
Circuit Coil for contactor 1A is damaged.
Hydraulic Pump
Do the checks in Status Code -146.

80
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Open thermal protector or motor This Status Code is indicated when the voltage
-141 controller is too hot. between PZ1 and PZ5 is greater than 1.8 volts.
Memory Recall Indication of Fault
No The hydraulic pump motor has reduced
power or no power in the SCR range.
Possible Cause
Open circuit, thermal protector.
Check for a loose or broken wire between
the following points:
Black wire between thermal protector and
PZ1.
Gray wire between thermal protector and
PZ5.
Circuit Malfunction of thermal protector.
Hydraulic Pump
Disconnect the wires from PZ1 and PZ5.
When the temperature is approximately
25 C (77 F), measure the resistance
between the black and gray wire. The
correct resistance is approximately 300
ohms.
Thermal protector is operating because
motor controller is too hot.
Permit the motor controller to cool.

Status Code Description Cause of Status Indication

Input missing from motor current sensor. This Status Code is indicated when the voltage
-142 between PY7 and battery negative is greater
than 1.6 volts and no current is flowing
through the hydraulic pump motor circuit.
Memory Recall Indication of Fault
No No power to the hydraulic pump
motor in the SCR range.
Possible Cause
Open sensor wire circuit to PZ4.
Circuit Check for a loose or broken wire (green
Hydraulic Pump wire) between the current sensor and PZ4
on the control card.

81
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Input missing from motor current sensor. This Status Code is indicated when the voltage
-143 between PY7 and battery negative is less than
0.84 volts and no current is flowing through
the hydraulic pump motor circuit.
Memory Recall Indication of Fault
No Stall currents in the SCR range are higher
than normal and cannot be controlled
with the current link adjustment.
Possible Cause
Open sensor wire circuit to PZ3.
Circuit Check for a loose or broken wire (yellow
Hydraulic Pump wire) between the current sensor and PZ3
on the control card.

Status Code Description Cause of Status Indication

SCR 1 in the hydraulic pump controller This Status Code is indicated when SCR 1 does
-144 does not go OFF correctly. not go to OFF correctly during operation.
Memory Recall Indication of Fault
No Hydraulic pump motor continues to
operate until the battery is disconnected.
Possible Cause
Malfunction of SCR 5 circuit.
Check for a short circuit across SCR 5.
Check for a short circuit across the
suppressor for SCR 5.
Check for an open circuit across SCR 2 or
an open gate lead to SCR 5.
Circuit Malfunction of SCR 2 circuit.
Hydraulic Pump
Check for a short circuit across SCR 2.
Check for a short circuit across the
suppressor for SCR 2.
Check for a open circuit across SCR 5 or
an open gate lead to SCR 2.
Open Inductor 1X.
Check for an open circuit between T5 and
T3. The correct resistance is zero ohms.
Malfunction of SCR 1.
The OFF time for SCR 1 is not within
specifications. No easy test is possible.
Replace SCR 1 after the other checks have
been done and no other problem is found.

82
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

SCR 1 in the hydraulic pump controller This Status Code is indicated when SCR 1
-145 does not go to ON correctly. does not go ON correctly during operation.
Memory Recall Indication of Fault
Yes The hydraulic pump control does
not operate.
Possible Cause
Malfunction of SCR 2 circuit.
Check for a short circuit across SCR 2.
Check for a short circuit across the
suppressor for SCR 2.
Check for an open circuit across SCR 2 or
an open gate lead to SCR 2.
Circuit Malfunction of SCR 1 circuit.
Hydraulic Pump
Check for an open circuit or loose
connections between SCR 1 and PZ8
(white/blue wire).
Check for an open circuit or loose
connections between SCR 1 and D3
suppressor and PZ9 (blue wire).
Malfunction of SCR 1.
An open or bad gate circuit to SCR 1. No
easy test is possible. Replace SCR 1 after
the other checks have been done and no
other problem is found.

Status Code Description Cause of Status Indication

Short circuit across SCR 1 in the This Status Code is indicated when the voltage
-146 hydraulic pump controller. at T2 is greater than 85% of battery voltage.
Memory Recall Indication of Fault
No Hydraulic pump motor continues to
operate until the battery is disconnected.
Possible Cause
Malfunction of SCR 1 circuit.
Check for a short circuit across SCR 1.
(See Status Code -144.)
Check for a short circuit across the
insulator between the heat sink for SCR 1
and the base plate.
Circuit Malfunction of SCR 1 OFF circuit.
Hydraulic Pump
See Status Code -144.

83
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

SCR 2 does not go to ON correctly. This Status Code is indicated when SCR 2
-147 has a failure and does not go ON.
Memory Recall Indication of Fault
Yes Hydraulic pump motor does not operate
or continues to operate until the
battery is disconnected.
Possible Cause
Malfunction of SCR 2 circuit.
Check that SCR 2 goes ON with a gate
signal.
Circuit Check for an open circuit or loose
Hydraulic Pump connection between SCR 2 gate and PZ10
(white/red wire).
Check for an open circuit or loose
connection between SCR 1 and C1 and
through the SCR 2 circuit.

Status Code Description Cause of Status Indication

Voltage check at T2 in the hydraulic This Status Code is indicated when a voltage
-148 pump controller is less than 12% check at T2 is less than 12% of battery voltage.
of battery voltage.
Memory Recall Indication of Fault
No Hydraulic pump control does not operate.
Possible Cause
Malfunction of diode D3 circuit.
Check for a short circuit across D3.
Check for a short circuit across the
suppressor for D3.
Circuit Control card type is wrong.
Hydraulic Pump
If the hydraulic pump control is used
without a pump contactor, the control card
must be set correctly. Check for the correct
setting.

84
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

SCR 5 in the hydraulic pump controller This Status Code is indicated when SCR
-149 does not go ON correctly. 5 does not go ON correctly.
Memory Recall Indication of Fault
Yes Hydraulic pump motor does not operate
or continues to operate until the
battery is disconnected.
Possible Cause
Malfunction of SCR 5 circuit.
Check for a short circuit across SCR 5.
Check for a short circuit across the
suppressor for SCR 5.
Check for an open circuit across SCR 2 or
an open gate lead to SCR 5.
Check for an open circuit or a loose
connection between SCR 5 and PZ12
(white/purple wire).
Circuit Malfunction of SCR 2 circuit.
Hydraulic Pump
Check for a short circuit across SCR 2.
Check for a short circuit across the
suppressor for SCR 2.
Check for an open circuit across SCR 5 or
an open gate lead to SCR 2.
Malfunction of C1.
Check for open capacitor C1.
Check for loose connections of capacitor
terminals.

85
Status Code Charts 2200 SRM 557

Status Code Description Cause of Status Indication

Low voltage on capacitor C1 in the This Status Code is indicated when SCR 2
-150 hydraulic pump motor controller. has a failure and does not go ON.
Memory Recall Indication of Fault
No Hydraulic pump motor does not operate
or continues to operate until the
battery is disconnected.
Possible Cause
Malfunction of SCR 2 circuit.
Check for an open circuit or loose
connection between spider assembly and
SCR 5.
Check for an open circuit or loose
connection between SCR 5 and SCR 2.
Circuit Check for an open circuit or loose
Hydraulic Pump connection between SCR 2 and PZ11 (red
wire) and between SCR 2 gate connection
and PZ10 (white/red wire).
Check that SCR 2 goes ON with a gate
signal.

Status Code Description Cause of Status Indication

Voltage on C1 in Hydraulic pump controller This Status Code is indicated when the voltage
-151 is too high when motor current is high. on C1 is greater than 225 volts and the motor
current is greater than 300 amps.
Memory Recall Indication of Fault
Yes Hydraulic pump motor does not operate
or continues to operate until the
battery is disconnected.
Possible Cause
Too much inductance from cables.
Check that the battery cables are too long.
Check that additional cables for other
equipment have been added.
Circuit Motor current too high.
Hydraulic Pump
Check for a short circuit at field winding.
Check for a short circuit across an
armature winding.

86
2200 SRM 557 Status Code Charts

Status Code Description Cause of Status Indication

Voltage on C1 in the hydraulic pump This Status Code is indicated when the voltage
-152 controller is too high when motor on C1 is greater than 225 volts and the motor
current is low. current is less than 200 amps.
Memory Recall Indication of Fault
Yes Hydraulic pump control does not operate.
Possible Cause
Too much inductance from cables.
Check that the battery cables are too long.
Circuit Malfunction of diode D3 circuit.
Hydraulic Pump
Check for an open circuit or loose
connection in the D3 circuit.

Status Code Description Cause of Status Indication

Short circuit in electronic driver for the This Status Code is indicated when
-154 hydraulic pump contactor. the electronic driver in the control card
has a short circuit.
Memory Recall Indication of Fault
No Hydraulic pump control does not operate.
Possible Cause
Circuit Control card has a problem.
Hydraulic Pump
Replace the control card.

87
EV-100ZX SCR Motor Controller Repair 2200 SRM 557

Status Code Description Cause of Status Indication

Polarity check of the output voltage This Status Code is indicated when the input
-157 from the current sensor. voltage to PZ4 and PZ3 is the wrong polarity.
Memory Recall Indication of Fault
Yes Hydraulic pump control does not operate.
Possible Cause
The yellow and green wires from the
current sensor to the control card
are connected wrong.
Check that the yellow wire is connected
to PZ3 and the green wire is connected to
PZ4.
Check from the current sensor to the
control card for open or loose connections.
Circuit Power cables are connected wrong
Hydraulic Pump in motor circuit.
Check that battery negative cable connects
to SCR negative and the motor A2 cable
connects to SCR A2.

