EV–100ZX SCR MOTOR CONTROLLER,
Description, Adjustments, Troubleshooting, Repairs, and Theory
GENERAL
Four SERVICE MANUAL sections are required for
the complete Description, Checks, Adjustments, Re-
pairs, and Troubleshooting of this motor controller:
• EV–100ZX SCR MOTOR CONTROLLER,
Description, Adjustments, Troubleshooting,
Repairs, and Theory, 2200 SRM 557 (this sec-
tion)
• TROUBLESHOOTING AND ADJUST-
MENTS WITH A COMPUTER For
EV–100ZX And EV–T100 Motor Controllers,
2200 SRM 597
• EV–100ZX SCR MOTOR CONTROLLER,
Parameter Tables, 2200 SRM XXX (different
SRM number for different lift truck models)
• ELECTRICAL SYSTEM, Repairs, Checks
And Adjustments, 2200 SRM 560
This section describes the operation and the functions 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 controllers
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 con-
nect to a serial port on a personal computer for checks,
adjustments, and troubleshooting.
a. A Cable Kit, Control Card to Computer, is re-
quired (Hyster Part No. 1358471).
b. The HYTECH software for a personal comput-
er is available on a 3.5 inch diskette (Hyster Part
No. 897702).
c. 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. A “Description” for the EV–100ZX SCR Motor
Controller.
b. 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 dis-
play.
c. Checks and replacement of the components of the
motor controller are described in “Repairs”.
d. 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 elec-
tronic diagnostic and adjustment device is called a
“Hand Set” and is described later in this section. A com-
puter with the control software installed has access to
128 function registers on the control cards. The Hand
Set has access to less function registers 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–100 motor controller
can not be repaired, but must be replaced. This section
describes the procedures for using the electronic diag-
nostic and adjustment devices for checking and adjust-
ing 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 com-
ponents include the following:
a. Key switch
b. START switch (earlier production units only).
c. Brake switch
d. Foot switch
e. Seat switch
f. Direction (FORWARD and REVERSE) switches
1
EV–100ZX Motor Controller
g. Accelerator potentiometer
h. Guidance and steering systems
Checks and replacement of these electrical components
are described in ELECTRICAL SYSTEM, Repairs,
Checks And Adjustments, 2200 SRM 560
Model Number Data For EV–100ZX Controller
The model numbers for the EV–100ZX controller indi-
cate the following information:
Example: IC3645EV 100 T1 ZH 1 play unit (instrument panel display) is available for the
(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
hydraulic pump motor
(04) This set of letters indicate the control card options:
ZH = Traction Controller with three–wire
potentiometer and with Battery Discharge
Indicator (BDI).
2
ZP = Pump Motor Controller with Truck
Management Module (TMM1)
ZY = Traction Controller with three–wire
potentiometer and without Battery Discharge
Indicator (BDI)
(05) This number indicates the revision code:
1= Active
The “ZX” series of motor controllers have an output to
operate a digital display with four digits. A digital dis-
instrument panel of some lift trucks. The “ZX” control
cards can use an adapter for a serial cable that will con-
nect 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 set-
tings are set using a PC or the Hand Set.
The control card is a printed circuit board with elec-
tronic parts in a plastic case. The position of the control
cards in the controllers can be seen in FIGURE 1. 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 components
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 or a PC or the Hand Set to the
control card. Some pins of plug PY are also used to con-
nect the control card to the control card for the hydraulic
pump motor. The functions of the of the signal wires are
described in TABLE 1. through TABLE 4.

13 2 1
8 9 4 5
1 MOTOR CONTROLLER WITH
3 10 11
13 8 9 4 5
1. CONTROLLER, TRACTION
2. CONTROLLER, SCR CONTROL
FOR HYDRAULIC PUMP MOTOR
3. CONTACTOR, HYDRAULIC PUMP MOTOR
4. FORWARD CONTACTOR
5. REVERSE CONTACTOR
6. CONTACTOR, 1A BY–PASS
7. CONTACTOR, REGENERATIVE BRAKING
(OPTION ON SOME MODELS)
8. CONTACTOR, FIELD WEAKENING
(OPTION ON SOME MODELS)
FIGURE 1. TYPICAL CONFIGURATIONS OF THE EV–100ZX MOTOR CONTROLLER IN
“E–XM” MODEL LIFT TRUCKS
EV–100ZX Motor Controller
14 15
MOTOR CONTROLLER WITH
REGENERATIVE BRAKING, 1A
BY–PASS, AND SCR
CONTROLLER FOR
HYDRAULIC PUMP
12
1364112
14 15
REGENERATIVE BRAKING, 1A
BY–PASS, AND CONTACTOR
CONTROL FOR HYDRAULIC
PUMP
12
9. RESISTOR, FIELD WEAKENING
(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)
3
EV–100ZX Motor Controller

MOTOR CONTROLLER WITH REGENERATIVE

BRAKING, 1A BY–PASS, AND SCR CONTROLLER 6 13
FOR HYDRAULIC PUMP

14
15

2 9 4
7
8
1
16

MOTOR CONTROLLER WITH REGENERATIVE

BRAKING, 1A BY–PASS, AND CONTACTOR
CONTROL FOR HYDRAULIC PUMP

6 13
3

14

15

5
11
9 4
12 7

16 8
10 1

1. CONTROLLER, TRACTION 13. FUSE 1 (TRACTION CIRCUIT)

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

FIGURE 2. TYPICAL CONFIGURATIONS OF THE EV–100ZX MOTOR CONTROLLER IN THE “J–XM”

MODEL LIFT TRUCKS

4
 EV–100ZX Motor Controller

EV–200ZX TRACTION AND SCR HYDRAULIC CONTROLLERS

EV–100 OR EV–200ZX TRACTION AND DUAL

1 CONTACTOR HYDRAULIC CONTROLLERS

EV–100ZX TRACTION AND SCR HYDRAULIC CONTROLLERS

1. TRACTION MOTOR CONTROLLER
2. MOTOR CONTROLLER(S) FOR LIFT EV–100 OR EV–200ZX TRACTION AND ONE
PUMP MOTOR CONTACTOR HYDRAULIC CONTROLLERS
3. POWER STEERING CONTACTOR
Labels that have a combination of numbers and letters are for power 1324927 1/2 R11
cables. Labels that have only numbers are for control wires. Modified

FIGURE 3. CONFIGURATIONS OF THE EV–100ZX OR EV–200ZX SCR MOTOR

CONTROLLERS IN THE E3.50–5.50XL (E70–120XL) LIFT TRUCKS

5
EV–100ZX Motor Controller

1
7
2

3
6
3
3 3
5

1. CONTROL CARD
(TRACTION OR HYDRAULIC PUMP)
2. TB SCREW TERMINALS (6)
3 3. PLUG GUIDES
4. PLUG PA (6–PIN) (WIDE GUIDES)
4 5. PLUG PB (6–PIN) (CLOSE GUIDES)
6. PLUG PY (14–PIN)
7. PLUG PZ (14–PIN)
12668
12671 3

FIGURE 4. CONTROL CARD CONNECTIONS

6
 EV–100ZX Motor Controller

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
Terminal Wire Color or Function
No. Wire Number

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.
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.

7
EV–100ZX Motor Controller

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
Terminal Wire Color or Function
No. Wire Number

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.
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.

8
 EV–100ZX Motor Controller

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
Terminal Wire Color or Function
No. Wire Number

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.
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.

9
EV–100ZX Motor Controller

TABLE 4. Terminal And Plug Wire Connections For Controller With SCR Control Of Traction Circuit
And SCR Control Of The Hydraulic Pump Motor — Control Card – Type ZP
Plug or
Terminal Wire Color or Function
No. Wire Number

PA1 GRN/GRY Signal wire between pump control card and brush wear indicator,steering pump.
PA2 DK–BLU/YEL Signal wire between pump control card and brush wear indicator,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 hyd. 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
TB4 10 high speed auxiliary hydraulic functions.
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.
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.

10

REGISTER PARAMETERS
General
The “ZX” series of control cards have an electronic de-
vice called an EEPROM (Electrically–Erasable–Pro-
grammable–Read–Only–Memory). The EEPROM has
a number of memory elements called registers. These
registers can have electronic data stored in them to con-
trol 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 measure-
ment numbers (parameters) to define a system. The EE-
PROM in the control card is a control system for the op-
eration 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 that the control card can be used on dif-
ferent models of lift trucks. This variation is needed
for lift trucks of different sizes and operating volt-
ages. Adjustment of the register to the wrong num-
ber for your lift truck model can cause the truck to
operate differently than normal. This different oper-
ation of the truck can cause an injury.
Do NOT adjust any of the registers without using the
parameters shown in EV–100ZX SCR MOTOR
CONTROLLER, Parameter Tables, 2200 SRM 595.
NOTE: The Parameter Tables show the permitted
ranges and the default setting for each control function.
The Factory Set Parameters are the recommended set-
tings for new units. These settings will give satisfactory
performance for most applications.
Some functions can be adjusted within the permitted
range to change the lift truck operation for a specific
application. Adjustment of a register to a number that is
different than the factory setting is allowed, but follow
the instructions carefully and stay within the minimum
and maximum limits. Adjustments other than the facto-
ry settings will cause the lift truck to operate differently
and can cause increased wear of parts.
Function Numbers
The Function Numbers are code numbers for the differ-
ent parameters that can be set for the “ZX” series control
EV–100ZX Motor Controller
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 numbers for the different
control cards in the Parameter Tables. These Parame-
ter Tables have the correct setting numbers for the pa-
rameters on each control card.
CONTROL CARD, CHECKS AND
ADJUSTMENTS
A Personal Computer (PC) or a Hand Set 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
constant
• 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 func-
tions:
♦ Creep Speed
♦ Controlled Acceleration and 1A Time
♦ Current Limit
♦ Steering pump time delay and define signal
input (seat switch or directional switch)
♦ Plugging distance (Current)
♦ Accelerator pedal position, plug range or
disable
♦ 1A drop out current or disable
♦ Field Weakening drop–out
♦ Field Weakening pick–up
♦ Regenerative Braking current limit
♦ Regenerative Braking drop–out
♦ Speed limit points (SL1, SL2 and SL3)
♦ Internal resistance compensation for battery
state of charge indication
♦ Battery voltage (36/48V is auto ranging)
• Selection of type of card operation:
♦ Traction circuit with Field Weakening
♦ Traction circuit with Regenerative Braking
and Field Weakening
♦ High or low current limit for all of the above
functions
11
EV–100ZX Motor Controller

the registers in the “ZX” series of control cards can not

1 be accessed with the Hand Set. The Hand Set can access
the registers that control the operation of the lift truck.
The values for the limits on the control card functions
must be set with either a PC or the Hand Set. The Hand
2
Set has a Light Emitting Diode (LED) display, a keypad
for data entry and an adjustment knob for changing
function values. See FIGURE 5.

NOTE: The vehicle will operate with the Hand Set con-
nected, however, the adjustment knob MUST be set
3 fully clockwise to make sure the control can operate at
PLUG WIRING
maximum speed.
MOD. PLUG
PLUG PY This section has the control card checks and adjustments
1 9 that can be made using the Hand Set. The control card
2 6 checks and adjustments are usually made with the con-
3 3
4 4
trol card installed in the lift truck. Bench checks and ad-
5 5 justments can also be made with the control card con-
6 8 nected as shown in FIGURE 7. The checks show the
7 1
8 2 stored setting numbers that have been stored for the dif-
4 ferent control card functions. This section also includes
5 a description of each of the different functions. Use the
6
adjustment knob on the Hand Set to adjust the function
settings. See FIGURE 5.

12657
How To Scroll Through The Fault Codes And
1. ADJUSTMENT 4. COIL CORD Clear Them (See FIGURE 6.)
KNOB 5. PLUG PY (14 PIN)
2. LED DISPLAY 6. MODULAR PLUG The EV100ZX controller has function registers (31
3. KEYPAD (8–PIN Hand Set) through 47) that store the last 16 status codes that caused
FIGURE 5. HAND SET the operation of the lift truck to stop and the battery
charge at the time the fault occurred. A PMT fault is re-
HAND SET set by turning the key to the OFF position and then to
ON position. The first of the 16 status codes will be
How To Check And Adjust The Registers overwritten each time a new status code occurs. The
The Hand Set can be used with the EV–100ZX series stored status can be cleared from the register by using
motor controllers. The Hand Set is used to access the the Hand Set. (The PC software programs clears the
registers for the traction or pump motor functions, indi- fault register automatically.) Use the procedure in
cate status codes (possible faults) and make adjustments FIGURE 6. to access and clear the fault code registers
to the operating limits set in the control cards. Some of with the Hand Set:

12
 EV–100ZX Motor Controller

NOTE: The bench supply voltage does not need to be

Check and Adjustment
mode. See the numbers the same as the voltage of the lift truck.
8888.
The Hand Set can also be used to check and adjust the
functions of the control card when it is connected to a
Key to OFF position bench power supply for bench checks and adjustments.
The following parts are required:

Push ESC and CONT a. A power source to supply a minimum of 24 DC

at the same time 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 Hand Set re-
Release ESC and CONT quires more power for its operation and a power
supply or two 12 volt automotive batteries in se-
ries must be used. A DC power supply to a maxi-
Status Code Displayed
mum of 84 volts can be used)
b. An electrical adaptor to connect to the Plug Z
Push CONT Button connector of the control card must be made.
c. A switch for the circuit
d. Approximately 45 cm (18 inches) of 18 gage wire
Battery charge shown
when fault occurred [only e. A PC or a Hand Set.
if equipped with BDI–
otherwise zero (0)]. If batteries are not used, the power supply must have a
full bridge rectifier with a filter to give a good quality
DC voltage. Make the following connections for the
Push CONT Button
bench checks and adjustments:
a. Connect the switch and a Plug Z to the power
Display hour reading Push ESC to source using the wire as shown in FIGURE 7.
when fault occurred. erase stored data
b. Make sure the switch is in the OFF position and
connect the wire to TB4
Push CONT Button c. Connect Plug Z to the Plug PZ connector on the
control card and the PC or the Hand Set to the
FIGURE 6. HOW TO SCROLL THROUGH THE Plug PY connector.
FAULT CODES AND CLEAR THEM
NOTE: There are no connections to the Plug A or Plug
Checks And Adjustments On The Work B connectors of the control card.
Bench (See FIGURE 7.)
NOTE: The bench checks and adjustments are done us-
CAUTION ing the same procedures described in the following
Prevent damage to the control card. The control pages.
card can be damaged if power is not correctly con-
nected or disconnected. Always disconnect the bat- WARNING
tery connector before connecting or disconnecting NEVER adjust any of the parameters without using
the control card plugs. the procedures and settings given in this section.

13
EV–100ZX Motor Controller
6
5 4
1 3. PLUG B CONNECTOR
6
21 10
5 43
76
9 keys can be used.
98
10
1211
1413
8
12668
FIGURE 7. BENCH CHECKS AND ADJUSTMENTS
When The Hand Set Is Connected To A
Control Card Installed In A Lift Truck
WARNING
Prevent movement of the lift truck when making
checks and adjustments. Before the Hand Set is con-
nected or disconnected to a control card that is in-
stalled in a lift truck, raise the drive wheels. Then
turn the key to the OFF position, disconnect the bat-
tery and discharge capacitor C1.
Make sure the power is off as described in the WARN-
ING. If the lift truck has an instrument panel display
connected, disconnect Plug Y at the SCR control card
(traction or hydraulic pump). Connect the Hand Set plug
at the connector for Plug Y on the control card. Connect
the battery and turn the key to the ON position. The fol-
lowing display sequence will occur:
• Display of 8888 for one second to check the dis-
play segments.
• Status Code display of –01 if seat is in the UP po-
sition.
• Another Status Code will be displayed if a possi-
ble fault has occurred.
• Blank display if the operator is on the seat and
there is no Battery Indicator function installed.
14
1. CONTROL CARD
2. PLUG A CONNECTOR
3 4. TB TERMINALS
2
5. PLUG Y CONNECTOR
6. PLUG Z CONNECTOR
7. 24 VOLT DC 0.5 AMP
POWER SUPPLY OR BATTERIES
8. PIN PZ7 (B+)
9. PIN PZ2 (B–)
10. TERMINAL TB4 (B+)
NOTE: If the Hand Set is used with this
power supply, connections to TB3 and
TB4 must be available so that all function
• Battery state of charge if the operator is on the
seat and there is a Battery Indicator function in-
stalled.
Turn the key to the OFF position. The following display
sequence will occur:
• Display shows the hourmeter reading for the trac-
tion motor for four seconds.
• Display shows the hourmeter reading for the hy-
draulic pump motor for four seconds. If there is
no SCR control for the hydraulic pump , the dis-
play will be 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 connected. See
FIGURE 4. Connect the Hand Set plug at connection
PY on the control card. Connect the battery. Push and
hold the CONT button of the Hand Set so that it is de-
pressed 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 will show “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 Hand Set numbers are shown in the Param-
eter Tables.
Function Numbers 16 through 30.
(The seat switch must be open.)
1. Push the keypad numbers for the desired register.
Think of the CONT key equaling 15. Push and hold
the CONT key plus the additional key number above
15 to total the required Hand Set number.
Example: for Function Number 18, push the CONT and
key 3 (15+3=18). The display will show the selected
register. After one second, the display will show the pa-
rameter that has been set in that register.
2. Push and hold the CONT key for one second. The dis-
play number will blink.
3. To change the parameter, check for the correct pa-
rameter for that register in the Parameter Tables.
Change the parameter by turning the Adjustment Knob
on the Hand Set. The display will continue to blink as the
number changes.
4. Push and hold the STORE key for one second. When
the new parameter is set (stored), the display will stop
blinking.
5. Push and hold the ESC key for one second. The dis-
play will show “8888”. To check or set another register,
do Steps 1 through 3. To return to normal operation (run
mode), push and hold ESC again for one second or
longer. The display will return to the status code mode or
display 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 Hand Set. If the mo-
tor 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 Hand Set con-
nected or the Hand Set can be disconnected.
NOTE: If the vehicle is operated with the Hand Set con-
nected, make sure to set the Adjustment Knob fully
EV–100ZX Motor Controller
clockwise to make sure the control can operate at top
speed.
Disconnect the plug at connection Y on the control card
to disconnect the Hand Set. Connect the plug for the in-
strument panel display at connection Y.
Function Numbers 48 through 62. (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 Hand Set is connected to the hydraulic
pump card.
2. Push the keypad numbers for the desired register.
Think of the CONT key equaling 47. Push and hold
the CONT key plus the additional key number above
47 to total the required Hand Set 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 will show the selected register. After one
second, the display will show the parameter that has
been set in that register.
NOTE: HS 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 Hand Set.
3. Push and hold the CONT key for one second. The dis-
play number will blink.
4. To change the parameter, check for the correct pa-
rameter for that register in the Parameter Tables.
Change the parameter by turning the Adjustment Knob
on the Hand Set. The display will continue to blink as the
setting changes.
5. Push and hold the STORE key for one second. When
the new parameter is set (stored), the display will stop
blinking.
6. Push and hold the ESC key for one second. The dis-
play will show “8888”. To check or set another register,
do Steps 1 through 3. To return to normal operation (run
mode), push and hold ESC again for one second or
longer.
FUNCTION NUMBER DESCRIPTIONS
The following pages have descriptions for the different
Function Numbers. The setting for each function is spe-
cific for each control card. To identify the control card,
15
EV–100ZX Motor Controller
check the label at the top edge of each card case. There
are some painted letters and numbers followed by letters
on the lower part of the label. The last two letters identi-
fy the type of card installed. The following types of con-
trol 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 Parameter
Tables and in the section headings for the control 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 motor.
WARNING
If any of the parameters are changed, the operators
must be told that the lift truck will operate differ-
ently.
Do not adjust the parameters outside of the range of
numbers shown in the Tables. Parameters set outside
of the ranges can cause damage to the components of
the traction system and can cause the lift truck to op-
erate differently than normal. This different opera-
tion of the lift truck can result in personal injury.
Function Number 1
STORED STATUS CODE
(Push 1)
This register contains the last status code of a possible
PMT fault that caused the lift truck to stop operation.
These codes can be removed from the display by turning
the key to the OFF position. The code will be stored in
registers in the control card. This status code will be re-
placed 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 pushing the STORE key for
one second. Adjustment of the values this register does
16
not change the operation of the lift truck. This register is
cleared when the battery is disconnected.
Function Number 2
CREEP SPEED
(Push 2)
This register permits the adjustment of the creep speed
of the lift truck. The range of adjustment is from 0 (5%)
to 255 (15%). The percent values are the SCR 1 “ON
Time”. A constant creep speed frequency will be main-
tained 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 permits the adjustment of the maximum
rate of acceleration. The setting determines the time al-
lowed to reach maximum SCR speed after the accelera-
tor is set for maximum speed from stop. The control will
stay in SCR acceleration for between 0.77 second (set-
ting 8) and 21.5 seconds (setting 255) before the 1A con-
tactor will close. The numbers in () are the parameters
for the times shown. The 1A contactor will automati-
cally close 0.2 second after the controlled acceleration
stops. The speed control input is less than 0.5 volt (ac-
celerator potentiometer set at less than 50 ohms). Do not
adjust the number in the register to less than the mini-
mum setting of 8.
Function Number 4
CURRENT LIMIT
(Push 4)
This register permits the adjustment of the current limit
of the motor controller. The current rating of the motor
controller will determine 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
factory setting.
Function Number 5
PLUGGING DISTANCE (CURRENT)
(Push 5)
This register permits the adjustment of 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 stop-
ping distance.
CAUTION
Traction motor or controller damage will occur if the
parameter is set above the maximum shown in the
Tables for the Parameter Registers.
The number for this parameter for the current value of
this register must be found if the Pedal Position Plug
(Function Number 16) will not be used. To find the num-
ber for the current 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 x 3.14A = 62.8A or 63A
63A + 200A (range min) =
263A
Function Number 6
1A DROP OUT CURRENT
(Push 6)
This register permits the adjustment of the parameter for
the current value at which the 1A contactor will dee-
nergize (open). The 1A contactor will open and the mo-
tor torque will be limited to SCR current to prevent mo-
tor currents that are too high. A value of 255 will disable
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 traction motor.
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface.
Do NOT set this register to a number greater than
the number set by Function Number 8. If this regis-
EV–100ZX Motor Controller
ter is set to a number less than 5, the Field Weakening
function will be deenergized.
Function Number 8
FIELD WEAKENING DROP OUT
(Push 8)
CAUTION
A parameter set HIGHER than the number shown
in the Tables for the Parameter Registers will make
the Field Weakening Contactor remain energized at
high currents. This operation can cause motor heat-
ing and damage the traction motor.
This register permits adjustment of the current value at
which the FW contactor will deenergize (open). This pa-
rameter permits the FW contactor to open when the lift
truck requires more than 300% of the running current
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 Registers will make the
lift truck slow at a rate faster than normal. A param-
eter 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 permits adjustment of the Regenerative
Braking current limit. The higher the current limit set-
ting, the shorter the stopping distance. The shorter stop-
ping distance causes faster wear on the drive train and
brushes of the traction motor.
Function Number 10
REGENERATIVE BRAKING START
(Push 10)
CAUTION
A parameter set greater than the number shown in
the Tables for the Parameter Registers can prevent
regenerative braking. The lift truck will remain in
the plugging mode longer and increase brush wear in
the traction motor.
17
EV–100ZX Motor Controller
This parameter permits adjustment of the percent ON
time at which the control will start to energize the regen-
erative braking circuit. The percent ON time can be be-
tween 0% and 95%. This adjustment sets the speed
where regenerative braking will start. 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 permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. The adjustment sets the speed limit for the time
when the input signal from the SL3 limit switch is re-
ceived by the control card. This signal can be a signal
from the sensor in the traction motor or the hydraulic
pump motor. If the sensor shows that a motor is too hot,
the control will decrease the maximum motor speed to
this speed setting. The SL3 limit switch is a normally
closed switch connected to battery negative. When the
switch opens, it enables the speed limit function. A set-
ting of 0 will disable the speed limit function. This zero
setting will permit top speed when no limit switch is
connected. A zero setting will 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 Status Codes –90 and –93.
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 Bat-
tery Discharge Indicator (BDI) function. Control cards
that have BDI are type ZH control cards. The Tables for
the Parameter Registers show the parameters for a bat-
tery in average condition.
For the best use of your battery energy, the register can
be adjusted using the following procedure. However,
you must use the procedure to change the parameter in
the register as the battery changes during months the
battery is used or battery damage can occur. Setting the
parameter too low for your battery can allow the battery
18
to discharge below the minimum specific gravity value.
This minimum specific gravity is the specification given
by the battery manufacturer to prevent battery damage.
Using the following procedure to adjust the parameter:
a. Operate the lift truck on a normal work cycle.
Travel at medium speeds.
b. When lift interrupt occurs, stop the lift truck and
wait for approximately 10 minutes.
c. 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
specific gravity reading is high, adjust the param-
eter in the register to a lower number. If the spe-
cific gravity reading is low, adjust the parameter
to a higher number.
NOTE: It can be necessary to charge the battery and do
Steps 1 through 3 again to get an accurate number for
your battery.
Function Number 15
BATTERY VOLTS
(Push 15)
This register permits adjustment for the operating volt-
age of the lift truck. The adjustment also permits correct
operation of 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.
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 Regis-
ter Parameters, a status code of –15 or –16 will occur.
Make sure the battery is fully charged and battery con-
nector has good connections before making this adjust-
ment. 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 re-
quired register number. Example: for Function 18, push
the CONT key and key 3 (15+3=18). The display will
show the selected function. After one second, the dis-
play will show the setting 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 permits adjustment of 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 maximum 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 plug-
ging distance current. See the description in Function
Number 5.
Example: If Plugging Distance Current (Function Num-
ber 5) is set at 500 amps, then set pedal plugging current
to 500 amps. The pedal position will have 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 x 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 Func-
tion Number 17 can cause the truck to operate differ-
ently than normal. This different operation of the
EV–100ZX Motor Controller
truck can cause an injury. NEVER set Function
Number 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 mo-
mentarily during normal operation. There is no
power steering if the steering pump stops. The sud-
den and difficult steering effort that is not expected
can cause injury or property damage.
This register permits the selection of the 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.
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 re-
quired. 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 re-
quired. The range for this register is 100 to 9900 hours.
19
EV–100ZX Motor Controller
Function Number 21
MAINTENANCE SPEED LIMIT
(Push CONT and 6)
This register can be set by the service person to control
the speed limit (maximum battery volts to the motor)
when the Maintenance Alert (Status Code –99) is acti-
vated by the control card. The range for this register is 0
to 180.
Function Numbers 22 through 28
TEMPORARY DATA REGISTERS
These registers can be read with the Hand Set, but the
data in them changes during lift truck operation. Do not
change the parameters in registers for Function numbers
22 through 27. Function number 28 is the fault indi-
cator pointer and must be set to zero when all faults
or malfunctions have been fixed or removed from
the controller.
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 instrument panel display to not
operate correctly and the lift truck can become dis-
abled.
Function Number 29
HOURMETER (Tens/Units)
(Push CONT and 14)
This register has the data for the accumulated operating
hours of the lift truck. 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 con-
trol 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 operating
hours of the lift truck. 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 con-
20
trol card must be entered so that the total operating hours
of the lift truck is correctly recorded.
Function Number 48 Through Function Number 62
SET LIFT TRUCK PERFORMANCE.
If the lift truck is equipped with a Premium instrument
panel, 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 on the instrument panel, the perfor-
mance level will increase by one step. At the maximum
(rabbit) level, the performance levels will begin at the
lowest (turtle) level again. The four performance levels
set by the manufacturer are:
a. Low performance for handling fragile loads.
b. Medium speed for less consumption of battery
charge during a work shift.
c. Higher performance with higher consumption of
battery charge during a work shift.
d. Maximum lift truck performance with higher
consumption of battery charge.
The four performance levels can be set to any level up to
the maximum limits. Two or more adjacent perfor-
mance levels can be set to the same limits. The perfor-
mance levels must be set at the same or in ascending or-
der (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 Func-
tion 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 permits the adjustment of the maximum
rate of acceleration 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 will stay in SCR acceleration for
3.5 seconds (setting 40) before the 1A contactor will
close. The numbers in () are the parameters for the times
shown. The 1A contactor will automatically close 0.2
second after the controlled acceleration stops. The