EV-100ZX SCR Motor Controller Repair

WARNING
Some adjustments in this section must be done
with the battery connected and power applied
to the controller. When making these adjust-
ments, make sure the drive wheels are raised
from the floor.
Some voltage measurements must be made
with the SRO circuit complete. Make sure the
drive wheels are raised from the surface be-
fore doing troubleshooting. If you are working
alone, put a weight in the seat to close the seat
switch. If your lift truck has a seat brake, use a
block behind the lower actuator bar to release
the seat brake when the operator is not in the
seat. Put the voltmeter so that you can see it
from the operator area. You can operate the
controls with your hand and also make the
voltage measurements.
Make sure you disconnect the battery and
separate the connector before you disassemble
any part of the controller. The capacitor stores
electrical energy and can cause injury if a
person discharges a capacitor through parts of
the body. AFTER the battery is disconnected,
make sure you also discharge the capacitor C1
by putting a metal bar (screwdriver or similar
tool) with an insulated handle across the two
connections to the capacitor.
NOTE: The electronic controller in many SitDrive lift
trucks cannot be seen from the operator area. Some
checks 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. Make
sure that you use the correct fastener for the part
that has been disassembled.
For a typical configuration of an EV-100ZX motor
controller refer to Figure 8.

88
2200 SRM 557 EV-100ZX SCR Motor Controller Repair

1. CONTROL CARD 8. REACTOR (INDUCTOR L1 AND 1X)

2. CAPACITOR C1 9. SCR 2 AND SCR 4 (NOT SHOWN)
3. BASE PLATE 10. SPIDER ASSEMBLY
4. SCR 1 11. SCR 5 AND SCR 2 SUPPRESSOR
5. DIODE D3 12. SCR 5 AND SCR 2 SUPPRESSOR
6. MOTOR CURRENT SENSOR 13. D4 SUPPRESSOR
7. DIODE D4 14. D3 SUPPRESSOR

Figure 8. EV-100ZX Motor Controller

89
EV-100ZX SCR Motor Controller Repair
FUSES
The fuses are found on the EV-100 control panel.
The power fuses for the traction circuit (500 amperes)
and for the hydraulic pump (325 amperes) are found
on the (+) bus bar. The condition of the fuses can
normally be checked by looking at them or checking
them with an ohmmeter. The location of the fuses
can be found in Figure 1.
SCR, CHECK
In this section, there are instructions to check the
SCRs. See Figure 9.
1. SCR 1
2. THERMAL PROTECTOR
3. CATHODE (POWER CONNECTION)
4. ANODE (POWER CONNECTION)
5. GATE
6. SCR 2 OR SCR 5
Figure 9. How to Check SCR 1, SCR 2, or SCR 5
WARNING
Make sure you disconnect the battery and
separate the connector before you disassemble
any part of the controller. Make sure you also
discharge capacitor C1.
NOTE: The following checks indicate most SCRs with
defects. The checks do not always indicate a fault
that does not occur regularly during operation. An
SCR with a type of fault that does not occur regularly
or normally indicates a resistance between the anode
and cathode of less than 100,000 ohms.
To check the SCRs, 6-volts is needed for a gate sig-
nal. Use an ohmmeter and a 6-volt supply for a gate
signal or use a Cir/Kit meter to check the SCRs. The
Cir/Kit has a 6-volt supply for testing SCRs.
90
2200 SRM 557
1. Disconnect the (+) or ( ) connection to the SCR
to make a check for a short circuit. Touch the
probes of the Cir/Kit or ohmmeter to the power
connections on the heat sinks (anode and cathode
of SCR 1). Measure the resistance. Change the
probe connections to the reverse direction and
measure the resistance. Replace the SCR if the
resistance indicates less than 50,000 ohms in ei-
ther 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 resistance
indicates zero or infinity on the R × 1 scale in ei-
ther direction.
CAUTION
Make sure you touch the gate connection only
momentarily with the 6-volt connection or you
can damage the SCR. Make sure the polarity of
your test circuit is correct.
3. Connect the (+) probe of the ohmmeter to the an-
ode and the ( ) probe to the cathode. Momentar-
ily connect 6-volts from the Cir/Kit [or a battery
between the gate (+) and the cathode ( )]. The
resistance indication on the Cir/Kit or the ohm-
meter decreases to less than 10 ohms on the R ×
1 Scale. Replace the SCR if the resistance does
not decrease when a 6-volt gate signal is applied
momentarily.
SCR ASSEMBLY
CAUTION
DO NOT USE this silicon compound on the
threads of the diodes.
NOTE: Silicon compound (Hyster Part Number.
1198757) is used between the heat sinks and the
parts of the controller. The purpose of this compound
is to fill in the micrometer size spaces between the
parts to give better heat flow. Always use a very
thin layer of compound between the parts. Too much
compound can be an insulator and cause both electri-
cal and heat faults. It is better to use no compound
instead of too much.
The SCR assembly cannot be disassembled. The
SCR assembly includes an SCR fastened between
two metal blocks used as heat sinks. The heat sinks
are also the power connections for the SCR. A plastic
case holds the complete assembly. There is a thin
2200 SRM 557
sheet of electrical insulation between the SCR 1
assembly and the base plate. The insulator permits
heat to transfer from the heat sinks to the base plate.
THERMAL PROTECTOR
The SCR 1 has a thermal protector fastened to
the cathode heat sink. See Figure 9. The thermal
protector is a resistor that changes resistance when
the temperature changes. When the temperature
is greater than 85 C (185 F), the thermal protector
changes the signal voltage to the control card. The
control card decreases the percent of ON time to
decrease the SCR 1 temperature. The normal resis-
tance for the thermal protector is 120 to 150 ohms at
18 C (65 F) when measured between pins PZ1 and
PZ5.
SCR 1 ASSEMBLY, REPLACE
1. Make notes of the positions of the suppressors
and remove the suppressors from the mount over
SCR 1. Disconnect the electric connections to the
SCR 1 assembly.
2. Remove the thermal protector from the heat
sink. Remove the two capscrews that connect
the power cables to the heat sinks (make a note
of the cathode sensor wire). Remove the two
mounting screws that hold the SCR 1 assembly
to the base plate.
CAUTION
The insulator is very thin. Dirt between the
surfaces of SCR 1 and the base plate can dam-
age the insulator and cause a short circuit.
3. Check the insulator between the SCR 1 assembly
and the base plate. Replace the insulator if it is
damaged. The insulator is also a heat conductor.
Use a very thin coat of silicon compound (Hyster
Part Number 1198757 or approved equivalent)
between the surfaces of the parts. Keep dirt from
the surfaces.
4. Install the new SCR 1 assembly. Make sure the
heat sinks make full contact with the insulator
and base plate. Check the resistance between
both heat sinks and the base plate with an ohm-
meter. A correct installation indicates infinity on
the ohmmeter.
5. Install the electrical connections to the SCR 1
assembly. Install the thermal protector on the
heat sink.
EV-100ZX SCR Motor Controller Repair
6. Install the mount and the suppressors over the
SCR 1 assembly. Make sure the connections are
made correctly.
OFF CIRCUIT FOR SCR 1
WARNING
Make sure you disconnect the battery and
separate the connector before you disassemble
any part of the controller. Make sure you also
discharge capacitor C1.
The OFF circuit for SCR 1 has the following parts:
Reactor assembly (Inductor L1 and 1X)
SCR 2
SCR 5
Suppressors for SCR 2 and SCR 5
Capacitor C1
The inductor and a capacitor assembly generate the
reverse polarity voltage to change the SCR 1 to OFF
for each pulse. SCR 2 and SCR 5 control the opera-
tion of the OFF circuit. The suppressors protect the
SCRs from electrical noise.
Reactor Assembly, Check
The reactor assembly is in a plastic case that fastens
to the base plate. The connections for the reactor are
under the mount for the suppressors and are difficult
to check with an ohmmeter. A fault does not often oc-
cur in the reactor assembly. Most faults that do occur
at the reactor assembly are caused by loose connec-
tions. The normal repair of the reactor assembly is
to replace it. This reactor assembly has two induc-
tor windings (L1 and 1X) joined by a common con-
nection. A good inductor winding indicates approxi-
mately zero ohms on the R × 1 scale.
Suppressors for SCR 2 and SCR 5, Check
The suppressors are one or more resistors, diodes,
and capacitors in a small plastic block. See Figure 8.
The suppressors prevent damage to the SCRs from
electrical noise. Sometimes a suppressor does not in-
dicate a defect except when in an operating circuit
and can cause a fault that does not occur regularly
during lift truck operation. A bad suppressor can
cause a fault similar to a bad SCR 2 or a bad SCR
5.
The best method to check for a bad suppressor is to
replace it and then check the operation of the lift
truck. The same suppressor is used for all functions.
91
EV-100ZX SCR Motor Controller Repair
SCR 2 and SCR 5, Check
NOTE: The plastic cases for SCR 2 and SCR 5 are the
same, but the part numbers are different because the
electrical components inside of the cases are differ-
ent. 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 an SCR 5 as an SCR 2. Check the part number
to make sure that you are using the correct SCR.
1. Disconnect either the (+) or ( ) power connection.
(The power connections have a (+) and ( ) mark
in the plastic case.) Touch the probes of an ohm-
meter to the (+) and ( ) power connections of the
SCR. Measure the resistance. Change the probe
connections to the reverse direction and measure
the resistance. Replace the SCR if the resistance
indicates less than 50,000 ohms in either direc-
tion. See Figure 10.
1. ANODE 3. CATHODE
2. GATE
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 resistance
indicates zero or infinity on the R × 1 scale in ei-
ther direction.
CAUTION
Make sure you touch the gate wire momentar-
ily with the 6-volt connection or you can dam-
age the SCR. Make sure the polarity of your test
circuit is correct.
NOTE: To check the SCRs, 6 volts are needed as a
gate signal. Use an ohmmeter and a 6-volt supply
for a gate signal.
92
2200 SRM 557
3. Momentarily connect 6-volts from the battery be-
tween the gate (+) and the cathode ( ). The re-
sistance indication on the ohmmeter decreases to
less than 10 ohms on the R × 1 Scale. Replace
the SCR if the resistance does not decrease when
a 6-volt gate signal is applied momentarily.
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 (Hyster Part
Number 1198757 or approved equivalent) between
the surfaces of the heat sink and the replacement
SCR. Install the SCR. Connect the electrical connec-
tions.
Capacitor C1, Check
Discharge C1 and disconnect the terminals before
checking C1 for a short circuit. Measure the re-
sistance between the terminals. The ohmmeter
indicates a low resistance and increase to more than
100,000 ohms. A capacitor with a short circuit must
be replaced. The capacitor is fastened with two
screws and brackets.
DIODES D3 AND D4
The heat sink assembly for the diodes D3 and D4 is
also the connection for the ( ) power cable. The heat
sink assembly is connected to the base plate. A thin
insulator with a silicone surface separates the heat
sink assembly from the base plate. See Figure 11.
1. DIODE D3 3. HEAT SINK
2. DIODE D4
Figure 11. Diodes D3 and D4
NOTE: The optional SCR controller used for the hy-
draulic pump has only diode D3.
2200 SRM 557 EV-100ZX SCR Motor Controller Repair

Diodes D3 and D4, Check

You need an ohmmeter to check the diodes. Discon-
nect the cathode cables from the connectors. The
diodes can stay attached to the heat sinks to make
checks.