speed control input is less than 0.5 volt (accelerator po-
tentiometer set at less than 50 ohms). Do not set the
number in the register to less than the parameter in the
register for Function Number 52.
Function Number 49
FIELD WEAKENING PICK UP
(Push CONT and 2 while the key switch and seat
switch are closed)
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface. The mini-
mum parameter is zero. Do not set the number in the reg-
ister greater than the number in the register for Function
Number 53.
Function Number 50
SPEED LIMIT 1
(Push CONT and 3 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register to
less than the parameter for Function Number 54. Do not
set the number in 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 permits the adjustment of the maximum
rate of acceleration in MODE 2. The parameter deter-
mines the time allowed to reach maximum SCR speed
after the accelerator is set for maximum speed from
stop. The control will stay in SCR acceleration for 2.6
seconds (setting 30) before the 1A contactor will close.
The numbers in () are the parameters for the times
shown. The 1A contactor will automatically close 0.2
second after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator po-
tentiometer set at less than 50 ohms). Do not set the
number in the register to less than the parameter for
EV–100ZX Motor Controller
Function Number 56. Do not set the number in the regis-
ter greater than the number in the register for Function
Number 48.
Function Number 53
FIELD WEAKENING PICK UP
(Push CONT and 6 while the key switch and seat
switch are closed)
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface. Do not set
the number in the register to less than the parameter for
Function Number 49. Do not set the number in the regis-
ter greater than the number in the register for Function
Number 57.
Function Number 54
SPEED LIMIT 1
(Push CONT and 7 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register to
less than the parameter for Function Number 58. Do not
set the number in the register greater than the number in
the register for Function Number 50.
Function Number 56
CONTROLLED ACCELERATION AND 1A
TIME
(Push CONT and 9 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 3. The parameter deter-
mines the time allowed to reach maximum SCR speed
after the accelerator is set for maximum speed from
stop. The control will stay in SCR acceleration for 1.8
seconds (setting 20) before the 1A contactor will close.
The numbers in () are the parameters for the times
shown. The 1A contactor will automatically close 0.2
second after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator po-
tentiometer set at less than 50 ohms). Do not set the
number in the register to less than the parameter for
21
EV–100ZX Motor Controller
Function Number 60. Do not set the number in the regis-
ter greater than the number in the register for Function
Number 52.
Function Number 57
FIELD WEAKENING PICK UP
(Push CONT and 10 while the key switch and seat
switch are closed)
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface. Do not set
the number in the register to less than the parameter for
Function Number 53. Do not set the number in the regis-
ter greater than the number in the register for Function
Number 61.
Function Number 58
SPEED LIMIT 1
(Push CONT and 11 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register
greater than the number in the register for Function
Number 58.
Function Number 60
CONTROLLED ACCELERATION AND 1A
TIME
(Push CONT and 13 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration 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 will stay in SCR acceleration for
0.94 seconds (setting 10) before the 1A contactor will
close. The numbers in () are the parameters for the times
shown. The 1A contactor will automatically close 0.2
second after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator po-
tentiometer set at less than 50 ohms). Do not set the
22
number in the register to less than 8. Do not set the num-
ber in the register greater than the number in the register
for Function Number 56.
Function Number 61
FIELD WEAKENING PICK UP
(Push CONT and 14 while the key switch and seat
switch are closed)
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface. Do not set
the number in the register to less than the parameter for
Function Number 57. Do not set the number in the regis-
ter 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 hy-
draulic pump.
WARNING
If any of the register parameters are changed, the op-
erators must be told that the lift truck will operate
differently.
Do not adjust the register parameters outside of the
range shown in the Parameter Tables for the register
parameters. Settings outside the ranges can cause
damage to the components of the hydraulic system
and different truck operation. This different opera-
tion of the truck can cause personal injury.
Function Number 1
STORED STATUS CODE
(Push 1)
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 will be replaced with
the same status code if another possible fault occurs.
The status code can be cleared from memory by adjust-
ing the setting number to zero. Any new number (in-
cluding zero) must be stored by pushing the STORE
key for one second. Adjustment of this register does not
change operation of the hydraulic system.
 EV–100ZX Motor Controller

Function Number 2 Function Number 11

INTERNAL RESISTANCE COMPENSATION SPEED LIMIT 1 (SL1)
START (Slow Speed) – Tilt and Slow Auxiliary
(Push 2) (Auxiliary and Slow Rotate for N30XMH)
(Push 11)
This register permits adjustment of the current level re-
quired to start the internal resistance compensation This register permits the adjustment of the speed limit
(Function Number 16). (maximum battery volts applied to the motor). When
switch SL–1 is closed, the signal to TB2 on the control-
Function Number 3 ler card causes the controller to apply the limit on battery
CONTROLLED ACCELERATION volts to the motor.
(Push 3)
Function Number 12
This register permits the adjustment of the maximum SPEED LIMIT 2 (SL2)
rate of acceleration. The parameter determines the time (Medium Speed) – Slow Lift and Medium
allowed to reach maximum SCR speed after the switch Auxiliary
closes. This parameter determines how fast the hydrau- (Slow Lift And Fast Rotate for N30XMH)
lic functions will begin to operate. The control will stay (Push 12)
in SCR operation for 0.1 to 22 seconds after the switch
closes. This register permits the adjustment of the speed limit
(maximum battery volts applied to the motor). When
Function Number 4 switch SL–2 is closed, the signal to TB3 on the control-
CURRENT LIMIT ler card causes the controller to apply the limit on battery
(Push 4) volts to the motor.

This register permits the adjustment of the current limit Function Number 13
of the control. The current limit is normally set at the SPEED LIMIT 3 (SL3)
maximum (255). (Push 13)
Not Connected.
Function Number 7
CONTROLLED ACCELERATION Function Number 14
COMPENSATION SPEED LIMIT 4 (SL4)
(Push 7) Fast Lift
This register permits the adjustment of the rate (in se- (Push 14)
conds) that it takes for the controller to add the internal This register uses SL4 limit switch for an input to TB6.
resistance compensation voltage that is applied to to This function permits adjustment of the speed limit
motor. This function will add 0.375 volts to the motor at (maximum battery volts to the motor). The range is 96%
the rate of time set in the register until the total (current x to 0%. A parameter set over the maximum parameter
resistance) compensation voltage has been added. shown in the Parameter Table can cause the motor or
controller to become too hot.
Range 0.0015 to 0.383 seconds
Set 0 to 255 Function Numbers Greater Than 15
Resolution 0.375 volts per set unit
Example: A parameter of 20 = 0.032 seconds NOTE: For registers greater than15, push and HOLD
the CONT key and the additional key number above 15
Example: If 2.08 volts is set in Function Number 16 and to total the required register number. Example: for Func-
added to the motor, this example would require 0.18 se- tion Number 18, push CONT key and key 3 (15+3=18).
conds to add a total of 2.08 volts. The display will show the selected register. After one
(2.08 volts/0.375 volts per unit)0.032 seconds = 0.1775 second, the display will show the parameter that has
or 0.18 seconds been set in that register.

23
EV–100ZX Motor Controller
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 is used to give the pump speed better stabil-
ity 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 will be added to the motor for each
100 ampere increment starting with the parameter set in
Function Number 2. The voltage selected will be added
in steps of 0.375 volts until the entire voltage is added.
For example, a parameter of 10 will add 2.28 volts in six
steps of 0.375 volts each.
Function Number 17
CARD TYPE SELECTION
(Push CONT and 2)
WARNING
Wrong parameters entered into the register in Func-
tion Number 17 can cause the truck to operate differ-
ently than normal or cause damage to the controller.
This different operation of the truck can result in
personal injury. NEVER set Function Number 17 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. See the correct setting in
the Parameter Tables.
Function Numbers 18 through 28
TEMPORARY DATA REGISTERS
These registers can be read with the Hand Set, but the
data in them changes during lift truck operation. Do not
change the parameters in registers for Hand Set numbers
21 through 27. Hand Set number 28 is the fault indi-
cator pointer and must be set to zero when all faults
or malfunctions have been fixed or removed from
the controller.
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
24
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 dis-
abled.
Function Number 29
HOURMETER (Tens/Units)
(Push CONT and 14)
This register has the data for the accumulated operating
hours of the hydraulic system. 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 hydraulic system is correctly recorded.
Function Number 30
HOURMETER (Thousands/Hundreds)
(Push CONT and 15)
This register has the data for the accumulated operating
hours of the lift truck. 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 con-
trol card must be entered so that the total operating 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 permits the adjustment of the maximum
rate of acceleration in MODE 1 (Turtle). The parameter
determines the time allowed to reach maximum SCR
speed from stop. Do not set the number in the register to
less than the parameter in the register for Function Num-
ber 52.
Function Number 49
SPEED LIMIT 2
(Push CONT and 2 while the key switch and seat
switch are closed)
This register permits the adjustment of the speed limit
for the hydraulic pump in MODE 1. The minimum pa-
rameter is zero. Do not set the number in the register
greater than the number in the register for Function
Number 53.

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 volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register to
less than the parameter for Function Number 54. 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 permits the adjustment of the maximum
rate of acceleration in MODE 2. The parameter deter-
mines the time allowed to reach maximum SCR speed
from stop. Do not set the number in the register to less
than the parameter for Function Number 56. Do not set
the number in the register greater than the number in the
register for Function Number 48.
Function Number 53
SPEED LIMIT 2
(Push CONT and 6 while the key switch and seat
switch are closed)
This register permits the adjustment of the speed limit
for the hydraulic pump in MODE 2. Do not set the num-
ber in the register to less than the parameter for Function
Number 49. Do not set the number in the register greater
than the number in the register for Function Number 57.
Function Number 54
SPEED LIMIT 3
(Push CONT and 7 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register to
less than the parameter for Function Number 58. Do not
EV–100ZX Motor Controller
set the number in the register greater than the number in
the register for Function Number 50.
Function Number 56
CONTROLLED ACCELERATION
(Push CONT and 9 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 3. The parameter deter-
mines the time allowed to reach maximum SCR speed
from stop. Do not set the number in the register to less
than the parameter for Function Number 60. Do not set
the number in the register greater than the number in the
register for Function Number 52.
Function Number 57
SPEED LIMIT 2
(Push CONT and 10 while the key switch and seat
switch are closed)
This register permits the adjustment of the speed limit
for the hydraulic pump in MODE 3. Do not set the num-
ber in the register to less than the parameter for Function
Number 53. Do not set the number in the register greater
than the number in the register for Function Number 61.
Function Number 58
SPEED LIMIT 3
(Push CONT and 11 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister 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 permits the adjustment of the maximum
rate of acceleration 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 number in the register greater
than the number in the register for Function Number 56.
25
EV–100ZX Motor Controller
Function Number 61
SPEED LIMIT 2
(Push CONT and 14 while the key switch and seat
switch are closed)
This register permits the adjustment of the speed limit
for the hydraulic pump in MODE 4. Do not set the num-
ber in the register to less than the parameter for Function
Number 57. Do not set the number in 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 permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. The maximum number in the register
is 255.
REGISTER PARAMETERS
Parameters must be between the minimum and maxi-
mum 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 table. Make
sure you use the correct table when you make adjust-
ments. It is a good procedure to check the parameter and
compare the parameter to the number in the table before
making the adjustment. The factory parameter, and the
value (current, 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 identify the TYPE of
card installed. The table titles show these card types for
the EV–100ZX motor controllers.
Make sure to read the WARNINGS and CAUTIONS
under each parameter description and in the section PA-
RAMETERS, CHECKS AND ADJUSTMENTS.
26
CAUTION
Do not set the Field Weakening functions without
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 Weakening. The
Field Weakening functions are set to not operate on
these lift trucks.
TROUBLESHOOTING
Many electrical malfunctions of the lift truck will be
shown in the status code number on the digital display.
There is a digital display on the Hand Set 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 Hand Set.
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
NOTE: 1. A blank display on the instrument panel dis-
play or the Hand Set, 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–cir-
cuit across the battery as soon as the regenerative brak-
ing contactor closes and will cause the power fuse to

open. If D7 is open, the regenerative braking will not op-
erate and the plugging will be too quick.
NOTE 2. A short–circuit in the 1A contactor coil will
cause 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 direc-
tion contactors will open.
NOTE 3. If the coil of the Field Weakening contactor
has a short–circuit, the lift truck will operate normally
until the FW contactor is energized. Then the lift truck
will lose power and the direction contactors will open.
The control card in the motor controller has a
troubleshooting system that continuously checks the
static and operating conditions of the control and power
circuits for the motor. The control card will indicate a
status code on a display connected to plug PY if the
troubleshooting circuits find a condition that is not nor-
mal. Some lift trucks can have an instrument panel dis-
play that will indicate the status codes from the control
cards for the traction motor and hydraulic pump motor.
Different control cards are used in the electric lift trucks.
A replacement control card must have the same part
number as the control card that was removed. A bad
control card can not be repaired by service persons and
must be replaced.
Status Codes (See TABLE 5.)
The status codes are code numbers for malfunctions that
the control card can sense. The control card will indicate
this code number on the digital display of the instrument
panel display (optional on some units) or the display on
a Hand Set. The control card will illuminate the numbers
of the status code on the display. The status codes are
twice illuminated (“flash”) on the display approximate-
ly every two seconds. Every third “flash” of the display
will indicate the battery charge instead of the status
code.
The control card senses the following malfunctions:
• input voltages that are too high or too low,
• input voltages that have the wrong polarity,
EV–100ZX Motor Controller
• input voltages in the wrong sequence or
• correct input voltages that occur at the wrong
time.
NOTE: A status code display does not always mean that
there is a malfunction. A temporary operating condition
can cause a status code display.
The status codes all have a dash (–) before the numbers.
If the battery is disconnected, the dash (–) will be miss-
ing on the display of the Hand Set when a battery is con-
nected again. If a status code number is indicated on the
digital display, checks and adjustments cannot be done.
See TABLE 5. and the following Status Code Charts to
find and correct the malfunction. There are no checks or
adjustments for the status codes. These code numbers
are only codes to help identify a possible malfunction.
TABLE 5. has a short description of the different status
codes.
There is a Status Code Chart in this section for each
status code. These charts have a more complete descrip-
tion of the status code, the circuit that has generated the
input for the status code, the symptom and the possible
causes.
REGISTER MAPS
The information in the Register Maps shown in
TABLE 6. and TABLE 7. is not needed by most service
people. This additional technical information is for ser-
vice engineers who have special troubleshooting re-
quirements. These registers and their descriptions are
designed by the General Electric Company. Many of
these registers are programmed by Hyster Company to
do certain functions. These register maps as pro-
grammed by Hyster Company are shown in the Param-
eter Tables.
NOTE: The number of the EEPROM register is off–set
by one from the PC Register Number and the Function
Number in the Register Map Tables. The EEPROM be-
gins its count from zero (0) while the PC and Hand Set
begin their count from one (1).
NOTE: EEPROM = Electrically–Erasable–
Programmable–Read–Only–Memory
27
EV–100ZX Motor Controller

TABLE 5. STATUS CODES LIST

STATUS DESCRIPTION STATUS DESCRIPTION
CODE CODE
CARD INPUTS REGENERATIVE BRAKING
BLANK No input voltage to control card or display –70 Current sensor input missing (yellow wire)
–01 No input signal from seat switch –71 Current sensor input missing (green wire)
–02 FWD switch closed on initial start –72 Regenerative braking contactor does
–03 REV switch closed on initial start not energize
–04 Start switch, low voltage after start –73 Regenerative braking contactor does not
–05 Start or brake switch did not close deenergize or deenergizes slowly
–06 Accelerator depressed, no direction selected –74 Regenerative braking contactor
–07 Accelerator input voltage too high energizes too slowly
–08 Accelerator input voltage too low or power to –75 SCR 1 does not go OFF during
control card after key in ON position regenerative braking
–09 Both FWD and REV switches closed –76 C1 voltage too high during
at same time regenerative braking
–11 The START switch is closed when the key switch
is closed and voltage is applied to the control LIFT TRUCK MANAGEMENT*
card. –90 Temperature too high, traction motor*
–15 Battery volts too low –91 Temperature too high, hydraulic pump motor*
–16 Battery volts too high –93 Brush wear, steering pump motor*
–17 Wrong control card installed –94 Brush wear, traction motor*
–21 Accelerator input is less than 0.25 volts. –95 Brush wear, hydraulic pump motor*
–99 Maintenance Alert Code.
CONTACTOR PANEL, TRACTION CIRCUIT
–23 Coil current low, Forward or Reverse contactor SCR CONTROL, HYDRAULIC PUMP
–24 Voltage at T2 too high –117 Wrong control card installed
–25 1A contactor does not open or opens too slowly –123 Pump PMT contactor coil current is too low
–26 Short–circuit in electronic driver for –124 Voltage at T2 too high
RB, SP or FW contactor –125 1A contactor does not deenergize or opens
too slowly
SCR CONTROL, TRACTION CIRCUIT –141 Open thermal protector or
–41 Open thermal protector or motor control temperature too high
motor control temperature too high –142 Motor sensor input missing (green wire)
–42 Motor sensor input missing (green wire) –143 Motor sensor input missing (yellow wire)
–43 Motor sensor input missing (yellow wire) –144 SCR 1 did not go OFF correctly
–44 SCR 1 did not go OFF correctly –145 SCR 1 did not go ON correctly
–45 SCR 1 did not go ON correctly –146 T2 voltage too high
–46 T2 voltage too high –147 SCR 2 does not go ON correctly
–47 SCR 2 does not go ON correctly –148 T2 voltage too low
–48 T2 voltage too low) –149 SCR 5 does not go ON correctly
–49 SCR 5 does not go ON correctly –150 C1 volts low
–50 C1 voltage too low –151 C1 volts high with high motor current
–51 C1 voltage too high with high motor current –152 C1 volts high with low motor current
–52 C1 voltage too high with low motor current –154 Short–circuit in electronic driver for the
–53 SCR 1 does not go OFF during plugging hydraulic pump contactor or 1A contactor
–54 Short–circuit, FWD, REV or 1A electronic driver –157 Polarity check, current sensor output voltage
–57 Polarity check, current sensor output voltage

* 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.

28
 EV–100ZX Motor Controller

TABLE 6. REGISTER MAP FOR CONTROL CARDS ZH AND ZY (TRACTION)

EEPROM PC Hand
Access
Register Register Set (HS) Description Restrictions
Number Number Number By:
0 1 1 Fault Code HS or PC Erases when battery is discon-
nected
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 Current Limit HS or PC None
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 Compensation HS or PC None
14 15 15 Battery Voltage Selection HS or PC None
15 16 16 Pedal Position Plugging HS or PC None
16 17 17 Type of Control Card Selection HS or PC None
17 18 18 Steering Pump Time Delay HS or PC None
18 19 19 Maintenance Alert (Tens/Units) HS or PC None
19 20 20 Maintenance Alert HS or PC None
(Thousands/Hundreds)
20 21 21 Maintenance Speed Limit HS or PC None
21 22 22 Mode Reference HS or PC
22 23 23 Hourmeter (minutes) HS or PC None
23 24 24 Hourmeter (seconds) HS or PC None
24 25 25 Fault Register Data HS or PC GE Temporary Storage
25 26 26 Battery Charge Data HS or PC GE Temporary Storage
26 27 27 Battery Voltage Data HS or PC GE Temporary Storage
27 28 28 Fault Count Pointer HS or PC None (Location of last fault re-
corded)
28 29 29 Hourmeter (Tens/Units) HS or PC None
29 30 30 Hourmeter (Thousands/Hundreds) HS or PC None
30 31 Auxiliary Hourmeter (Tens/Units) PC Only Reset to Zero only
31 32 Auxiliary Hourmeter 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/Hundreds) 1 PC Only Reset to Zero only
36 37 Fault 2 PC Only Reset to Zero only

29
EV–100ZX Motor Controller

TABLE 6. REGISTER MAP FOR CONTROL CARDS ZH AND ZY (TRACTION) (Continued)

Hand
EEPROM PC
Set (HS) Access
Register Function
Function Function Restrictions
Number Number By:
Number
37 38 BDI 2 PC Only Reset to Zero only
38 39 Hours (Tens/Units) 2 PC Only Reset to Zero only
39 40 Hours (Thousands/Hundreds) 2 PC Only Reset to Zero only
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/Hundreds) 3 PC Only Reset to Zero only
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/Hundreds) 4 PC Only Reset to Zero only
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/Hundreds) 5 PC Only Reset to Zero only
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/Hundreds) 6 PC Only Reset to Zero only
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/Hundreds) 7 PC Only Reset to Zero only
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/Hundreds) 8 PC Only Reset to Zero only
64 65 Fault 9 PC Only Reset to Zero only
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/Hundreds) 9 PC Only Reset to Zero only
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/Hundreds) 10 PC Only Reset to Zero only
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/Hundreds) 11 PC Only Reset to Zero only

30
 EV–100ZX Motor Controller

TABLE 6. REGISTER MAP FOR CONTROL CARDS ZH AND ZY (TRACTION) (Continued)

Hand
EEPROM PC
Set (HS) Access
Register Function
Function Function Restrictions
Number Number By:
Number
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/Hundreds) 12 PC Only Reset to Zero only
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/Hundreds) 13 PC Only Reset to Zero only
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/Hundreds) 14 PC Only Reset to Zero only
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/Hundreds) 15 PC Only Reset to Zero only
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/Hundreds) 16 PC Only Reset to Zero only
96 97 48 Instrument Panel Display CA–1 HS or PC None
97 98 49 Instrument Panel Display FWPU–1 HS or PC None
98 99 50 Instrument Panel Display SL1–1 HS or PC None
99 100 51 NOT USED HS or PC None
100 101 52 Instrument Panel Display CA–2 HS or PC None
101 102 53 Instrument Panel Display FWPU–2 HS or PC None
102 103 54 Instrument Panel Display SL1–2 HS or PC None
103 104 55 NOT USED HS or PC None
104 105 56 Instrument Panel Display CA–3 HS or PC None
105 106 57 Instrument Panel Display FWPU–3 HS or PC None
106 107 58 Instrument Panel Display SL1–3 HS or PC None
107 108 59 NOT USED HS or PC None
108 109 60 Instrument Panel Display CA–4 HS or PC None
109 110 61 Instrument Panel Display FWPU–4 HS or PC None
110 111 62 Instrument Panel Display SL1–4 HS or PC None
111 112 NOT USED PC Only
112 113 Secure Hourmeter (Tens/Units) PC Only Read Only
113 114 Secure Hourmeter PC Only Read Only
(Thousands/Hundreds)

31
EV–100ZX Motor Controller

TABLE 6. REGISTER MAP FOR CONTROL CARDS ZH AND ZY (TRACTION) (Continued)

Hand
EEPROM PC
Set (HS) Access
Register Function
Function Function Restrictions
Number Number By:
Number
114 115 Secure Auxiliary Hourmeter PC Only Read Only
(Thousands/Hundreds)
115 116 Secure Auxiliary Hourmeter PC Only Read Only
(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)

Hand
EEPROM PC
Set (HS) Access
Register Function
Function Function Restrictions
Number Number By:
Number
0 1 1 Fault Code HS or PC Erases when battery is discon-
nected
1 2 2 Internal Resistance Compensation HS or PC None
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 Compensation HS or PC None
Rate
7 8 8 NOT USED
8 9 9 NOT USED
9 10 10 NOT USED
10 11 11 Speed Limit (SL1) HS or PC None
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 Compensation HS or PC None
16 17 17 Type of Control Card Selection HS or PC None

32
 EV–100ZX Motor Controller

TABLE 7. REGISTER MAP FOR CONTROL CARD ZP (HYDRAULIC PUMP) (Continued)

Hand
EEPROM PC
Set (HS) Access
Register Function
Function Function Restrictions
Number Number By:
Number
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 pan-
el 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 re-
corded)
28 29 29 Hourmeter (Tens/Units) HS or PC None
29 30 30 Hourmeter HS or PC None
(Thousands/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
34 35 Hours (Tens/Units) 1 PC Only Reset to Zero only
35 36 Hours (Thousands/Hundreds) 1 PC Only Reset to Zero only
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/Hundreds) 2 PC Only Reset to Zero only
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/Hundreds) 3 PC Only Reset to Zero only
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/Hundreds) 4 PC Only Reset to Zero only
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/Hundreds) 5 PC Only Reset to Zero only

33
EV–100ZX Motor Controller

TABLE 7. REGISTER MAP FOR CONTROL CARD ZP (HYDRAULIC PUMP) (Continued)

Hand
EEPROM PC
Set (HS) Access
Register Function
Function Function Restrictions
Number Number By:
Number
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/Hundreds) 6 PC Only Reset to Zero only
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/Hundreds) 7 PC Only Reset to Zero only
60 61 Fault 8 PC Only Reset to Zero only
61 62 NOT USED
62 63 Hours (Tens/Units) 8 PC Only Reset to Zero only
63 64 Hours (Thousands/Hundreds) 8 PC Only Reset to Zero only
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/Hundreds) 9 PC Only Reset to Zero only
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/Hundreds) 10 PC Only Reset to Zero only
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/Hundreds) 11 PC Only Reset to Zero only
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/Hundreds) 12 PC Only Reset to Zero only
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/Hundreds) 13 PC Only Reset to Zero only
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/Hundreds) 14 PC Only Reset to Zero only
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

34
 EV–100ZX Motor Controller

TABLE 7. REGISTER MAP FOR CONTROL CARD ZP (HYDRAULIC PUMP) (Continued)

Hand
EEPROM PC
Set (HS) Access
Register Function
Function Function Restrictions
Number Number By:
Number
91 92 Hours (Thousands/Hundreds) 15 PC Only Reset to Zero only
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/Hundreds) 16 PC Only Reset to Zero only
96 97 48 Instrument Panel Display CA–1 HS or PC None
97 98 49 Instrument Panel Display SL2–1 HS or PC None
98 99 50 Instrument Panel Display SL4–1 HS or PC None
99 100 51 NOT USED HS or PC None
100 101 52 Instrument Panel Display CA–2 HS or PC None
101 102 53 Instrument Panel Display SL2–2 HS or PC None
102 103 54 Instrument Panel Display SL4–2 HS or PC None
103 104 55 NOT USED HS or PC None
104 105 56 Instrument Panel Display CA–3 HS or PC None
105 106 57 Instrument Panel Display SL2–3 HS or PC None
106 107 58 Instrument Panel Display SL4–3 HS or PC None
107 108 59 NOT USED HS or PC None
108 109 60 Instrument Panel Display CA–4 HS or PC None
109 110 61 Instrument Panel Display SL2–4 HS or PC None
110 111 62 Instrument Panel Display SL4–4 HS or PC None
111 112 NOT USED PC Only
112 113 Secure Hourmeter (Tens/Units) PC Only Read Only
113 114 Secure Hourmeter PC Only Read Only
(Thousands/Hundreds)
114 115 Secure Auxiliary Hourmeter PC Only Read Only
(Thousands/Hundreds)
115 116 Secure Auxiliary Hourmeter PC Only Read Only
(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

35
 STATUS CODE CHARTS

Status Code Description Cause Of Status Indication

No display on the instrument panel display No input voltage to the control card or the
NONE or the Hand Set display unit.
Memory Recall Indication of Fault CONTROL KEY
FUSE SWITCH
No No display on the instrument panel display or
the Hand Set
Possible Cause
No control voltage TB4
Make sure the key switch is ON and there is
voltage between PZ7 and PZ3 (battery
negative). Check that there is voltage between POWER
Circuit TB4 and PZ3. FUSE

Traction and Open circuit between control card plug Y and

Hydraulic Pump the instrument panel display or the Hand Set:
POS C1
Check for an open circuit or loose connections
between each wire going to the plug on the PZ7
control card and the instrument panel display or
the Hand Set.
Malfunction of the instrument panel display or
the Hand Set:
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 regenerative braking contactor closes and
the fuse will open. If the regenerative braking
diode is open, there will be no indicated fault
except that there will be stiff plugging and no
regenerative braking.

Status Code Description Cause Of Status Indication

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

1
Status Code Charts

Status Code Description Cause Of Status Indication

FORWARD direction switch is closed This Status Code will be indicated when TB5
–02 when the key switch is turned to ON. is greater than 60% of battery voltage when
the key switch is turned to ON.

Memory Recall Indication of Fault START

SEAT
SWITCH SWITCH
No Forward contactor will not close. Static Return
to OFF (SRO) circuit activated.
Possible Cause
FORWARD direction switch is closed when the TB4 TB3
key switch is turned to ON. TB2
Move the direction control lever to NEUTRAL FORWARD
and then select a direction. SWITCH
Circuit TB5
FORWARD direction switch has a short–circuit.
Traction
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.

Status Code Description Cause Of Status Indication

REVERSE direction switch is closed when This Status Code will be indicated when TB6
–03 the key switch is turned to ON. is greater than 60% of battery voltage when
the key switch is turned to ON.