Touch the probes of the ohmmeter to the heat sink

and the cathode cable. Measure the resistance.
Change the probe connections to the reverse di-
rection and measure the resistance. A good diode
indicates 7-14 ohms on the R × 1 Scale in one di-
rection and greater than 50,000 ohms in the other
direction.
Diodes D3 and D4, Replace
CAUTION
Do not use a hammer and punch to loosen or
tighten diodes.
NOTE: Diodes D3 and D4 have a suppressor con-
nected in parallel to the diode. Replace the suppres-
sor and test the operation if troubleshooting indi-
cates that the suppressor is bad.
Disconnect the cathode cable. Use a deep socket to
remove the diodes. Put the wire through the top of
the socket and use a handle or wrench to turn the
socket. Use a thin layer of silicone grease (Hyster
Part Number 0280577) between the surfaces of the
heat sink and replacement diode. Tighten the diode
to a torque of 3.4 N•m (30 lbf in).
1. SENSOR WIRES 2. SENSOR SHUNT
Figure 12. Motor Current Sensor
CONTACTORS
The FORWARD and REVERSE (direction) contac-
tor assemblies control the direction of current flow
through the traction motor. See Figure 13. The con-
tactor is a heavy-duty switch that opens and closes
the power circuit. The traction circuit has a FOR-
WARD and REVERSE contactor assembly. Each
contactor assembly has the following parts: two sets
of normally open (NO) contacts, two sets of normally
closed (NC) contacts, and a coil. The coil is an elec-
tromagnet that moves the NO contacts to the closed
position against spring pressure. The coil is in the
control circuit. The contactor tips are in the traction
circuit.

MOTOR CURRENT SENSOR

The motor current sensor is a short piece of the cir-
cuit bus bar with two sensor wires connected to it.
All of the traction motor current flows through this
power connector. The metal between the connection
points of the sensor wires has a small resistance.
This small resistance between the two sensor wires
sends a voltage signal to the control card. The volt-
age signal increases as the motor current increases.
The control card compares the voltage with the cur-
rent limit (C/L) adjustment. The control card con-
trols the current flow so that the traction circuit is
not damaged. See Figure 12 and Figure 8.

1. POWER 4. COIL TERMINALS

TERMINALS 5. MOUNT BRACKET
2. NC CONTACTS 6. COIL
3. NO CONTACTS

Figure 13. Direction Contactor

93
EV-100ZX SCR Motor Controller Repair
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 the
traction motor. The contacts normally have a long
service life because the current flow through the con-
tacts is stopped before the contacts open. The SCR 1
is OFF before the contactor coil is de-energized. The
only condition where the contacts open during a large
current flow is a Pulse Monitor Trip (PMT).
The other contactors used in the motor controller
have one set of NO contacts. These contactors are
not the same, but their operation is similar. A typical
contactor of this kind is shown in Figure 14.
1. POWER 4. COIL TERMINALS
TERMINALS 5. MOUNT BRACKET
2. CONTACTS 6. COIL
3. SUPPRESSOR
Figure 14. Typical Contactor Assembly
(Regenerative Braking Shown)
Contactor, Repair
Make an identification and disconnect the wires and
cables from the contactor assembly. Remove the
94
2200 SRM 557
mounting screws and remove the contactor assem-
bly. See Figure 15.
CAUTION
ALWAYS replace all of the contacts in a con-
tactor at the same time. Replace the contacts
in the contactor for the hydraulic pump after
1000 hours of operation. Replace the contacts
in the other contactors when the thickness of
any area of a contact is less than 30 percent
of the thickness of a new contact or if there is
any transfer of contact material. DO NOT USE
A FILE ON THE CONTACTS. DO NOT LUBRI-
CATE THE CONTACTS.
Contactor Contacts. The contacts in a contactor
are made of special silver alloy. The contacts look
black and rough from normal operation. This condi-
tion does not cause problems with the operation of
the lift truck. Cleaning is not necessary.
Coil. Check the coil with an ohmmeter for an open
circuit or a short circuit. Replace the coil if it is dam-
aged. Make sure the coil wires are connected again
to the correct terminals. The coils in the contactors
for the hydraulic pump and the regenerative brak-
ing have an external suppressor. The coil and the
suppressor can be checked separately with an ohm-
meter.
A suppressor diode (and sometimes a resistor in se-
ries) is part of the coil. The diode causes the ohm-
meter to indicate a difference in resistance in one di-
rection. Reverse the probes of the ohmmeter to the
opposite terminals and measure the resistance. Use
the highest resistance indication.
2200 SRM 557 EV-100ZX SCR Motor Controller Repair

1. MAGNET BASE 9. COVER 17. MOVABLE TIP

2. COIL 10. BUS 18. SPRING SEAT
3. MAGNET FRAME 11. BUS 19. TIP SPRING
4. BUS 12. RETURN SPRING 20. UPPER BUS INSULATION
5. BUS 13. ARMATURE 21. NUT
6. SPACER 14. BUS BASE 22. WASHER
7. BUS CLAMP 15. MOVABLE TIP CARRIER
8. BUS 16. PLUNGER BUSHING

Figure 15. Direction Contactor

95
EV-100ZX SCR Motor Controller Repair 2200 SRM 557

CONTROL CARD
NOTE: Do NOT remove the circuit board from the
case when replacing a control card. There are no in-
ternal repairs that can be made by service personnel.
The control card and case must be replaced as a unit.
There are special repair services available that can
repair damaged control cards. See your dealer for
Hyster lift trucks.
See Figure 16.

1. CONTROL CARD (TRACTION OR HYDRAULIC 4. PLUG PA (6-PIN) (WIDE GUIDES)

PUMP) 5. PLUG PB (6-PIN) (CLOSE GUIDES)
2. TB SCREW TERMINALS (6) 6. PLUG PY (14-PIN)
3. PLUG GUIDES 7. PLUG PZ (14-PIN)

Figure 16. Control Card Connections

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 one of the plugs must be replaced, the operation
to remove a pin connector must be done carefully. A
special tool (Hyster Part Number 897408) must be
used to remove the pin connector from the plug. How
the pin connectors are held in the plug is shown in
Figure 17. Use the tool as shown to release the lock
so that the pin connector can be removed from the
plug. If a pin connector must be removed, the service
person must work carefully so that the pin connectors
and the plug are not damaged.
When a new pin connector is installed in the plug,
make sure it is not damaged and is locked into the
correct position in the plug. If the pin connection
becomes loose during operation of the lift truck, the
malfunction is not regular and is very difficult to find
and repair.

96
2200 SRM 557
1. PLUG
2. RUBBER SEAL
3. PIN CONNECTOR (REMOVED FROM PLUG)
4. LOCK
5. PIN CONNECTOR (INSTALLED IN PLUG)
6. TOOL (HYSTER PART NUMBER 897408)
(UNLOCKS PIN CONNECTOR FOR REMOVAL)
Figure 17. Control Card Plug
Brush Wear Indicators
The brush wear indicators illuminate when the mo-
tor brushes must be replaced. The sensor wires for
the brush wear indicators are an insert in the brush
material when it is made. The sensor wires are in-
sulated from the brush material. When the brush
wears within approximately 1.5 mm (0.060 in.) of the
brush lead, the insulation between the sensor wire
and the brush material is destroyed. The connection
between the brush and the sensor wire causes the in-
dicator to illuminate.
The operation of the brush wear indicators can be
checked during periodic maintenance. The battery
must be removed from the lift truck for access to the
motors.
Use a jumper cable so that the battery can be con-
nected for operation of the motors. See Figure 18.
EV-100ZX SCR Motor Controller Repair
Disconnect the sensor wires from the outside of the
motor case. Touch the ends of the sensor wires to-
gether. The warning light illuminates if the circuit
is operating correctly. The thermal switch can be re-
placed if it is damaged. However, the motor must be
disassembled to replace the thermal switch.
NOTE: CONNECT THE BATTERY SO THAT THE
MOTOR CAN BE OPERATED. THE BATTERY MUST
BE REMOVED FOR ACCESS TO THE MOTOR. USE
A JUMPER CABLE TO CONNECT THE BATTERY TO
THE LIFT TRUCK. RAISE THE DRIVE WHEELS. SEE
HOW TO RAISE DRIVE TIRES IN THE PERIODIC
MAINTENANCE SECTION OR THE OPERATING
MANUAL.
1. RAISE DRIVE 2. JUMPER
WHEELS 3. BATTERY
Figure 18. Connect Battery for Motor Operation
WARNING
Prevent damage and injury if the lift truck
moves. Raise the drive wheels from the floor
during these tests.
Use a jumper cable so that the battery can be con-
nected for operation of the motors. See Figure 18.
Disconnect the sensor wires, one at a time, from out-
side of the motor case. Touch the end of the sensor
wire to battery negative. The warning light illumi-
nates if the circuit is operating correctly. The mo-
tor brushes must be replaced when they are worn. If
equipped with brush wear indicators, the condition
of the commutator and the motor brushes must still
be checked during periodic maintenance.
97
Theory of Operation
Theory of Operation
ELECTRONIC SPEED CONTROLS
NOTE: The description of the current flow in the
electrical circuits in this section uses the Conven-
tional Theory of Current Flow. This theory describes
the current as flowing from positive to negative. An
electric lift truck uses a two-wire electrical system.
There is no common ground through the frame. Both
the positive supply and the negative return current
flow through wires and cables. There must be a
minimum resistance of 50,000 ohms between the
electrical circuits and the frame of the lift truck.
The EV-100ZX series of motor controllers have solid-
state electronic circuits that control the operation of
a DC motor. The speed of DC motors is controlled
by the average applied voltage. The higher the aver-
age applied voltage, the faster the motor rotates. If
a switch is put in the traction motor circuit and the
switch is changed to OFF and ON quickly, the trac-
tion motor rotates. See Figure 19. The speed of rota-
tion increases as the time the switch is ON increases.
The speed of rotation decreases if the switch is OFF
for a longer time than it is ON. The speed of the mo-
tor can be controlled using this principle.
Figure 19. Basic Motor Circuit
98
2200 SRM 557
Legend for Figure 19
1. BATTERY
2. STEERING MOTOR
3. HYDRAULIC PUMP MOTOR
4. TRACTION MOTOR ARMATURE
5. TRACTION MOTOR FIELD
6. CONTACTOR
7. SCR 1 SWITCH
An electronic switch called an SCR is used to gen-
erate the rapid ON and OFF times. It has no mov-
ing parts. (An SCR is also called a thyristor in some
countries. SCR is used in this manual.)
Silicon Controlled Rectifier (SCR)
A silicon controlled rectifier (SCR) is a solid-state de-
vice that operates like a very fast switch. Rectifiers
and diodes are electronic devices that permit electric-
ity to flow in only one direction. See Figure 20. A rec-
tifier or diode permits electricity to flow easily from
the anode to the cathode. An SCR is a rectifier that
has an additional element called a gate. An SCR only
permits electricity to flow when a positive signal volt-
age is applied momentarily to the gate. An SCR per-
mits electricity to flow from the anode to the cathode
after the signal to the gate is removed. The follow-
ing conditions stop the flow of electricity through an
SCR:
• The signal voltage to the gate must be removed and
the current flow through the SCR must be momen-
tarily stopped.
• The voltage at the anode and the cathode must be
equal so that there is no current flow. The current
flow can be changed momentarily to charge a large
capacitor so that the current flow through the SCR
is momentarily 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.
2200 SRM 557 Theory of Operation

Legend for Figure 20

C. SCR ON
D. SCR OFF
1. BATTERY
2. SCR 1 SWITCH
3. CURRENT FLOW THROUGH SCR 1
4. POSITIVE GATE SIGNAL
5. TRACTION MOTOR FIELD
6. TRACTION MOTOR ARMATURE
7. CURRENT SENSOR
8. NO GATE SIGNAL
9. MOMENTARY INTERRUPTION OF CURRENT
FLOW

Motor Circuit That Operates With Pulses

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

When a signal is momentarily applied to the gate, the

SCR permits current flow from the battery through
the motor. When the gate signal is removed and the
current flow is suddenly changed to charge a large
capacitor, the SCR is changed to OFF. The battery
voltage is applied to the motor in pulses. The pulses
of energy through the SCR to the motor are very fast.
The motor cannot follow each pulse, but the motor
runs smoothly on the average voltage generated by
the ON and OFF times. The average motor voltage
applied to the traction motor is shown in Figure 21.
The frequency of the pulses also changes the aver-
age motor voltage. As the frequency of the pulses
Figure 20. SCR Control increases, the average motor voltage increases. The
controller for the motor circuit has an oscillator that
controls the ON time by sending a gate signal to the
SCR (begin the pulse).

99
Theory of Operation
Figure 21. Average Motor Voltage
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
OFF time and is controlled by the position of the ac-
celerator pedal.
100
2200 SRM 557
A potentiometer on the accelerator pedal sends a sig-
nal (5 volts decreasing to 0 volts) to the controller.
The controller has a voltage controlled oscillator that
increases in frequency when the voltage decreases
from the accelerator potentiometer. The oscillator
controls the ON time by sending a gate signal to SCR
1 (begin the pulse). The oscillator sends another sig-
nal to the special circuit that changes SCR 1 to OFF
(end of the pulse). The position of the accelerator
pedal causes a variation in the 0 to 5 volts supplied
to the oscillator and 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. See Fig-
ure 21. The minimum pulse that the controller can
give is 1 millisecond ON and 45 milliseconds OFF.
This minimum pulse occurs at the slowest speed of
lift truck travel. The pulse rate is also least.
When the oscillator frequencies give equal ON and
OFF times (approximately 1.7 milliseconds each),
the pulse rate is the greatest. Approximately 50% of
the average battery voltage is available to the motor.
The maximum average voltage to the motor gives
the highest operating speed. This voltage occurs
when the ON time is long compared to a short OFF
time. The pulse rate is again least. At the maximum
speed, the ON time is approximately 20 milliseconds
and the OFF time is approximately 0.8 millisec-
onds. This maximum speed sends approximately 96
percent of the battery voltage to the motor. Many
EV-100 controllers for the traction motor use a 1A
bypass contactor and a field weakening contactor to
increase the maximum travel speed of the lift truck.
These functions are described later in this section.
The pulse rate is approximately 50 Hertz at a low av-
erage motor voltage. See Figure 22. When the pulse
rate increases to a maximum of 300 Hertz, the av-
erage motor voltage increases. This increase in volt-
age is caused by an increase in the ON time and a
decrease in the OFF time. The continued increase
in ON time causes the pulse rate to decrease again
toward a minimum of 50 Hertz when the average mo-
tor voltage is greater than 50 percent.
2200 SRM 557
Figure 22. SCR Oscillator Frequency
Traction Circuit
The control card supplies approximately 5.0 volts
to the accelerator potentiometer for the traction
circuit. When the accelerator potentiometer is con-
nected and correctly adjusted, the voltage is 3.5 to
3.7 volts when measured between the accelerator
potentiometer and battery negative. This voltage is
measured at the slowest speed (CREEP speed) of
the lift truck and the accelerator potentiometer is at
its highest resistance. The accelerator potentiometer
decreases this voltage by decreasing the resistance
between the control card and battery negative. This
accelerator voltage controls the oscillator in the
control card when the accelerator potentiometer is
moved by the operator. The oscillator controls the
ON time of SCR 1 and controls the travel speed of
the lift truck. When the accelerator pedal is pushed
farther down, the control voltage to the control
card decreases. The maximum ON time (fast travel
speed) occurs when the control voltage is 0.0 to 0.2
volts. Most lift trucks are equipped with a bypass
circuit (1A) that is energized when the accelerator
voltage decreases to less than 1.0 volts. The 1A
Theory of Operation
bypass circuit disables the SCR control and applies
battery voltage directly to the traction motor.
Hydraulic Pump Motor
Some lift trucks are equipped with an SCR controller
to control the speed of the hydraulic pump motor.
The switches fastened to the linkage for the main
control valve change the resistance in the control cir-
cuit. These changes in the resistance change the volt-
age that controls the oscillator in the control card.
The changes in motor speed are controlled in 3 steps
instead of the continuous variation when the voltage
is controlled with a potentiometer.
SCR 1 OFF Circuit
A special circuit is necessary to generate a momen-
tary interruption in current flow to change SCR 1 to
OFF. The parts of this circuit are the capacitor C1,
inductor assembly L1, SCR 2, and SCR 5. SCR 2 dis-
charges the capacitor C1 to the cathode of SCR 1.
This discharge changes SCR 1 to OFF. SCR 5 and
the inductor L1 are used to charge the capacitor C1
with the correct polarity.
An SCR controller uses the principle of self-induction
in its operation. It is important to remember that
self-induction is like a flywheel in a mechanical de-
vice. When the torque is increased or decreased in
a mechanical device, the flywheel gives a resistance
to any change in speed. Self-induction does the same
function in an electric circuit and resists any change
in current flow.
The current flow through the motor circuit creates a
magnetic field around the power cables. When SCR
1 is changed to OFF, this magnetic field decreases
rapidly and creates an induction voltage that is pro-
portional to the current flow. At maximum current
flow, this induction voltage can be greater than 300
volts when measured across the capacitor C1.
101
Theory of Operation 2200 SRM 557

SCR 1 OFF Operation

STEP 1.
When the battery is first connected, the top plate of
C1 is connected to battery positive. The direction
contactor is closed in preparation to operate the lift
truck. C1 cannot charge immediately to battery
voltage because there is no electrical path to the
bottom plate. C1 slowly charges to battery voltage
in approximately 4 minutes because there 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 the
electrical path to the bottom plate of C1. This action
leaves the bottom plate of C1 equal to battery nega-
tive and C1 is charged to battery voltage. When C1
is charged, SCR 2 goes OFF because there is no cur-
rent flow.

102
2200 SRM 557 Theory of Operation

STEP 3.
A signal is sent to SCR 1 and SCR 5 to go ON. Current
flows through SCR 1, the motor circuit and returns to
battery negative. The polarity at point A is now posi-
tive compared to the bottom plate of C1 because SCR
1 is ON.

NOTE: The inductor L2 shown in STEP 4 is not a component in the motor controller. L2 is the symbol for the
inductance caused by the power cables when electric current flows through them.

STEP 4.
When SCR 5 is ON, the positive charge at point A
now moves through SCR 5 to change the charge on
C1. The momentary current flow through L1 creates
a magnetic field. When C1 is charged, the current
flow through SCR 5 stops and SCR 5 goes OFF. The
magnetic fields decreases and the induction voltage
causes a current flow from L1 into the bottom plate
of C1. This action of L1 charges C1 to a voltage
higher than battery voltage, making the battery side
of the capacitor (+) to appear ( ) when compared to
the charge on the bottom plate. This action leaves
the top plate of C1 negative compared to the bottom
plate, and C1 now has a reverse charge. This action
takes less than 1 millisecond.

103
Theory of Operation 2200 SRM 557

STEP 5.
The current flows through SCR 1 until a signal is
sent to SCR 2 to go ON. When SCR 2 goes ON, the
higher positive voltage moves from C1 and momen-
tarily makes point B more positive than the battery.
This momentary positive voltage makes SCR 1 go
OFF.