Memory Recall Indication of Fault

SEAT
No Reverse contactor will not close. Static Return SWITCH
to OFF (SRO) circuit activated.
START
Possible Cause SWITCH
TB4 TB3
REVERSE direction switch is closed when the
key switch is turned to ON. TB2
Move the direction control lever to NEUTRAL
REVERSE
and then select a direction. SWITCH
Circuit TB6
REVERSE direction switch has a short–circuit.
Traction
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.

2
 Status Code Charts

Status Code Description Cause Of Status Indication

Low voltage when the START switch is This Status Code will be indicated when the
–04 closed after the key switch and the seat voltage at TB2 is less than 60% of battery
switch are closed. voltage 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 will not close.
Possible Cause
SEAT
FORWARD or REVERSE direction switch is SWITCH
closed when the key switch is turned to ON.
Push on the accelerator to close the START START
switch. The Status Code will change to –03 if SWITCH
the REVERSE direction switch or to –02 if the TB4 TB3
Circuit FORWARD direction switch is closed. Move the
TB2
Traction direction control lever to NEUTRAL and then
select a direction.
Short–circuit between TB2 and 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 will be 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.

Status Code Description Cause Of Status Indication

START switch or brake switch does not This Status Code will be indicated when TB1
–05 close is less than 2.5 volts and TB2 is less than
60% of battery voltage.
Memory Recall Indication of Fault
SEAT
No Forward or Reverse contactor will not close. SWITCH
Possible Cause
Malfunction of the brake switch circuit. START
SWITCH
Check the brake switch to make sure it closes TB4 TB3
when the brake pedal is released.
TB2
Check for an open circuit or loose connections in
the wires from the brake switch to the seat
Circuit switch, to TB3, and from the brake switch to the TB1 PZ6
Traction START switch.
Malfunction of the START switch circuit.
Check the START switch to make sure it closes
when the accelerator is actuated. ACCELERATOR
POTENTIOMETER
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.

NEGATIVE

3
Status Code Charts

Status Code Description Cause Of Status Indication

Accelerator actuated and no direction This Status Code will be indicated when TB5
–06 switch is selected. and 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 will not close. SEAT
SWITCH
Possible Cause
Accelerator pedal is actuated before a START
SWITCH
direction switch is closed.
TB4 TB3
The Status Code will be cleared when a direction
switch is closed or the accelerator pedal is TB2
released.
Circuit REVERSE
Malfunction of the circuit for the FORWARD or FORWARD SWITCH
Traction TB1 PZ6 TB5
REVERSE switches. SWITCH
Check the direction switches to make sure they TB6
close when the direction control lever is moved
to that position.
Open circuit between the direction switches ACCELERATOR
and TB5 or TB6. POTENTIOMETER

Check for an open circuit or loose connections in

the wires for the direction control circuits to TB5
or TB6.

NEGATIVE

Status Code Description Cause Of Status Indication

Accelerator input voltage is too high. This Status Code will be indicated when the
–07 accelerator input voltage at TB1 is higher than
3.7 volts and a direction contactor is closed.

Memory Recall Indication of Fault

No Forward or Reverse contactor will close, but the
motor controller will not operate when the
accelerator pedal is actuated or the –07 Status
Code clears when the lift truck begins to accelerate.
TB1 PZ6
Possible Cause
Accelerator potentiometer has a malfunction or
needs adjustment.
Circuit The correct output voltage at TB1 is more than 3.0
ACCELERATOR
Traction volts. Repair or adjust the accelerator potentiometer POTENTIOMETER
so that it will correctly change from 3.5 to less than 0.5
volts (minimum 0.30 volts) when the accelerator
pedal is actuated.
Open circuit between battery negative and TB1 in
the accelerator input circuit. NEGATIVE
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.

4
 Status Code Charts

Status Code Description Cause Of Status Indication

Accelerator input voltage is too low after the This Status Code will be indicated when the
–08 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 are opened and
closed.

Memory Recall Indication of Fault

No Forward or Reverse contactor will not close.
Possible Cause
Accelerator potentiometer has a malfunction or
needs adjustment. TB1 PZ6
The correct output voltage at TB1 is more than 3.0
volts. Repair or adjust the accelerator potentiometer
so that it will correctly change from 3.5 to less than 0.5
Circuit volts (minimum 0.30 volts) when the accelerator
Traction pedal is actuated. ACCELERATOR
POTENTIOMETER
Short–circuit between battery negative and 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. NEGATIVE
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.

Status Code Description Cause Of Status Indication

Both FORWARD and REVERSE direction This Status Code will be 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 will not close.
Possible Cause TB2
FORWARD or REVERSE direction switches
REVERSE
are welded closed or need adjustment. FORWARD SWITCH
TB1 PZ6 TB5
Replace or adjust the direction switches to make SWITCH
sure that they are both open when the direction TB6
control lever is in NEUTRAL..
Circuit
Short–circuit between battery positive and TB5
Traction or TB6. ACCELERATOR
POTENTIOMETER
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.
NEGATIVE
Disconnect the wires and measure the voltage at
TB5 and TB6. The correct voltage will be less
than 60% of battery voltage.

5
Status Code Charts

Status Code Description Cause Of Status Indication

The START switch is closed when the key This Status Code will be indicated when TB2
–11 switch is closed and voltage is applied to is greater than 60% of battery voltage when
the control card. the key switch is closed.

Memory Recall Indication of Fault

No Forward or Reverse contactor will not close.
SEAT
Possible Cause SWITCH

START switch needs adjustment or is

damaged. START
SWITCH
Input voltage must be less than 60% of battery TB4 TB3
voltage when the key switch is closed. Replace
or adjust the START switch. TB2
Circuit
Short–circuit between battery positive and TB2
REVERSE
Traction in START switch circuit.
TB5 FORWARD SWITCH
(ZX Control Card TB1 SWITCH
Disconnect the wire from TB2. Check for a
Only) short–circuit between the end of the wire and the TB6
battery positive. Resistance must be greater
than 4.7 K ohms.
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.

Status Code Description Cause Of Status Indication

Battery voltage is too low. This Status Code will be indicated when the
–15 battery volts are 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 will not close.
Possible Cause
Discharged battery. MINIMUM
BATTERY
Check the battery for the correct open circuit NOMINAL VOLTAGE AT
voltage as shown in the illustration at right and BATTERY 1.95 VOLTS
charge the battery as required. VOLTS PER CELL

Bad connection at battery connector or in the 36 35.1

Circuit 48 46.8
power cables.
Traction 72 70.2
Check the power cables and the battery 80 81.9
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 15 for the correct adjustment for
the battery that is being used. See the
instructions for the Hand Set. Make the correct
adjustments.

6
 Status Code Charts

Status Code Description Cause Of Status Indication

Battery voltage is too high. This Status Code will be indicated when
–16 the battery volts are greater than 2.40
volts per cell when the key switch is
turned to ON.

Memory Recall Indication of Fault

RB SENSOR
No Forward or Reverse contactor will not close.
Possible Cause
POS YELLOW
Control card needs adjustment. D7
WIRE
Check Function 15 for the correct adjustment for the
battery that is being used. See the instructions for the
Hand Set. Make the correct adjustments. PA4
Open circuit in current sensor circuit for the
Circuit
regenerative braking.
Traction
Check for a broken yellow wire from the current RB
sensor to PA4. Check for loose connections or a MAXIMUM
BATTERY
broken weld at the current sensor. Check PA4 for a NOMINAL VOLTAGE AT
loose plug or pin connection. BATTERY 2.40 VOLTS
VOLTS PER CELL
Battery is charged wrong or wrong battery is
installed. 36 43.2
48 57.6
Check the battery for the correct open circuit voltage 72 86.4
(see the table in the illustration at the right). If the 80 100.8
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).

Control Function 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.

Status Code Description Cause Of Status Indication

Selection for type of control card is wrong. This Status Code will be indicated when
–17 the control card type selection is set to a
wrong number.

Memory Recall Indication of Fault

No Forward or Reverse contactor will not close.
Possible Cause
Control card type selection is wrong.
Check Function 17 in the instructions for the Hand Set.
Make the correct adjustments for the type of control
card.

Circuit
Traction

7
Status Code Charts

Status Code Description Cause Of Status Indication

Accelerator input is less than 0.25 volts. This Status Code will be indicated when
–21 the control card type selection is set to a
wrong number.
Memory Recall Indication of Fault
No Controller will not operate.
Possible Cause
Accelerator potentiometer needs adjustment or is
damaged. TB1 PZ6
Input voltage at 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 and TB1 in
ACCELERATOR
Traction accelerator input circuit. POTENTIOMETER
(ZX Control Card
Disconnect wire from TB1 and check for short–circuit
Only) from end of wire to battery negative. Resistance must
be greater than 4.7 K ohms.
Open–circuit between accelerator potentiometer and
NEGATIVE
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.

Status Code Description Cause Of Status Indication

Forward or Reverse contactor or any other contactor This Status Code will be indicated
–23 has a short–circuit or low current to the coil. when there is a current draw in a
contactor coil of less than 100 ma.

Memory Recall Indication of Fault

No Forward or Reverse contactor will 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 code –24. +
F +
Possible Cause R
1A +
Malfunction of the coil circuit for Forward and Reverse PB4
+
contactors. PB5
RB
+
Circuit Check for open circuit or loose connection between PB4 and
PS
PB6 FW
Traction the positive side of the Forward contactor coil and between
PB5 and the positive side of the Reverse contactor coil. PB2
Remove Plug B. Check the resistance in the wire from PB4 PB3
to the positive side of the Forward contactor coil. The correct
value is 10 to 14 ohms. Do the same check for the Reverse PB1
contactor coil.
Check for an open Forward–Reverse control fuse. NOTE: The PS coil does not apply
when the lift truck has “On–Demand”
Malfunction of the coil circuit for 1A, RB, PS, or FW power steering.
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.

8
 Status Code Charts

Status Code Description Cause Of Status Indication

T2 voltage is greater than 12% of battery voltage. This Status Code will be indicated when
–24 T2 voltage is greater than 12% of
battery voltage and the circuit for the
direction contactors is energized.

Memory Recall Indication of Fault T2

No The motor controller does not operate. The Status Code
can change between code –23 and code –24. Do all of F FIELD R
the Possible Cause checks for this Status Code. If the
problem is not found, do the checks in code –23. F R
Possible Cause A1
A1
Most common cause is that the contacts on one of the
direction contactors or the RB contactor does not close NOTE: The PS coil does
Circuit correctly to make an electrical connection. not apply when the lift
A2 truck has “On–Demand
Traction Clean the contact of the direction contactors and the RB power steering.
RB
contactor with alcohol. New contacts can have a surface
condition that prevents conducting electric current. Check A2
+
that the contacts close correctly. +
F +
Malfunction of coil circuit for Forward and Reverse R
contactor. 1A +
PB4 +
Check for welded contacts or contactors that do not close RB
PB5 +
correctly. PS
PB6 FW
Malfunction of RB contactor.
PB2
Check that the contacts and contactor will close correctly. PB3
Check for an open circuit or loose connections between the PB1
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.

Status Code Description Cause Of Status Indication

1A Contactor does not open or opens slowly. This Status Code will be indicated when
–25 the 1A Contactor opens in greater than
0.060 seconds.

Memory Recall Indication of Fault

Yes Forward and Reverse, and 1A contacts wear rapidly. POS
Status Code –46 can be indicated and no fault is
found.
Possible Cause
1A
NOTE: This Status Code can only be found when the
Hand Set is connected. This Status Code is shown
here as additional information for Status Code –46.
Circuit Malfunction of 1A Contactor. T2
Traction Check 1A Contactor for slow operation when it opens.

9
Status Code Charts

Status Code Description Cause Of Status Indication

Electronic driver in control card for the RB, PS, This Status Code will be indicated when
–26 or FW contactor has a short–circuit. there is a short–circuit in the electronic
driver for the 1A, RB, or PS contactor
coil.
Memory Recall Indication of Fault
Yes The 1A, RB, or PS contactor closes immediately +
when the key switch is closed. +
1A
Possible Cause RB +

Malfunction of an electronic driver in the control card. PB6 PS

Circuit
Replace the control card. PB2
Traction PB3

Status Code Description Cause Of Status Indication

Open thermal protector or motor controller is too This Status Code will be indicated when the
–41 hot. voltage between PZ1 and PZ5 is greater 1.8
volts.

Memory Recall Indication of Fault BLK

PZ1
No The traction motor has reduced power on no power
in the SCR range.
Possible Cause
PZ5
Open circuit, thermal protector. THERMAL GRY
PROTECTOR
Check for a loose or broken wire between the following
points:
Black wire between thermal protector and PZ1
Circuit Gray wire between thermal protector and PZ5.
Traction Malfunction of thermal protector.
Disconnect the wires from PZ1 and PZ5. When the
temperature is approximately 25°C (75°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 will be indicated when the
–42 voltage 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
A2
No No power to the traction motor in the SCR range.
Possible Cause SCR 1 GRN
PZ4
CURRENT
Open sensor wire circuit to PZ4. SENSOR

Check for a loose or broken wire (green wire) between

Circuit
the current sensor and PZ4 on the control card.
Traction NEGATIVE

10
 Status Code Charts

Status Code Description Cause Of Status Indication

Input missing from motor current sensor. This Status Code will be indicated when the
–43 voltage 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 A2
normal and can not be controlled with the C/L
adjustment.
SCR 1
Possible Cause CURRENT
SENSOR PZ3
Open sensor wire circuit to PZ3. YEL
Check for a loose or broken wire (yellow wire) between
Circuit the current sensor and PZ3 on the control card.
Traction
NEGATIVE

Status Code Description Cause Of Status Indication

SCR 1 does not go to OFF correctly. This Status Code will be indicated
–44 when SCR 1 does not go to OFF
correctly during operation.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open and close, then will +
only close when the key switch is opened and closed. SCR 1 C1
–
Possible Cause
SCR 2
Malfunction of SCR 5 circuit.
1X
Check for a short–circuit across SCR 5.
Check for a short–circuit across the suppressor for SCR T5
Circuit 5.
Check for a open circuit across SCR 2 or an open gate SUPPRESSOR
Traction lead to SCR 5.
SCR 5

Malfunction of SCR 2 circuit.

Check for a short–circuit across SCR 2. T4 L1 T3
Check for a short–circuit across the suppressor for SCR
2.
SUPPRESSOR
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.