STEP 6.
When SCR 1 is OFF, the magnetic field around the
power cables begins to decrease. This decrease in
the magnetic field generates a voltage that causes
the bottom plate of C1 to become more negative than
battery negative. The voltage across C1 can now be
as high as 150 volts. When the current flow through
SCR 2 stops, SCR 2 goes OFF. This action leaves C1
charged at a much higher voltage. C1 is now charged
for the next cycle.

The fast pulse times and the necessary signals to the

SCRs require a special electronic control. These con-
trol cards cannot be repaired except by the manufac-
turer. A service person must replace a bad control
card with a new or rebuilt control card.

INDUCTION CURRENT FROM MOTOR
When a DC motor is controlled by a pulsed circuit,
the magnetic field in the armature and field is con-
tinuously expanding and decreasing. This expansion
and decrease of the magnetic field is lost energy for
doing work unless the controller is designed to use
this energy. A diode D3 is added to the circuit for
this purpose.
When SCR 1 goes OFF, the decreasing magnetic field
generates a voltage and current in the motor. Diode
D3 permits the current to flow through the field and
armature again to do work. See Figure 23. The
torque of a DC motor is directly proportional to the
amount of current flow through it. At slower speeds,
the motor torque is high, and SCR OFF time is rel-
atively long. When SCR 1 is OFF, the decreasing
magnetic field generates a voltage and current in the
motor. (This current is often called the flyback cur-
rent.) Diode D3, often called the flyback diode, per-
mits the current to flow through the field and arma-
ture again to do work. At slower speeds, motor torque
is high without a high current draw from the bat-
tery. (High current draw from the battery is to be
avoided if possible, because it is less efficient.) At
higher speeds, the torque requirement is less, but
SCR 1 OFF time is also less, so that less induction
current (flyback current) is generated. Most of the
motor current comes from the battery at high speeds.

104
2200 SRM 557 Theory of Operation

The graph in Figure 23 shows the typical induction
current during equal ON and OFF times of SCR 1.
The three groups of components are fastened to the
rear plate of the battery compartment. Typical con-
troller configurations are shown in Figure 1. (If the
SCR controller for the hydraulic pump motor is not
used, a single contactor for the hydraulic pump mo-
tor is installed in that position.)

The control card makes checks as part of the logic

sequence. The control card only permits lift truck
operation during the correct conditions. The control
card checks and controls the functions described in
the following paragraphs.

Pulse Monitor Trip (PMT) (Traction Circuit

Only)
The PMT circuit is part of the control card function.
When the SRO checks are complete, the control card
senses the voltage across SCR 1. If the voltage across
SCR 1 stays at a low voltage, there is a fault in the
traction circuit. If the control card senses a short cir-
cuit (low voltage) across SCR 1, it does not permit
a direction contactor to close. The PMT circuit also
checks the traction circuit for faults during lift truck
operation. If SCR 1 stays ON for greater than 32 mil-
liseconds, the PMT circuit opens the direction contac-
tor. The control card immediately closes the contac-
tor again. If the fault occurs again, the control card
opens the contactor until the fault is corrected or the
PMT circuit is reset. The circuit is reset when the
key switch is turned to OFF and then to ON again.

When the control card senses a fault across SCR 1, it

removes the signal that closes a direction contactor.
A loss of signal from the control card de-energizes
1. BATTERY 5. MOTOR and opens the direction contactors. A PMT occurs
2. SCR 1 (OFF) ARMATURE when the control card senses a malfunction in the
3. DIODE D3 6. MOTOR CURRENT operation of SCR 1 and stops sending a signal to the
4. MOTOR FIELD SENSOR direction contactors.
Figure 23. Induction Current SRO Circuit (Traction Circuit Only)
CONTROL CARDS The lift truck is equipped with a safety circuit, called
the Static Return to OFF (SRO) circuit, that pre-
The control cards for the traction circuit and the hy- vents the operation of the lift truck if the starting se-
draulic circuit are described separately in the follow- quence is not correct. The function of the SRO circuit
ing paragraphs. is to make sure the operator is in the seat and ready
NOTE: The configuration of the controller divides the to operate the controls. The starting sequence:
base plate into three groups: 1. The operator must be on the operator’s seat and
1. Traction controller group the seat switch closed. (The seat switch closes
2. Contactor group when the weight of the operator is on the seat.)
3. Controller group for the hydraulic pump motor

105
Theory of Operation
2. Turn the key switch to the ON position. The key
switch supplies the battery voltage to the control
circuits.
3. Move the direction lever to FORWARD or RE-
VERSE. Move the accelerator pedal to close the
START switch after Step 1 and Step 2 are com-
plete. The operator’s foot must be removed from
the brake pedal so that the brake switch is closed.
If Step 3 is done before Step 1 and Step 2, the lift
truck does not travel in either direction. The seat
switch and key switch each send a signal voltage to
a timer circuit. Both voltages must be sent to the
timer circuit before the timer sends a voltage signal
to terminal TB3 on the control card. The timer cir-
cuit has a 6-second delay if the seat switch is opened.
Figure 24. Sequence of Operation
106
2200 SRM 557
This delay permits the operator to change position in
the seat without causing the lift truck to stop. The
voltages from the parts to the SRO circuit are sent to
the control card. The SRO circuit is reset when the
START switch or a direction switch is momentarily
opened.
The control card must sense battery voltage at ter-
minals TB4 and TB3, then at TB2, then at TB6 (seat
switch closed) or the control card will not permit a
direction contactor to close.
SEQUENCE OF OPERATION
The sequence of operation describes a complete cycle
of the SCR traction circuit in Figure 24.
2200 SRM 557 Theory of Operation

Control Card Adjustments (Traction

Circuit)
The control card checks the current in the traction
circuit and controls the current to prevent damage.
The control card has several control adjustments.

The control card for the traction circuit has a con-

trol adjustment called CREEP. This adjustment con-
trols the minimum current level in the traction cir-
cuit when the direction contactors are closed. This
adjustment can be changed to meet the needs of a
specific application. The CREEP adjustment con- 1. SENSOR WIRES 2. SENSOR SHUNT
trols how far the accelerator pedal moves between
the closing of the START switch and the application Figure 25. Motor Current Sensor
of enough power to move the lift truck. This adjust- The 1A or Bypass Circuit permits the battery to
ment is only made after the adjustment between the be connected directly to the traction motor. See Fig-
accelerator pedal and the accelerator potentiometer ure 26. This circuit disconnects the control of the
is correct. SCR circuit and is used for maximum power from the
The C/A (Controlled Acceleration) adjustment traction motor. When the battery is connected to the
controls the maximum rate that the average voltage traction motor through the 1A circuit, the maximum
is increased by the controller to accelerate the trac- voltage available to the traction motor is increased
tion motor. This maximum rate is not controlled by by approximately 10 percent.
the rate that the accelerator pedal is pushed down
for maximum acceleration. A high rate of accelera-
tion increases the wear on the brushes of the traction
motor. The acceleration time can be adjusted for the
operating conditions of the user. The acceleration
rate can be adjusted to give a smooth acceleration
for better load handling.

The C/L (Current Limit) adjustment controls the

pulse rate if the current flow reaches the limit set by
the adjustment. The traction circuit has a current
sensor in the power circuit in series with the trac-
tion motor. All of the current that flows through the
traction motor flows through the current sensor. The
current sensor is a shunt with two sensor wires con-
nected. See Figure 25. The metal of the shunt has a
small resistance between the two sensor wires. This
small resistance sends a signal voltage to the control
card. This signal voltage increases as the motor cur-
rent increases. The control card compares the signal 1. BATTERY 5. MOTOR
voltage with the C/L adjustment. When the signal 2. SCR 1 (OFF) ARMATURE
voltage reaches the limit set on the C/L, the control 3. DIODE D3 6. MOTOR CURRENT
card reduces the pulse rate. The current sensor is 4. MOTOR FIELD SENSOR
7. CONTACTOR 1A
connected between the heat sink for D3 and D4 and
the terminal for a power cable. Figure 26. 1A Bypass Circuit

107
Theory of Operation
The control card controls the operation of the 1A cir-
cuit. A 1A TIME adjustment permits the SCR con-
trol to begin the operation of the traction motor be-
fore the 1A contactor closes. This time delay prevents
full battery current being applied across the traction
motor when it is not rotating. (Full battery voltage
applied across a stalled traction motor causes a large
current draw. This large current draw causes a large
amount of heat in the motor and wastes battery en-
ergy.) This adjustment also permits smoother oper-
ation of the lift truck. The control card begins 1A
TIME when the accelerator voltage is decreased to
less than 1.0 volts. 1A TIME is normally 1 to 3 sec-
onds. The full battery power is available to the trac-
tion motor through the 1A circuit after the time delay
1A TIME.
PLUG. Plugging uses the traction motor as a brake
to slow or stop a lift truck. When a lift truck is be-
ing stopped, the motion of the lift truck causes the
traction motor to rotate and operate like a generator.
Plugging uses a current flow from the battery to be
opposite the current flow generated by the traction
motor. Plugging generates heat in the traction mo-
tor. See Figure 27.
1. BATTERY 6. MOTOR CURRENT
2. SCR 1 (OFF) SENSOR
3. DIODE D3 7. CONTACTOR 1A
4. MOTOR FIELD 8. DIODE D4
5. MOTOR
ARMATURE
Figure 27. Plugging Circuit
108
2200 SRM 557
Plugging is energized when the direction switches
in the direction control lever are moved to the op-
posite direction from which the lift truck is travel-
ing. The direction contactors change to their opposite
positions and reverse the current flow through the
motor field. The induction current generated in the
traction motor now flows opposite to the current flow
from the battery. The lift truck stops very quickly if
the induction current is not controlled. A diode D4
permits part of the induction current from the ar-
mature to flow with the battery current through the
armature again. This reduction of the opposite in-
duction current permits the lift truck to stop more
smoothly.
The control card for the traction circuit has a PLUG
adjustment. This adjustment controls the maximum
application of the plugging current. The position of
the accelerator pedal controls the plugging distance
up to the maximum application. This adjustment can
be changed as needed for an operator. The shorter
the plugging distance, the faster is the wear on the
traction motor brushes.
Regenerative Braking. When a lift truck is be-
ing stopped, energy is generated by the traction mo-
tor. The lift truck causes the traction motor to ro-
tate and operate like a generator. Plugging uses bat-
tery energy in opposition to the energy generated by
the traction motor. This energy generates heat in
the traction motor. Lift trucks used in heavy duty
operations can generate enough heat to damage the
traction motors and cause the motor brushes to wear
rapidly.
Regenerative braking returns the energy generated
by the traction motor to the battery. See Figure 28.
The regenerative braking contactor opens during re-
generative braking. When the voltage generated by
the traction motor is less than the battery voltage,
the lift truck moves slowly. The contactor for re-
generative braking then closes and plugging is used
to stop the slowly moving lift truck. Regenerative
braking generates less heat in the traction motor and
reduces brush wear. Another electric circuit must
be added to the motor controller to control this op-
eration. The energy generated during regenerative
braking must be controlled within limits so that the
parts of the electric circuit are not damaged. The ad-
justments used to control regenerative braking are:
2200 SRM 557 Theory of Operation

When the plugging function is in operation, the volt-

age generated by the traction motor is normally less
than battery voltage.

Field Weakening. Some 36-48 volt lift trucks and

some 72-80 volt XM series lift trucks have a field
weakening circuit. The field weakening circuit per-
mits a faster travel speed than the 1A circuit. The
traction motor must be operating during 1A condi-
tions of high speed and small load before the field
weakening circuit is used.

The field weakening contactor connects a bypass

shunt around the motor field. This shunt gives a
second path for the current flow and weakens the
magnetic field in the motor field. The increased
current flow through the armature causes the motor
to turn faster. See Figure 29. This increased speed
caused by field weakening is only possible when the
traction motor has a small load, for example, high
speed travel on a flat surface. The field weakening
decreases the power available from the traction
motor to increase the travel speed.
1. BATTERY 8. DIODE D4
2. SCR 1 (OFF) 9. REGENERATIVE
3. DIODE D3 BRAKING (RB)
4. MOTOR FIELD CONTACTOR
5. MOTOR 10. DIODE D7
ARMATURE 11. REGENERATIVE
6. MOTOR CURRENT BRAKING
SENSOR CURRENT
7. CONTACTOR 1A SENSOR

Figure 28. Regenerative Braking

REGEN C/L (Regenerative Braking Current Limit)

REGEN D.O. (Regenerative Braking Drop Out)

The regenerative braking current limit controls

the maximum application of regenerative braking
during operation. The position of the accelerator
pedal by the operator controls the plugging distance
up to the limit set by the REGEN C/L adjustment.

The regenerative braking drop out adjusts the

voltage level where the regenerative braking contac-
tor closes during regenerative braking. The regener- 1. BATTERY 7. CONTACTOR 1A
ative braking contactor closes when the key switch is 2. SCR 1 (OFF) 8. FIELD
turned to ON. During regenerative braking, the con- 3. DIODE D3 WEAKENING (FW)
tactor opens and the energy generated by the traction 4. MOTOR FIELD CONTACTOR
5. MOTOR 9. FIELD
circuit is sent to the battery. When the voltage level ARMATURE WEAKENING (FW)
is less than the level set by the REGEN D.O., the re- 6. MOTOR CURRENT RESISTOR
generative braking contactor closes and the remain- SENSOR
der of the lift truck speed is decreased by plugging.
Figure 29. Field Weakening Circuit

109
Theory of Operation
The field weakening contactor is controlled by two
adjustments 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 with a
small load, the armature current decreases to a min-
imum current of approximately 185 amperes. The
F.W.P.U. is adjusted to close the field weakening con-
tactor at approximately 1.3 times this minimum ar-
mature current. The field weakening shunt is a strip
of metal that connects the field weakening contac-
tor to the FORWARD and REVERSE contactors.
The field weakening shunt is calibrated at less than
1.0 ohm and is parallel to the field of the traction
motor in the circuit. The field weakening contactor
closes after the 1A contactor closes. The 1A contac-
tor closes after the accelerator potentiometer voltage
is less than 1.0 volts and the 1A TIME function has
occurred.
If the lift truck begins to travel up a ramp, the ar-
mature current increases. When the armature cur-
rent increases 2.75-3.0 times the minimum armature
current, the F.W.D.O. opens the field weakening con-
tactor. If the accelerator pedal is moved to a slower
speed, the control card opens the field weakening
contactor.
RAMP START is a function of the EV-100LX control
card for the traction circuit. This function permits an
operator to stop a lift truck with a load when going
up a slope. If the operator does not change the direc-
tion controls, the lift truck can be started again on
the slope. A lift truck often rolls backward a little
distance when starting again on a slope. If the oper-
ator does not change the direction controls, the con-
trol card does not sense the reverse operation of the
motor armature and applies enough power to go up
the slope. If the operator has changed the direction
controls, the control card senses that the expected op-
eration is PLUGGING when the lift truck rolls back-
ward. The control card does not apply enough power
during PLUGGING to make the lift truck go up the
slope.
Accelerator Control
The control card supplies approximately 5.0 volts at
terminal TB1 of the control card. The accelerator
potentiometer decreases the voltage between TB1 of
the control card and battery negative. This voltage
controls the frequency of the oscillator which controls
the SCR speed of the lift truck.
110
2200 SRM 557
The voltage signal from the accelerator potentiome-
ter is 0-5 volts. The voltage is normally adjusted to
3.5-3.7 volts. At 3.50-3.7 volts, the lift truck moves at
CREEP speed. The 1A TIME begins its cycle at 1.0
volts so that the 1A contactor can close. The max-
imum speed of the lift truck when operating in the
SCR range occurs when the voltage is 0.0-0.2 volts.
The 1A contactor applies battery voltage directly to
the traction motor.
SCR CONTROL (HYDRAULIC PUMP
MOTOR)
The control card for the hydraulic pump motor is not
the same as the control card for the traction circuit.
This control card has a different label. The SCR func-
tion for speed control is the same, but the many func-
tions necessary for control of a traction circuit are not
needed for the hydraulic pump motor. A contactor is
not used in the power circuit. The 325-ampere fuse
for the hydraulic pump circuit is found between the
(+) bus bar and the SCR 1 anode of the controller.
This control card does not have an SRO check nor
a PMT check. If SCR 1 has a short circuit, the hy-
draulic pump motor runs until the battery is dis-
connected. The main control valve is an open cen-
ter valve and the hydraulic function stops when the
hand lever is returned to the NEUTRAL position.
The SCR controller for the hydraulic pump motor
controls the motor at three speeds:
Speed 1 is for the TILT function and for optional
functions that require the third or fourth spool of
the main control valve (slow speed for some attach-
ments).
Speed 2 is for the low speed LIFT function and
high speed operation of an optional function that re-
quires the third spool of the main control valve.
Speed 4 is only for the high speed LIFT function.
This speed applies full battery voltage across the hy-
draulic pump motor. The SPD 3 adjustment is not
used.
The control card sends three reference voltages to the
switches controlled by the linkage to the main con-
trol valve. When a contact on a switch is closed, the
reference voltage is connected with battery negative
and the control card senses the change in the refer-
ence voltage. The voltage controlled oscillator in the
control card causes SCR 1 to operate at a certain fre-
quency (see the paragraphs that describe Electronic
2200 SRM 557 Theory of Operation

Speed Controls). The speeds of operation can be ad- REVERSE) each have two sets of NC and NO con-
justed for an operating application. tacts. When a coil for a direction contactor is en-
ergized, the NO contacts close and the NC contacts
CONTACTORS open. This design prevents the contacts from being
closed in the wrong sequence.
Contactors are switches, controlled by electromag-
nets, that close and open a power circuit. The con-
trol card has internal electronic drivers and the elec-
tronic drivers control the current to the coils of the
electromagnets for the contactors. The electromag-
netic field in the coil moves the armature against
spring pressure to close the contact. When the coil is
de-energized, the spring pressure moves the arma-
ture and opens the contacts. When a spring holds
the contacts of a switch open, the switch is called
normally open (NO). If a spring holds the contacts of
a switch closed, the switch is called normally closed
(NC).

Some lift trucks have an SCR control for the hy-

draulic pump motor. Some lift trucks also have
an electronic driver that energizes the coil for the
hydraulic pump contactor.

Lift trucks equipped with regenerative braking, 1A,

and field weakening circuits have contactors with 1. POWER 5. MOUNT BRACKET
TERMINALS 6. COIL
one set of NO contacts. See Figure 30. When the lift 2. NC CONTACTS (SUPPRESSOR
truck does not have an SCR controller for the hy- 3. NO CONTACTS IS ADDED TO
draulic pump motor, the hydraulic pump contactor 4. COIL TERMINALS OUTSIDE OF COIL)
also has one set of NO contacts.
Figure 31. Direction Contactor

CIRCUIT PROTECTION
Traction Circuit Fuse
The 500 ampere fuse for the traction circuit is found
on the motor controller between the (+) bus bar and
the anode of SCR 1. If the current flow becomes great
enough to damage the traction circuit because of a
short circuit or electrical overload, the fuse fails.

Current Limit
SCR 1 becomes damaged from heat unless the cur-
rent flow has limits. A current sensor is installed in
1. POWER 4. COIL TERMINALS the traction circuit between the armature and bat-
TERMINALS 5. MOUNT BRACKET tery negative. The current sensor sends a voltage
2. CONTACTS 6. COIL
3. SUPPRESSOR signal to the control card. The control card compares
the adjustment C/L with the signal from the current
Figure 30. Typical Contactor Assembly sensor. If the current flow reaches the limit, the con-
(Regenerative Braking Shown) trol card overrides the other signals to the oscillator.
The pulse width and frequency are decreased to de-
A typical set of direction contactors is shown in Fig- crease the average motor current.
ure 31. The direction contactors (FORWARD and

111
Theory of Operation 2200 SRM 557

Thermal Protection an SCR controller for the hydraulic pump motor, a

TMM1 card is added to the controller. The TMM1 re-
The parts of the traction circuit can be damaged by ceives the signals from the brush wear sensors and
too much heat. A heat sensor is connected to the motor temperature switches and sends the signals
SCR 1 heat sink. When the temperature increases through the traction controller to the display panel.
toward the design limit [85 C (185 F)], the resistance See Figure 33 and Table 8.
in the sensor increases. This increase in resistance
decreases the SCR 1 ON time by decreasing the pulse
width and frequency to SCR 1. The average motor
current is decreased to prevent damage. When the
heat sink cools, the thermal protection returns the
control to normal operation. This input signal over-
rides all other input signals (except the 1A signal) to
the oscillator during lift truck operation.