11
Status Code Charts

Status Code Description Cause Of Status Indication

SCR 1 does not go to ON correctly. This Status Code will be indicated
–45 when SCR 1 does not go ON
correctly during operation.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open and close, then will +
only close when the key switch is opened and closed. C1
–
Possible Cause SCR 1
WHT/BLU
Malfunction of SCR 2 circuit. PZ8
Check for a short–circuit across SCR 2. PZ9
BLU
Check for a short–circuit across the suppressor for SCR
Circuit 2.
SCR 2
Check for a open circuit across SCR 2 or an open gate
Traction lead to SCR 2.
Malfunction of SCR 1 circuit.
1X
Check for an open circuit or loose connections between
SCR 1 and PZ8 (white/blue wire).
SUPPRESSOR
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 will be indicated when
–46 (Also see Status Code –25) the voltage at T2 is greater than 85% of
battery voltage.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors will not close. P
Possible Cause
Malfunction of SCR 1 circuit. SCR 1

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. 1A
Circuit Malfunction of Contactor 1A.
Traction Check for welded contacts on Contactor 1A that will
hold the contactor closed.
T2

12
 Status Code Charts

Status Code Description Cause Of Status Indication

SCR 2 does not go to ON correctly. This Status Code will be indicated when
–47 (Also see Status Code –25) SCR 2 has a failure and does not go
ON.

Memory Recall Indication of Fault SPIDER

Yes Forward or Reverse contactors open and close, then

will only close when the key switch is opened and SCR 5
closed.
RED
Possible Cause WIRE
RED/WHITE SCR 2
Malfunction of SCR 2 circuit. WIRE
Check that SCR 2 will go ON with a gate signal.
Circuit Check for an open circuit or loose connection +
between SCR 2 gate and PZ10 (white/red wire).
Traction C1
Check for an open circuit or loose connection –
between SCR 1 and C1 and through the SCR 2 SCR 1
circuit.
Check for Forward or Reverse contactors PZ10
momentarily opening and closing.
RED/WHITE
Check for Forward or Reverse contactors WIRE
momentarily opening and closing during operation
when traveling over bumps and dock plates.

T5 1X
SCR 2

Status Code Description Cause Of Status Indication

Voltage check at T2 is less than 12% of battery This Status Code will be indicated when
–48 voltage. a voltage check at T2 is less than 12%
of battery voltage.

Memory Recall Indication of Fault

Yes Forward or Reverse contactors will not close.
SCR 1
Possible Cause
Malfunction of Forward or Reverse contactors.
T2
Check for welded contacts that hold a Forward or
F R
Reverse contactor closed.
Check for slow operation of a Forward or Reverse F R
contactor.
Circuit
Malfunction of diode D3 circuit. A1
Traction
Check for a short–circuit across D3.
SUPPRESSOR
Check for a short–circuit across the suppressor for
D3 A2
D3.
A2

CURRENT
SENSOR

NEGATIVE

13
Status Code Charts

Status Code Description Cause Of Status Indication

SCR 5 does not go ON correctly. This Status Code will be indicated
–49 when SCR 5 does not go ON
correctly.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open and close, then will SCR 1
+
only close when the key switch is opened and closed. PZ12 PZ14 C1
Possible Cause –
SCR 2
Malfunction of SCR 5 circuit.
Check for a short–circuit across SCR 5.
Check for a short–circuit across the suppressor for SCR 1X
Circuit 5.
Check for a open circuit across SCR 2 or an open gate SUPPRESSOR
Traction lead to SCR 5. SCR 5
Check for an open circuit or a loose connection between
W/PUR
SCR 5 and PZ12 (white/purple wire). WIRE
T4 L1 T3
Malfunction of SCR 2 circuit.
Check for a short–circuit across SCR 2. SCR 5
SUPPRESSOR
Check for a short–circuit across the suppressor for SCR
2.
SCR 2
Check for a open circuit across SCR 5 or an open gate
lead to SCR 2.
T5 T4
Malfunction of C1. ORG WIRE T3
Check for open capacitor C1.
REACTOR
Check for loose connections at capacitor terminals.

Status Code Description Cause Of Status Indication

Low voltage on capacitor C1. This Status Code will be indicated when
–50 SCR 2 has a failure and does not go
ON.
Memory Recall Indication of Fault SPIDER

No Forward or Reverse contactor will close. Motor

controller does not operate. SCR 5

Possible Cause RED

Malfunction of SCR 2 circuit. WIRE
RED/WHITE SCR 2
Check for an open circuit or loose connection WIRE
between spider assembly and SCR 5.

Circuit Check for an open circuit or loose connection +

between SCR 5 and SCR 2.
Traction C1
Check for an open circuit or loose connection –
between SCR 2 and PZ11 (red wire) and between SCR 1
SCR 2 gate connection and PZ10 (white/red wire).
Check that SCR 2 will go ON with a gate signal. PZ10

RED/WHITE
WIRE

T5 1X
SCR 2

14
 Status Code Charts

Status Code Description Cause Of Status Indication

Voltage on C1 too high when motor current is This Status Code will be indicated when
–51 high. the voltage 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 +
will only close when the key switch is opened and
C1
closed. SCR 1 –
Possible Cause
Too much inductance from cables. T2
Check that the battery cables are too long. F R

Circuit Check that additional cables for other equipment

have been added. F R
Traction
Motor current too high.
A1
Check for a short–circuit a field winding.
Check for a short–circuit across an armature winding. SUPPRESSOR
D3 A2
A2

CURRENT
SENSOR

NEGATIVE

Status Code Description Cause Of Status Indication

Voltage on C1 too high when motor current is This Status Code will be indicated when the
–52 low. voltage on C1 is greater than 225 volts and
the motor current is less than 200 amps.

Memory Recall Indication of Fault

+
Yes Forward or Reverse contactors open and close, then
C1
will only close when the key switch is opened and SCR 1 –
closed.
Possible Cause T2
Too much inductance from cables. F R
Check that the battery cables are too long.
F R
Circuit Check that additional cables for other equipment
have been added.
Traction A1
Malfunction of diode D4 circuit.
Check for a short–circuit across D4.
Check for an open circuit or loose connection in the A2
D4 circuit.
A2
D3 D4
Malfunction of diode D3 circuit.
Check for an open circuit or loose connection in the CURRENT
SENSOR
D3 circuit.

NEGATIVE

15
Status Code Charts

Status Code Description Cause Of Status Indication

SCR 1 does not go OFF correctly during plugging cycle. This Status Code will be
–53 indicated when any failure of
SCR 1 to go OFF during the
plugging cycle.
Memory Recall Indication of Fault
+
Yes Forward or Reverse contactors open and close, then will only
C1
close when the key switch is opened and closed. SCR 1 –
Possible Cause
SCR 1 failure is not caused by plugging.
Cause the traction motor to stall in both directions and check F R
for a new status code that will also indicate the failure. Do
Troubleshooting for the new or additional Status Code. F R
Circuit
SCR 1 failure is caused by plugging.
Traction A1
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 A2 D4
the yellow and green wire from the current sensor to the
A2
control card for open or loose connections.
Malfunction in motor circuit. GRN PZ4
CURRENT
SENSOR PZ3
Check motor circuit for open or loose connections. YEL
Check motor brushes for wear and installed correctly.
NEGATIVE
Check for Forward or Reverse contactors momentarily opening
and closing.
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

Short–circuit in an electronic driver for the This Status Code will be indicated when
–54 Forward, or Reverse, or 1A contactor. the 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 will not operate.
Possible Cause
Fuse 7 is open.
Check for a short–circuit that can cause Fuse 7 to
open. Replace Fuse 7.
Control card malfunction.
Circuit Replace the control card.
Traction

16
 Status Code Charts

Status Code Description Cause Of Status Indication

Polarity check of the output voltage from the current This Status Code will be
–57 sensor. indicated when the input
voltage to PZ4 and PZ3 is the
wrong polarity.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open and close, then will only
close when the key switch is opened and closed. F R
Possible Cause
F R
The yellow and green wires from the current sensor to the
control card are connected wrong.
A1
Check the yellow wire is connected to PZ3 and the green wire
is connected to PZ4.
Circuit
Check from the current sensor to the control card for open or A2
Traction loose connections.
A2
Power cables are connected wrong in motor circuit. SCR 1 GRN PZ4
Check that the power cables are connected correctly in the CURRENT
SENSOR PZ3
motor circuit. YEL

NEGATIVE

Status Code Description Cause Of Status Indication

No voltage input from current sensor for This Status Code will be indicated when
–70 regenerative braking (yellow wire). the input signal to PA4 is missing.
Memory Recall Indication of Fault RB SENSOR

No Motor controller will not operate.

POS
Possible Cause YELLOW D7
WIRE
Open circuit in current sensor circuit for the GREEN
regenerative braking. WIRE

Check for a broken yellow wire from the current RB PA4 PA5
sensor to PA4. Check for loose connections or a
broken wire at the current sensor. Check PA4 for a
Circuit loose plug or pin connection. Check that the control
Traction card type is set correctly

Status Code Description Cause Of Status Indication

No voltage input from current sensor for This Status Code will be indicated when
–71 regenerative braking (green wire). the input signal to PA5 is missing.
Memory Recall Indication of Fault RB SENSOR

No Motor controller will not operate.

Possible Cause POS YELLOW
D7
WIRE
Open circuit in current sensor circuit for the GREEN
WIRE
regenerative braking.
Check for a broken green wire from the current RB PA4 PA5
sensor to PA5. Check for loose connections or a
broken wire at the current sensor. Check PA5 for a
Circuit loose plug or pin connection. Check that the control
Traction card type is set correctly.

17
Status Code Charts

Status Code Description Cause Of Status Indication

Regenerative braking contactor does not close. This Status Code will be indicated when
–72 the control card is ready to operate and
the voltage at PA6 is 2.5 volts or
greater.
Memory Recall Indication of Fault + RB
TRACTION A1 COIL
No Regenerative braking control does not operate.
MOTOR
D7
Possible Cause
Open circuit in the PA6 circuit. A2

Check for open circuit or loose connections between PA6

PA6 and the A2 connection (positive connection) of PB2
the RB contactor.
Check for open circuit or loose connections between
Circuit D7 and the A2 connection (positive connection) of the RB
Traction RB contactor. CONTACTS
A2

Status Code Description Cause Of Status Indication

Regenerative braking contactor does not open This Status Code will be indicated when
–73 or opens slowly. the RB contacts do not open within 100
milliseconds after power is removed
from the RB contactor coil.
Memory Recall Indication of Fault
A1
Yes Forward or Reverse contactors open and close, then
TRACTION
will only close when the key switch is opened and MOTOR D7
closed. A2
Possible Cause PA6
RB contactor malfunction.
Check the RB contactor for smooth operation and
wear on the moving parts.
Circuit
Input signal to PA6 is not regular. RB
Traction CONTACTS
Check for open circuit or loose connections in the
A2
PA6 circuit from PA6 to the A2 connection (positive
connection) of the RB contactor.

18
 Status Code Charts

Status Code Description Cause Of Status Indication

Regenerative braking contactor closes slowly. This Status Code will be indicated when the
–74 RB 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 will
only close when the key switch is opened and closed.
Possible Cause A1 + RB
TRACTION COIL
RB contactor malfunction. MOTOR
D7
Check the RB contactor for smooth operation and wear
on the moving parts. A2

Circuit Input signal to PA6 is not regular. PA6

PB2
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. RB
CONTACTS
Check the resistance of the RB contactor coil. The A2
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.

19
Status Code Charts

Status Code Description Cause Of Status Indication

SCR 1 does not go OFF during regenerative This Status Code will be indicated when
–75 braking. there is any failure of SCR 1 to go OFF
during regenerative braking.

Memory Recall Indication of Fault

Yes Forward or Reverse contactors open and close, then will RB SENSOR
only close when the key switch is opened and closed.
Possible Cause POS
YELLOW
WIRE
To find if SCR 1 fault is caused by regenerative braking. GREEN
WIRE
Cause the traction motor to stall in both directions and
check for a new status code that will also indicate the A1 PA4 PA4 PA6
failure. Do Troubleshooting for the new or additional TRACTION
MOTOR
Circuit Status Code. D7
Traction If Status Code 75 continues: A2
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. RB
CONTACTS
Wire 17 from the RB contactor to PA6.
NEGATIVE
Malfunction in motor circuit.
Check motor circuit for open or loose connections.
Check motor brushes for wear and installed correctly.
Check for Forward or Reverse contactors momentarily
opening and closing.
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 on C1 too high during regenerative This Status Code will be indicated when
–76 braking. the 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 FUSE 1
500 A C1
will only close when the key switch is opened and SCR 1 –
closed.
Possible Cause +
Bad connection or not regular connection in battery
power circuit. BATTERY
Check battery power circuit for loose connections.
Circuit –
Check the power fuse and battery connections that
Traction can open during regenerative braking.
NEGATIVE
Too much inductance from cables.
Check that the battery cables are too long.

20
 Status Code Charts

Status Code Description Cause Of Status Indication

Traction motor temperature too high. This Status Code will be indicated when
–90 the voltage at terminal PA3 of the
hydraulic pump control card is at zero
volts.
Memory Recall Indication of Fault
PA5 PA4 PA3
No Status Code is indicated as a flashing number on the
instrument panel display. The lift truck speed will be
reduced when either the hydraulic pump motor or the
ORN/PNK
traction motor are too hot.
Possible Cause TEMPERATURE SWITCH
TRACTION MOTOR
A1
Traction motor is too hot. Temperature sensor has
closed to battery negative.. ARMATURE
BLK BLK
Circuit Permit traction motor to cool. A2
Traction and Other causes.
Hydraulic Pump PA 3 has a short–circuit to battery negative. DK BLU/PNK
GRN/PPL
There is a short–circuit in the sensor wires.
NEGATIVE
There is a short–circuit or other malfunction in the
sensor.

Status Code Description Cause Of Status Indication

Hydraulic pump motor temperature is too high. This Status Code will be indicated when
–91 the voltage at terminal PA6 of the
hydraulic pump control card is at zero
volts.
Memory Recall Indication of Fault
PB1 PB2 PA6
No Status Code is indicated as a flashing number on the
instrument panel display. The lift truck speed will be
reduced when either the hydraulic pump motor or the
traction motor are too hot.
Possible Cause TEMPERATURE SWITCH
HYDRAULIC PUMP MOTOR
S1
Hydraulic pump motor is too hot. Temperature sensor
has closed to battery negative.. ARMATURE
BLK
Circuit Permit the hydraulic pump motor to cool. A2
Hydraulic Pump Other causes. ORN/YEL

GRN/PNK
PA 2 has a short–circuit to battery negative.
DK BLU/GRY
There is a short–circuit in the sensor wires.
There is a short–circuit or other malfunction in the
sensor.

21
Status Code Charts

Status Code Description Cause Of Status Indication

Steering pump motor brushes are worn and This Status Code will be indicated when
–93 must be replaced. the voltage at terminal PA1 or PA2 of
the hydraulic pump control card is at
zero volts.
Memory Recall Indication of Fault
PA* PA* PA1
No Status Code is indicated as a flashing number on the
instrument panel display.
Possible Cause BRUSH WEAR SENSOR
STEERING PUMP MOTOR
Steering pump motor brushes are worn. The sensor
has closed to battery negative.. A1
Replace the brushes.
ARMATURE
Other causes.
Circuit A2
PA * or PA * has a short–circuit to battery negative.
Steering Pump
There is a short–circuit in the sensor wires. GRN/GRY

There is a short–circuit or other malfunction in the DK BLU/YEL

sensor.

Status Code Description Cause Of Status Indication

Traction motor brushes are worn and must be This Status Code will be indicated when
–94 replaced. the voltage at terminal PA4 or PA5 of
the hydraulic pump control card is at
zero volts.
Memory Recall Indication of Fault
PA5 PA4 PA3
No Status Code is indicated as a flashing number on the
instrument panel display.
Possible Cause ORN/PNK

Traction motor brushes are worn. The sensor has BRUSH WEAR SENSOR
closed to battery negative.. TRACTION MOTOR
A1
Replace the brushes.
ARMATURE
Other causes. BLK BLK
Circuit A2
PA 4 or PA 5 has a short–circuit to battery negative.
Traction and
Hydraulic Pump There is a short–circuit in the sensor wires. DK BLU/PNK
There is a short–circuit or other malfunction in the GRN/PPL
sensor.
NEGATIVE

22
 Status Code Charts

Status Code Description Cause Of Status Indication

Hydraulic pump motor brushes are worn and This Status Code will be indicated when
–95 must be replaced. the voltage at terminal PB1 or PB2 of
the hydraulic pump control card is at
zero volts.
Memory Recall Indication of Fault
PB1 PB2 PA6
No Status Code is indicated as a flashing number on the
instrument panel display.
Possible Cause
Hydraulic pump motor brushes are worn. The sensor BRUSH WEAR SENSOR
has closed to battery negative.. HYDRAULIC PUMP MOTOR
S1
Replace the brushes.
ARMATURE
Other causes. BLK
Circuit A2
PA 2 has a short–circuit to battery negative.
Hydraulic Pump ORN/YEL
There is a short–circuit in the sensor wires. GRN/PNK

There is a short–circuit or other malfunction in the DK BLU/GRY

sensor.

Status Code Description Cause Of Status Indication

Maintenance Alert Code. This Status Code will be indicated when
–99 the maintenance alert hours are
reached.
Memory Recall Indication of Fault
No Status Code flashes ON and OFF.
Possible Cause
Maintenance Alert Hours have been reached. Do the
scheduled maintenance and reset the Maintenance
Alert hours. See Functions 19 and 20 in the Handset
instructions.

Circuit
Traction
(ZX Control Card
Only)

Status Code Description Cause Of Status Indication

Wrong control card type has been selected. This Status Code will be indicated when
–117 the wrong number for the control card
has been selected.
Memory Recall Indication of Fault
No Hydraulic motor controller will not operate.
Possible Cause
Wrong control card type has been selected.
See Function 17 in the instructions for the Hand Set.
Set the control card type correctly.

Circuit
Hydraulic Pump

23
Status Code Charts

Status Code Description Cause Of Status Indication

Low voltage to hydraulic pump contactor coil. This Status Code will be indicated
–123 when the current 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 will not close. +
P
Status code can change between code –123 and 1A
code –124. Do the checks for code –123 first. If the
PB4
problem not found, do the checks for code –124.
PB5
Possible Cause
PB6
Malfunction in coil circuit of hydraulic pump PB2
contactor.
PB3
Circuit
Check for open circuit or loose connections PB1
Hydraulic Pump between PB4 and the battery positive side of
contactor coil.
Disconnect Plug A and check the resistance
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.

Status Code Description Cause Of Status Indication

T2 voltage is greater than 12% of battery This Status Code will be indicated
–124 voltage. when T2 voltage is greater than 12%
of battery voltage and the electronic
driver for the hydraulic pump is
energized.
Memory Recall Indication of Fault T2
No The motor controller does not operate. The Status
Code can change between code –123 and code P
–124. Do the checks for code –124 first. If the
problem is not found, do the checks for code –123.
Possible Cause
Malfunction of hydraulic pump contactor. +
Check for welded contacts or contactors that do A1 +
P
Circuit 1A
not close correctly.
Hydraulic Pump PB4
Check that the armature assembly moves freely.
PB5
Check the contactor coil. (See code –123.) A2
PB6
Open motor circuit. 1A
PB2
Check for an open circuit or loose connections A2 PB3
in the motor circuit from the A1 connection to the
PB1
A2 connection on the SCR control panel.
Coil for contactor 1A is damaged.
Do the checks in code –123.

24
 Status Code Charts

Status Code Description Cause Of Status Indication

Hydraulic pump contactor does not open or This Status Code will be indicated when T2
–125 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 POS
hydraulic pump contactor.
Possible Cause SCR 1
NOTE: This status code can only be seen by using
the Hand Set or a PC and looking at Function 1. This
status code is added as help when trouble shooting
status code 146.
Circuit
Coil for contactor 1A is damaged.
Hydraulic Pump Do the checks in code –146.
T2

Status Code Description Cause Of Status Indication

Open thermal protector or motor controller is too This Status Code will be indicated when the
–141 hot. voltage between PZ1 and PZ5 is greater 1.8
volts.

Memory Recall Indication of Fault BLK

PZ1
No The hydraulic pump motor has reduced power on no
power in the SCR range.
Possible Cause
PZ5
Open circuit, thermal protector. THERMAL GRY
PROTECTOR
Check for a loose or broken wire between the following
points:
Black wire between thermal protector and PZ1
Circuit Gray wire between thermal protector and PZ5.
Hydraulic Pump Malfunction of thermal protector.
Disconnect the wires from PZ1 and PZ5. When the
temperature is approximately 25°C (75°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.

25
Status Code Charts

Status Code Description Cause Of Status Indication

Input missing from motor current sensor. This Status Code will be indicated when the
–142 voltage 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 A2
range.
Possible Cause GRN
SCR PZ4
CURRENT
Open sensor wire circuit to PZ4. SENSOR
Check for a loose or broken wire (green wire) between
the current sensor and PZ4 on the control card.
Circuit
Hydraulic Pump
NEGATIVE

Status Code Description Cause Of Status Indication

Input missing from motor current sensor. This Status Code will be indicated when the
–143 voltage 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 A2
normal and can not be controlled with the C/L
adjustment.
SCR
Possible Cause CURRENT
SENSOR PZ3
Open sensor wire circuit to PZ3. YEL
Check for a loose or broken wire (yellow wire) between
Circuit the current sensor and PZ3 on the control card.
Hydraulic Pump
NEGATIVE

26
 Status Code Charts

Status Code Description Cause Of Status Indication

SCR 1 in the hydraulic pump controller does not go This Status Code will be indicated
–144 OFF correctly. when SCR 1 does not go to OFF
correctly during operation.
Memory Recall Indication of Fault
No Hydraulic pump motor continues to operate until the +
battery is disconnected. SCR 1 C1
–
Possible Cause
SCR 2
Malfunction of SCR 5 circuit.
1X
Check for a short–circuit across SCR 5.
Check for a short–circuit across the suppressor for SCR T5
Circuit 5.
Check for a open circuit across SCR 2 or an open gate SUPPRESSOR
Hydraulic Pump lead to SCR 5.
SCR 5

Malfunction of SCR 2 circuit.

Check for a short–circuit across SCR 2. T4 L1 T3
Check for a short–circuit across the suppressor for SCR
2.
SUPPRESSOR
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.

27
Status Code Charts

Status Code Description Cause Of Status Indication

SCR 1 in the hydraulic pump controller does not go This Status Code will be indicated
–145 to ON correctly. when SCR 1 does not go ON
correctly during operation.
Memory Recall Indication of Fault
Yes The hydraulic pump control will not operate. +

Possible Cause C1
–
Malfunction of SCR 2 circuit. SCR 1
WHT/BLU
PZ8
Check for a short–circuit across SCR 2.
PZ9
Check for a short–circuit across the suppressor for SCR BLU
2.
Circuit Check for a open circuit across SCR 2 or an open gate
lead to SCR 2. SCR 2
Hydraulic Pump
Malfunction of SCR 1 circuit. 1X

Check for an open circuit or loose connections between T5

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). SUPPRESSOR

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 hydraulic This Status Code will be indicated when
–146 pump controller. the voltage at T2 is greater than 85% of
battery voltage.
Memory Recall Indication of Fault
No Hydraulic pump motor continues to operate until the POS
battery is disconnected.
Possible Cause SCR 1
Malfunction of SCR 1 circuit.
Check for a short–circuit across SCR 1. (See Status
Code –144.)

Circuit Check for a short–circuit across the insulator between

the heat sink for SCR 1 and the base plate.
Hydraulic Pump
Malfunction of SCR 1 OFF circuit.
See Status Code –144.. T2

28
 Status Code Charts

Status Code Description Cause Of Status Indication

SCR 2 does not go to ON correctly. This Status Code will be indicated when
–147 SCR 2 has a failure and does not go
ON.
Memory Recall Indication of Fault SPIDER

Yes Hydraulic pump motor will not operate or continues to

operate until the battery is disconnected. SCR 5

Possible Cause RED

Malfunction of SCR 2 circuit. WIRE
RED/WHITE SCR 2
Check that SCR 2 will go ON with a gate signal. WIRE
Check for an open circuit or loose connection
Circuit between SCR 2 gate and PZ10 (white/red wire). +
Check for an open circuit or loose connection C1
Hydraulic Pump between SCR 1 and C1 and through the SCR 2 –
circuit. SCR 1

PZ10

RED/WHITE
WIRE

T5 1X
SCR 2

Status Code Description Cause Of Status Indication

Voltage check at T2 in the hydraulic pump This Status Code will be indicated when
–148 controller is less than 12% of battery voltage. a voltage check at T2 is less than 12%
of battery voltage.
Memory Recall Indication of Fault
No Hydraulic pump control will not operate.
SCR 1
Possible Cause
Malfunction of diode D3 circuit.
T2
Check for a short–circuit across D3.
Check for a short–circuit across the suppressor for
D3. S1
Circuit Control card type is wrong.
If the hydraulic pump control is used without a pump SUPPRESSOR
Hydraulic Pump
contactor, the control card must be set correctly. See D3 A2
Function 17 for the correct setting. A2

CURRENT
SENSOR

NEGATIVE

29
Status Code Charts

Status Code Description Cause Of Status Indication

SCR 5 in the hydraulic pump controller does not go This Status Code will be indicated
–149 ON correctly. when SCR 5 does not go ON
correctly.
Memory Recall Indication of Fault
Yes Hydraulic pump motor will not operate or continues to SCR 1
+
operate until the battery is disconnected. PZ12 PZ14 C1
Possible Cause –
SCR 2
Malfunction of SCR 5 circuit.
Check for a short–circuit across SCR 5.
Check for a short–circuit across the suppressor for SCR 1X
Circuit 5.
Check for a open circuit across SCR 2 or an open gate SUPPRESSOR
Hydraulic Pump lead to SCR 5. SCR 5
Check for an open circuit or a loose connection between
W/PUR
SCR 5 and PZ12 (white/purple wire). WIRE
T4 L1 T3
Malfunction of SCR 2 circuit.
Check for a short–circuit across SCR 2. SCR 5
SUPPRESSOR
Check for a short–circuit across the suppressor for SCR
2.
SCR 2
Check for a open circuit across SCR 5 or an open gate
lead to SCR 2.
T5 T4
Malfunction of C1. ORG WIRE T3
Check for open capacitor C1.
REACTOR
Check for loose connections at capacitor terminals.

Status Code Description Cause Of Status Indication

Low voltage on capacitor C1 in the hydraulic This Status Code will be indicated when
–150 pump motor controller. SCR 2 has a failure and does not go
ON.
Memory Recall Indication of Fault SPIDER

No Hydraulic pump motor will not operate or continues to

operate until the battery is disconnected. SCR 5

Possible Cause RED

Malfunction of SCR 2 circuit. WIRE
RED/WHITE SCR 2
Check for an open circuit or loose connection WIRE
between spider assembly and SCR 5.

Circuit Check for an open circuit or loose connection +

between SCR 5 and SCR 2.
Hydraulic Pump C1
Check for an open circuit or loose connection –
between SCR 2 and PZ11 (red wire) and between SCR 1
SCR 2 gate connection and PZ10 (white/red wire).
Check that SCR 2 will go ON with a gate signal. PZ10

RED/WHITE
WIRE

T5 1X
SCR 2

30
 Status Code Charts

Status Code Description Cause Of Status Indication

Voltage on C1 in Hydraulic pump controller is This Status Code will be indicated when
–151 too high when motor current is high. the voltage 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 will not operate or continues to +
operate until the battery is disconnected.
C1
Possible Cause SCR 1 –

Too much inductance from cables.

Check that the battery cables are too long. T2
Check that additional cables for other equipment
Circuit have been added.
Motor current too high.
Hydraulic Pump
Check for a short–circuit a field winding. S1
Check for a short–circuit across an armature winding.
SUPPRESSOR
D3 A2

CURRENT
SENSOR

NEGATIVE

Status Code Description Cause Of Status Indication

Voltage on C1 in the hydraulic pump controller This Status Code will be indicated when the
–152 is too high when motor current is low. voltage on C1 is greater than 225 volts and
the motor current is less than 200 amps.