Suppressors
Electrical noise is high voltage pulses caused by
other electric parts operating momentarily. Electri-
cal noise can damage SCRs and diodes. Suppressors
are included in the controller to prevent electrical
noise from entering SCRs and the control card and
damaging the electronic parts. The suppressors are
one or more resistors and capacitors in a small plas-
tic block. They are installed on a mount as shown in
Figure 32.

TRUCK MANAGEMENT MODULE (TMM1)

The Truck Management Module is a multifunction
accessory card that can be used to give additional sta- NOTE: DOTTED LINES INDICATE INTERNAL CON-
tus codes or operator warnings on the display panel NECTIONS.
display. If a lift truck has brush wear indicators
Figure 32. Suppressor Mount
and motor temperature switches and does not have

Figure 33. Truck Management Module (TMM1)

112
2200 SRM 557 Theory of Operation

Table 8. Terminal and Plug Wire Connections for TMM1 Module

Input Output
Output Fault
Terminal Function Terminal Actuation
Voltage Code
No. No.
TB1 Signal wire for temperature switch, TB7 Battery - 0.6 volts 90
traction motor.
TB2 Not Used. — — — —
TB3 Signal wire for temperature switch, TB7 Battery - 1.6 volts 91
hydraulic pump motor.
TB4 Not Used. — — — —
TB5 Signal wire for brush wear indicator, TB9 Battery - 0.6 volts 93
steering pump.
TB6 Signal wire for brush wear indicator, TB9 Battery - 0.6 volts 93
steering pump.
TB7 Not Used. — — — —
TB8 Signal wire for brush wear indicator, TB9 Battery - 1.6 volts 94
traction motor.
TB9 Not Used. — — — —
TB10 Signal wire for brush wear indicator, TB9 Battery - 1.6 volts 94
traction motor.
TB11 Signal wire for brush wear indicator, TB9 Battery - 2.3 volts 95
hydraulic pump motor.
TB12 Signal wire for brush wear indicator, TB9 Battery - 2.3 volts 95
hydraulic pump motor.
TB13 5-volt supply.
TB15 Battery negative.

DISPLAY PANELS
Display Panel
WARNING
Some adjustments can cause the lift truck to
operate differently than normal. This different
operation of the truck can result in personal
injury or damage. Do NOT try to make adjust-
ments for the instrument panel display with-
out using the procedures in the section EV-100/
200ZX Motor Controller Parameter Tables 2200
SRM 595.
There are two display panels available on lift trucks
with the EV-100ZX SCR motor controller:
• a basic display that gives the operator basic infor-
mation about the operation of the lift truck
• a performance display that includes diagnostic ca-
pabilities similar to the Handset
Some lift trucks can only have one of the two panel
displays.
Basic Display
The EV-100 ZX Series motor controller can have two
Basic display panels that includes one of two types of
Battery Indicators.

113
Theory of Operation 2200 SRM 557

Early Display Panel operation with a discharged battery can dam-

When the key switch is turned to the ON position,
a start program causes each warning light to illu-
minate to show that the function is operating. This
early display panel has the following functions (see
Figure 34):
(1) Hourmeter. The hourmeter display shows the
operating time of 0000 to 9999 hours. The time for
the traction circuit is shown for 4 seconds after the
lift truck is operating and the key is turned to the
OFF position.
CAUTION
Operating the lift truck with the needle in the
red band can decrease battery life. Continued
age the battery, motors or the contactors.
(2) Voltmeter. The earlier Basic Display Panel has
a battery indicator without lift interrupt (voltmeter).
This meter has a green, yellow and red band on the
meter face to indicate the voltage of the battery. The
needle starts in the green band with a fully charged
battery and moves to the red band as the battery
discharges. The battery must have a current draw
(load) to check the battery charge. Hold the tilt lever
in the tilt BACKWARD position or for the N30XMH,
hold the rotate lever in the ROTATE position and
look at the indicator. If the needle is in the red band,
charge the battery.

Standard Display 18-Pin Connector

Pin Function Pin Function
1-11 No Connection 15 Hyd. Contactor Coil
12 Battery Negative ( ) 16 Seat Switch
13 Parking Brake Switch 17 Key Switch (IGN)
14 Brake Fluid Switch 18 Battery Positive (+) (from Fuse 6)

1. HOURMETER 6. KEY SWITCH LEADS

2. BATTERY METER 7. RED/BRN IGN TERMINAL
3. PARKING BRAKE INDICATOR 8. BRN BAT TERMINAL
4. BRAKE FLUID TOO LOW INDICATOR 9. 18-PIN CONNECTOR
5. SEAT BELT INDICATOR

Figure 34. Basic Display Panel and Plug Connector (Early Display Panel)

114
2200 SRM 557
(3) Warning light, parking brake indicator. The
red light is ON when the parking brake is applied
and the seat switch is closed, and goes OFF when
the parking brake is released.
(4) Warning light, brake fluid reservoir is low
(Early Only). The red light is ON for 1 second when
the key switch is turned to the START position and
must go OFF after 1 second. If the warning light
is ON during operation, the brake fluid level in the
reservoir is too low.
(5) Warning light, fasten seat belt. The red light
is ON for 8-10 seconds after the key switch is turned
to the ON position.
Later Display Panel
When the key switch is turned to ON, a start pro-
gram causes each warning light to illuminate to show
that the function is operating. This later display
panel has the following functions:
(1) Battery Charge Indicator With Lift Inter-
rupt. Later Basic display panels have a battery
indicator that is a scale with a series of 5 round
LEDs in three colors (green, orange, red). See Fig-
ure 35. There are two green LEDs and bars at the
top, two orange LEDs and bars in the center and
a red LED and bar at the bottom. As the battery
voltage decreases during operation, different LEDs
illuminate to indicate a discharged battery. No more
than two LEDs are illuminated at one time. When
the battery is fully charged, the two green LEDs
of the scale are illuminated. When the battery dis-
charges during operation, the LEDs illuminate from
1. BATTERY DISCHARGE INDICATOR
2. PARKING BRAKE SYMBOL AND LED
Figure 35. Basic Display Panel and Plug Connector (Later Display Panel)
Theory of Operation
top to bottom (green to red). The red LED indicates
that the battery is discharged. The battery must
be charged or a charged battery must be installed
before lift truck operation can continue.
The battery charge indicator uses the traction control
shunt to measure the current during operation. This
current and battery voltage are checked at the same
time for an accurate reading of battery voltage with
a load (during use). This method can make operation
of the lift truck different when the battery is low or a
different battery is connected. This method permits
better use of the battery charge.
The controller also checks the battery voltage each
time a battery is connected. The traction control pre-
vents lift truck operation if the battery voltage is not
correct as set by traction function 15. A status code of
-16 (voltage too high) or -15 (voltage too low) indicates
on the display panel. The battery can have a voltage
that is too high or too low. A battery with the cor-
rect voltage can also be deeply discharged from use
or other reasons and have a voltage that is less than
the minimum of the voltage range.
Batteries that have different ampere hour ratings or
are of different ages can sometimes be used in the
same lift truck. It can be necessary to adjust trac-
tion Function Number 14 so that the weakest battery
is not damaged. Follow the procedure for adjusting
traction in Traction Control Cards (Label Letters -
ZH and ZY).
3. FASTEN SEAT BELT SYMBOL AND LED
4. DIGITAL DISPLAY
115
Theory of Operation
(2) Warning light, parking brake indicator. The
red light is ON when the parking brake is applied
and the seat switch is closed, and goes OFF when
the parking brake is released.
(3) Warning light, fasten seat belt. The red light
is ON for 8-10 seconds after the key switch is turned
to the ON position.
(4) Digital Display. This indicator is blank when
the lift truck is operating correctly. The status codes
and the hourmeter values are shown on this four-
digit LCD display. When a fault occurs, the status
code is shown with a dash (-) in the left digit posi-
tion. The warning light, Service Interval is also illu-
minated when a fault occurs.
When it is time for periodic maintenance, the warn-
ing light, Service Interval is illuminated and a status
code -99 is indicated. The register in the controller
card must be reset by the service person before this
warning light goes OFF.
The hourmeter display shows the operating time of
0000 to 9999 hours. The time for the traction cir-
cuit is shown for 4 seconds after the lift truck is op-
erating and the key is turned to the OFF position.
The indicator lights for the traction motor and for the
hourmeter will also be illuminated during this time.
If there is an SCR control card for the hydraulic pump
motor, this time will then be shown on the hourme-
ter for another 4 seconds. The indicator lights for the
hydraulic motor and for the hourmeter are also illu-
minated during this time.
Performance Display
When the key switch is turned to the ON position,
a start program causes each warning and indicator
light to illuminate to show that the function is op-
erating. The functions and operation of the indica-
tors for these early and later display panels is the
same. These display panels have the following func-
tions (see Figure 36 and Figure 37):
(1) Battery Charge Indicator With Lift Inter-
rupt. This battery charge indicator shows the
battery charge with an LED bar graph. There are
four green bars, four orange bars, and two red bars.
When the battery is discharged during operation, the
LED bar that is illuminated decreases sequentially
from the top green bar through the orange bars to
the red bars. When the battery is discharged to the
red LED bars, the battery is 73 percent discharged
116
2200 SRM 557
and the lift interrupt function does not permit op-
eration of the hydraulic motor. The battery must
be charged or a charged battery must be installed
before lift truck operation can continue. The top
green bar is illuminated when the battery is more
than 90 percent charged.
The battery charge indicator uses the traction control
shunt to measure the current during operation. This
current and battery voltage are checked at the same
time for an accurate reading of battery voltage with
a load (during use). This method can make operation
of the lift truck different when the battery is low or a
different battery is connected. This method permits
better use of the battery charge.
The controller also checks the battery voltage each
time a battery is connected. The traction control pre-
vents lift truck operation if the battery voltage is not
correct as set by traction Function Number 15. A sta-
tus code of -16 (voltage too high) or -15 (voltage too
low) is indicated on the display panel. The battery
can have a voltage that is too high or too low. A bat-
tery with the correct voltage can also be deeply dis-
charged from use or other reasons and have a voltage
that is less than the minimum of the voltage range.
Batteries that have different ampere hour ratings or
are of different ages can sometimes be used in the
same lift truck. It can be necessary to adjust trac-
tion Function Number 14 so that the weakest battery
is not damaged. Follow the procedure for adjusting
traction Function Number 14 in the Checks And Ad-
justments.
(2) Digital Display. This indicator is blank when
the lift truck is operating correctly. The status codes
and the hourmeter values are shown on this four-
digit LCD display. When a fault occurs, the status
code is shown with a dash (-) in the left digit posi-
tion. The warning light, Service Interval (11) is also
illuminated when a fault occurs.
The hourmeter display shows the operating time of
0000 to 9999 hours. The time for the traction cir-
cuit is shown for 4 seconds after the lift truck is op-
erating and the key is turned to the OFF position.
The indicator lights for the traction motor and for the
hourmeter are also illuminated during this time. If
there is an SCR control card for the hydraulic pump
motor, this time is then shown on the hourmeter for
another 4 seconds. The indicator lights for the hy-
draulic motor and for the hourmeter are also illumi-
nated during this time.
2200 SRM 557 Theory of Operation

Enhanced Display 18-Pin Connector

Pin Function Pin Function
1 Traction Card PY 5 10 Pump Card PY 4
2 Pump Card PY 5 11 Brush Wear Indicator & Temperature
Jumper*
3 No Connection 12 *
4 Traction Card PY 14 13 Parking Brake Switch
5 Traction Card PY 13 14 Brake Fluid Switch
6 Pump Card PY 14 15 No Connection
7 Pump Card PY 13 16 No Connection
8 No Connection 17 Key Switch (IGN)
9 Traction Card PY 4 18 No Connection
*Pin 11 to 12 Jumper (in Wire Harness). BWI and Temperature LEDs Disabled if Cut.

1. BATTERY DISCHARGE INDICATOR 11. STATUS CODE MAINTENANCE INDICATOR

2. DIGITAL DISPLAY 12. HOURMETER INDICATOR
3. FASTEN SEAT BELT INDICATOR 13. STATUS CODE BUTTON
4. BRAKE FLUID TOO LOW INDICATOR 14. PERFORMANCE LEVEL BUTTON
5. PARKING BRAKE INDICATOR 15. PERFORMANCE LEVEL LEDS
6. STEERING PUMP MOTOR INDICATOR 16. KEY SWITCH LEADS
7. BRUSH WEAR INDICATOR 17. RED/BRN IGN TERMINAL
8. TRACTION MOTOR INDICATOR 18. BRN BAT TERMINAL
9. LIFT PUMP MOTOR INDICATOR 19. 18-PIN CONNECTOR
10. MOTOR TEMPERATURE INDICATOR

Figure 36. Performance Display Panel and Plug Connector (Early Display Panel)

117
Theory of Operation
1. BATTERY DISCHARGE INDICATOR
2. DIGITAL DISPLAY
3. FASTEN SEAT BELT INDICATOR
4. BRAKE FLUID TOO LOW INDICATOR
5. PARKING BRAKE INDICATOR
6. STEERING PUMP MOTOR INDICATOR
7. BRUSH WEAR INDICATOR
8. TRACTION MOTOR INDICATOR
Figure 37. Performance Display Panel and Plug Connector (Later Display Panel)
(3) Warning Light, Fasten Seat Belt. The red light
is ON for 8-10 seconds after the key switch is turned
to the ON position.
(4) Warning Light, Brake Fluid Reservoir Is
Low (Early Only). The red light is ON for 1 sec-
ond when the key switch is turned to the START
position and must go OFF when the key switch is in
the ON position. If the warning light is ON when
the key switch is in the ON position, the brake fluid
level in the reservoir is too low.
(5) Warning Light, Parking Brake Indicator.
The red light is ON when the parking brake is
applied and the seat switch is closed and goes OFF
when the parking brake is released.
A warning buzzer makes a noise if the operator
leaves the seat (key switch ON) and the parking
brake is not applied.
(6) Indicator Light, Steering Pump Motor. This
light illuminates with another warning light if a
fault occurs in the steering pump motor. If the brush
wear sensor is activated in the motor, the warning
light, brush wear goes ON and the indicator light
for the steering pump motor shows which motor has
the problem.
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2200 SRM 557
9. LIFT PUMP MOTOR INDICATOR
10. MOTOR TEMPERATURE INDICATOR
11. STATUS CODE MAINTENANCE INDICATOR
12. HOURMETER INDICATOR
13. STATUS CODE BUTTON
14. PERFORMANCE LEVEL BUTTON
15. PERFORMANCE LEVEL LEDS
(7) Warning Light, Motor Brushes Are Worn.
When the sensor for brush wear closes, this warning
light and the indicator light for the motor that has
the problem both illuminate.
(8) Indicator Light, Traction Motor. This light
illuminates with another warning light if a fault oc-
curs in the traction motor. Example: If the brush
wear sensor is activated in the motor, the warning
light, brush wear (7) goes ON and the indicator
light for the traction motor shows which motor has
the problem.
(9) Indicator Light, Hydraulic Motor. This light
illuminates with another warning light if a fault oc-
curs in the hydraulic pump motor. Example: If the
temperature over limit switch closes in the motor, the
warning light, motor temperature over limit goes ON
and the indicator light for the hydraulic motor shows
which motor has the problem.
(10) Warning light, Motor Temperature Over
Limit. The traction motor and the hydraulic pump
motor have thermal switches inside the motors.
When the temperature increases to the limit set by
the manufacturer of the motor, the thermal switch
closes and the warning light on the display panel
illuminates. The indicator light for traction motor)
2200 SRM 557
or for the hydraulic motor shows which motor has
the problem.
(14, 15) Set Lift Truck Performance. The lift
truck can be set to four performance levels by the
operator. (If the customer does not want this func-
tion available to the operator, a service person can
set all four levels to the same setting.) Each time
the operator pushes the button, performance level
increases by one step. At the maximum (rabbit)
level, the performance levels begin at the lowest
(turtle) level again. The four performance levels set
by the manufacturer are:
1. Low performance for handling fragile loads.
2. Medium speed for less consumption of battery
charge during a work shift.
3. Higher performance with higher consumption of
battery charge during a work shift.
4. Maximum lift truck performance with maximum
consumption of battery charge.
The performance settings can be made with either
the PC or the Handset (Function Numbers 11, 12,
and 13).
The four performance levels can be set to any level up
to the maximum limits. Two or more adjacent per-
formance levels can be set to the same limits. The
performance levels must be set at the same or in as-
cending order (from turtle to rabbit). The register
interlocks do not permit a higher performance level
setting toward the turtle than the adjacent registers
toward the rabbit.
Fault Code Memory. The control cards for the trac-
tion motor controller and hydraulic pump motor each
have memory registers in which the last 16 status
codes can be stored. Each status code is stored with
the hourmeter time and the battery charge at the
time of the fault. The status code for the last fault
is indicated on the Status Code Indicator. If the key
switch is turned to OFF, the status code is removed
from the four-digit display.
The push button causes the status codes for the for
the faults to be shown on the Status Code Indicator.
When the button is pushed and held down, the in-
dicator light for the traction motor (8) illuminates.
The status codes in memory for the detected faults
are displayed, starting with the most recent fault. If
the push button is released, the display stops. If the
button is pushed again, the display starts from the
beginning again. The hourmeter time and the bat-
tery charge at the time of the fault are not shown.
Theory of Operation
A Handset or a PC must be used to show this addi-
tional information. A Handset or a PC must be used
to clear the status code from the register.
If the button is pushed twice and then held down,
the indicator light for the hydraulic pump motor il-
luminates. The status codes in memory for the de-
tected faults are displayed, starting with the most re-
cent fault. If the push button is released, the display
stops. If the button is pushed twice to start the se-
quence again, the display starts from the beginning.
The hourmeter time and the battery charge at the
time of the fault are not shown. A Handset or a PC
must be used to show this additional information. A
Handset or a PC must be used to clear the status code
from the register.
There can be 16 status codes in the memory for each
system (traction or lift). Push and hold the push
button to display all the status codes in the memory
for detected faults of the traction system. The Trac-
tion Motor Indicator is ON to show that the status
codes are for the traction system. If the push button
is released then pushed and held again, the digital
display starts over showing all the status codes for
the traction system. Push the button twice and hold
the push button to display all the status codes in the
memory for detected faults of the lift system. The Lift
Pump Motor Indicator is ON to show that the status
codes are for the lift system. If the push button is re-
leased then pushed twice and held again, the digital
display starts over showing all the status codes for
the lift system.
Brush Wear Indicators
The brush wear indicators illuminate when the mo-
tor brushes must be replaced. The sensor wires for
the brush wear indicators are an insert in the brush
material when it is made. The sensor wires are in-
sulated from the brush material. When the brush
wears within approximately 1.5 mm (0.060 in.) of the
brush lead, the insulation between the sensor wire
and the brush material is destroyed. The connection
between the brush and the sensor wire causes the in-
dicator to illuminate.
The operation of the brush wear indicators can be
checked during periodic maintenance. The battery
must be removed from the lift truck for access to the
motors.
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2200 SRM 557 8/03 (6/98)(11/97)(5/96)(11/95)(10/94) Printed in U.S.A.