Memory Recall Indication of Fault +

Yes Hydraulic pump control will not operate C1
SCR 1 –
Possible Cause
Too much inductance from cables.
T2
Check that the battery cables are too long.
Malfunction of diode D3 circuit.
Check for an open circuit or loose connection in the S1
Circuit D3 circuit.
Hydraulic Pump
A2

D3
CURRENT
SENSOR

NEGATIVE

31
Status Code Charts

Status Code Description Cause Of Status Indication

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

Status Code Description Cause Of Status Indication

Polarity check of the output voltage from the current This Status Code will be
–157 sensor. indicated when the input
voltage to PZ4 and PZ3 is the
wrong polarity.
Memory Recall Indication of Fault
Yes Hydraulic pump control will not operate.
Possible Cause S1

The yellow and green wires from the current sensor to the
control card are connected wrong. A2
Check the yellow wire is connected to PZ3 and the green wire
is connected to PZ4.
GRN PZ4
Circuit Check from the current sensor to the control card for open or CURRENT
loose connections. SENSOR PZ3
YEL
Hydraulic Pump
Power cables are connected wrong in motor circuit.
Check that the battery negative cable connects to SCR NEGATIVE
negative and the motor A2 cable connects to SCR A2.

32
 REPAIRS

12
13
14 11
10

1 9

12657

7
3
6
2
4
5

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

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

FIGURE 1. TYPICAL CONFIGURATION OF THE EV–100ZX MOTOR CONTROLLER

Some voltage measurements must be made with the

WARNING SRO circuit complete. Make sure the drive wheels
Some adjustments in this section must be done with
are raised from the surface before doing
the battery connected and power applied to the con-
troubleshooting. If you are working alone, put a
troller. When making these adjustments, make sure
weight in the seat to close the seat switch. If your lift
the drive wheels are raised from the floor.

1
Repairs
truck has a seat brake, use a block behind the lower
actuator bar to release the seat brake when the op-
erator in 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 dis-
connected, make sure you also discharge the capaci-
tor C1 by putting a metal bar (screwdriver or similar
tool) with an insulated handle across the two connec-
tions to the capacitor.
NOTE: The electronic controller in many SitDrive lift
trucks can not be seen from the operator area. Some
checks and adjustments are difficult to do unless another
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.
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) is found on the (+)
bus bar. The condition of the fuses can normally be
checked by looking at them or checked with an ohmme-
ter. The location of the fuses can be found in NO TAG
CHECK AN SCR (See FIGURE 2.)
In the TROUBLESHOOTING section, there are in-
structions to check the SCRs.
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 will indicate most SCRs
with defects. The checks will not always indicate a fault
that does not occur regularly during operation. An SCR
with a type of fault that does not occur regularly will
2
normally indicate a resistance between the anode and
cathode of less than 100 000 ohms.
Six volts is needed for a gate signal to check the SCRs.
Use an ohmmeter and a six volt supply for a gate signal
or use a Cir/Kit meter to check the SCRs. The Cir/Kit
has a six volt supply for testing SCRs.
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 either
direction.
2 1 5 6
5
4
3
4
3
11566
1. SCR 1
2. THERMAL PROTECTOR
3. CATHODE (POWER CONNECTION)
4. ANODE (POWER CONNECTION)
5. GATE
6. SCR 2 OR SCR 5
FIGURE 2. HOW TO CHECK SCR 1, SCR 2, OR
SCR 5
2. Measure the resistance between the gate connection
and the cathode. Change the probe connections to the re-
verse direction and measure the resistance again. Re-
place the SCR if the resistance indicates zero or infinity
on the R x 1 scale in either direction.
3. Connect the (+) probe of the ohmmeter to the anode
and the (–) probe to the cathode. Momentarily connect
six volts from the Cir/Kit [or a battery between the gate
(+) and the cathode (–)]. The resistance indication on the
Cir/Kit or the ohmmeter will decrease to less than 10
ohms on the R x 1 Scale. Replace the SCR if the resis-
tance does not decrease when a six volt gate signal is ap-
plied momentarily. Make sure you touch the gate con-
nection only momentarily with the six volt connection

or you will damage the SCR. Make sure the polarity of
your test circuit is correct.
THE SCR ASSEMBLY
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 sheet of electrical in-
sulation between the SCR 1 assembly and the base plate.
The insulator permits heat to transfer from the heat sinks
to the base plate.
NOTE: Silicon compound (Part No. 1198757) is used
between the heat sinks and the parts of the controller.
The purpose of this compound is to fill in the microme-
ter size spaces between the parts to give better heat flow.
Always use a very thin layer of compound between the
parts. Too much compound will be an insulator and
cause both electrical and heat faults. It is better to use no
compound instead of too much. DO NOT USE this sili-
con compound on the threads of the diodes.
THERMAL PROTECTOR
The SCR 1 has a thermal protector fastened to the cath-
ode heat sink. See FIGURE 2. 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 volt-
age to the control card. The control card decreases the
percent of ON time to decrease the SCR 1 temperature.
The normal resistance for the thermal protector is 120 to
150 ohms at 18°C (65°F) when measured between pins
PZ1 and PZ5.
REPLACE THE SCR 1 ASSEMBLY
1. Make notes of the positions of the suppressors and re-
move the suppressors from the mount over SCR 1. Dis-
connect the electric connections to the SCR 1 assembly.
2. Remove the thermal protector from the heat sink. Re-
move 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.
3. Check the insulator between the SCR 1 assembly and
the base plate. Replace the insulator if it is damaged. The
Repairs
insulator is also a heat conductor. Use a very thin coat of
silicon compound (Part Number 1198757 or approved
equivalent) between the surfaces of the parts. Keep dirt
from the surfaces.
CAUTION
The insulator is very thin. Dirt between the surfaces
of SCR 1 and the base plate can damage the insulator
and cause a short–circuit.
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 ohmmeter. A correct installation will
indicate infinity on the ohmmeter.
5. Install the electrical connections to the SCR 1 assem-
bly. Install the thermal protector on the heat sink.
6. Install the mount and the suppressors over the SCR 1
assembly. Make sure the connections are made cor-
rectly.
THE “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 generates the re-
verse polarity voltage to change the SCR 1 to OFF for
each pulse. SCR 2 and SCR 5 control the operation of
the “OFF” circuit. The suppressors protect the SCRs
from electrical noise.
Check The Reactor Assembly
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 occur in the
reactor assembly. Most faults that do occur at the reactor
3
Repairs
assembly are caused by loose connections. The normal
repair of the reactor assembly is to replace it. This reac-
tor assembly has two inductor windings (L1 and 1X)
joined by a common connection. A good inductor wind-
ing will indicate approximately zero ohms on the R x 1
scale.
Check Suppressors For SCR 2 And SCR 5
The suppressors are one or more resistors and capacitors
in a small plastic block. (See items 11 and 12 in
FIGURE 1.) The suppressors prevent damage to the
SCRs from electrical noise. Sometimes a suppressor
will not indicate a defect except when in an operating
circuit and will cause a fault that does not occur regu-
larly 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 re-
place it and then check the operation of the lift truck. The
same suppressor is used for all functions.
Check SCR 2 And SCR 5
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 case are different.
An SCR 2 has a higher electrical rating than an SCR 5.
An SCR 2 can be used as an SCR 5, but do not use an
SCR 5 as an SCR 2. Check the part number to make sure
that you are using the correct SCR.
2 1
1. ANODE
2. GATE
3. CATHODE
3 DIODES D3 AND D4
FIGURE 3. SCR 2 AND SCR 5
1. Disconnect either the (+) or (–) power connection.
(The power connections have a (+) and (–) mark in the
plastic case.) Touch the probes of an ohmmeter to the (+)
and (–) power connections of the SCR. Measure the re-
sistance. Change the probe connections to the reverse
direction and measure the resistance. Replace the SCR if
4
the resistance indicates less than 50 000 ohms in either
direction.
2. Measure the resistance between the gate connection
and the cathode. Change the probe connections to the re-
verse direction and measure the resistance again. Re-
place the SCR if the resistance indicates zero or infinity
on the R x 1 scale in either direction.
NOTE: Six volts is needed as a gate signal to check the
SCRs. Use an ohmmeter and a six volt supply for a gate
signal to check the SCRs.
3. Momentarily connect six volts from the battery be-
tween the gate (+) and the cathode (–). The resistance in-
dication on the ohmmeter will decrease to less than 10
ohms on the R x 1 Scale. Replace the SCR if the resis-
tance does not decrease when a six volt gate signal is ap-
plied momentarily. Make sure you touch the gate wire
momentarily with the six volt connection or you will
damage the SCR. Make sure the polarity of your test cir-
cuit is correct.
Replace SCR 2 And SCR 5
Disconnect the electrical connections to the SCR. Re-
move the two screws that hold the SCR.
Use a thin layer of silicon compound (Part No. 1198757
or approved equivalent) between the surfaces of the heat
sink and the replacement SCR. Install the SCR. Connect
the electrical connections.
Check Capacitor C1
Discharge C1 and disconnect the terminals before
checking C1 for a short–circuit. Measure the resistance
between the terminals. The ohmmeter will indicate 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.
The heat sink assembly for the diodes D3 and D4 is also
the connection for the (–) power cable. The heat sink as-
sembly is connected to the base plate. A thin insulator
with a silicone surface separates the heat sink assembly
from the base plate.
NOTE: The optional SCR controller used for the hy-
draulic pump only has a diode D3.

Check The Diodes D3 And D4
You will 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 direction and measure
the resistance. A good diode will indicate 7–14 ohms on
the R x 1 Scale in one direction and greater than 50 000
ohms in the other direction.
1. DIODE D3
2. DIODE D4 3 traction motor current flows through this power connec-
3. HEAT SINK 1
11567
2 control card controls the current flow so that the traction
FIGURE 4. DIODES D3 AND D4
Replacement, Diodes D3 and D4
CAUTION
Do not use a hammer and punch to loosen or tighten
diodes.
Disconnect the cathode cable. Use a deep socket to re-
move 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 (Part No. 5042242–52) be-
tween the surfaces of the heat sink and replacement di-
ode. Tighten the diode to a torque of 3.4 N.m (30 lbf in).
NOTE: Diodes D3 and D4 have a suppressor connected
in parallel to the diode. Replace the suppressor and test
the operation if troubleshooting indicates that the sup-
pressor is bad.
Repairs
1
2
1. SENSOR WIRES
2. SENSOR SHUNT
FIGURE 5. MOTOR CURRENT SENSOR
MOTOR CURRENT SENSOR
(See FIGURE 5. and FIGURE 1.)
The motor current sensor is a short piece of the circuit
bus bar with two sensor wires connected to it. All of the
tor. The metal between the connection points of the sen-
sor wires has a small resistance. This small resistance
between the two sensor wires sends a voltage signal to
the control card. The voltage signal increases as the mo-
tor current increases. The control card compares the
voltage with the ”C/L” current limit adjustment. The
circuit is not damaged.
CONTACTORS
The FORWARD and REVERSE (direction) contactor
assemblies control the direction of current flow through
the traction motor. The contactor is a heavy–duty switch
that opens and closes the power circuit. The traction cir-
cuit has a FORWARD and REVERSE contactor as-
sembly. 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 electromagnet 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 cir-
cuit.
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 serv-
ice life because the current flow through the contacts is
stopped before the contacts open. The SCR 1 is OFF be-
5
Repairs

fore the contactor coil is deenergized. The only condi-

tion where the contacts open during a large current flow CAUTION
is a Pulse Monitor Trip (PMT). ALWAYS replace all of the contacts in a contactor at
the same time. Replace the contacts in the contactor
1 for the hydraulic pump after 1000 hours of
2 1
operation. Replace the contacts in the other
contactors when the thickness of any area of a
contact is less than 30% of the thickness of a new
contact or if there is any transfer of contact material.
1
Coil. Check the coil with an ohmmeter for an open cir-
4 4 cuit or a short–circuit. Replace the coil if it is damaged.
Make sure the coil wires are connected again to the cor-
rect terminals. The coils in the contactors for the hydrau-
5 lic pump and the regenerative braking have an external
3 3
12180 suppressor. The coil and the suppressor can be checked
separately with an ohmmeter. [A suppressor diode (and
sometimes a resistor in series) is part of the coil. The di-
6 ode will cause the ohmmeter to indicate a difference in
1. POWER TERMINALS
resistance in one direction. Reverse the probes of the
2. NC CONTACTS ohmmeter to the opposite terminals and measure the re-
3. NO CONTACTS sistance. Use the highest resistance indication.]
4. COIL TERMINALS
5. MOUNT BRACKET
6. COIL
2
FIGURE 6. DIRECTION CONTACTOR 1

The other contactors used in the motor controller have 3 6

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 7.
4
Contactor Repair (See FIGURE 8.)
Make an identification and disconnect the wires and ca-
bles from the contactor assembly. Remove the mounting 2 1
screws and remove the contactor assembly. 5
1. POWER TERMINALS
Contactor Contacts. The contacts in a contactor are 2. CONTACTS
made of special silver alloy. The contacts will look black 3. SUPPRESSOR
4. COIL TERMINALS
and rough from normal operation. This condition does
5. MOUNT BRACKET
not cause problems with the operation of the lift truck. 6. COIL
Cleaning is not necessary. DO NOT USE A FILE ON
THE CONTACTS. DO NOT LUBRICATE THE CON- FIGURE 7. TYPICAL CONTACTOR ASSEMBLY
(REGENERATIVE BRAKING SHOWN)
TACTS.

6
 Repairs

5
4 9
11

8
14
4 10

1. BASE–MAGNET 7 6
13
2. COIL 21
3. FRAME–MAGNET 22
4. BUS
5. BUS 20
6. SPACER 12 21
7. CLAMP–BUS
8. BUS 3 17 20 22
9. COVER 18 17
10. BUS 19
11. BUS 18
12. SPRING–RETURN 2 18
19
13. ARMATURE
17 18
14. BASE–BUS
15. CARRIER–MOVABLE TIP 15, 17
16. BUSHING–PLUNGER 3 16
17. TIP–MOVABLE
18. SEAT–SPRING 1
15,
19. TIP SPRING 16
20. INSULATION–UPPER BUS
21. NUT
12180
22. WASHER 2

FIGURE 8. DIRECTION CONTACTOR

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

7
Repairs

1
7
2

3
6
3
3 3 1. CONTROL CARD
(TRACTION OR
5 HYDRAULIC PUMP)
2. TB SCREW
TERMINALS (6)
3. PLUG GUIDES
4. PLUG PA (6–PIN)
(WIDE GUIDES)
3 5. PLUG PB (6–PIN)
4 (CLOSE GUIDES)
6. PLUG PY (14–PIN)
7. PLUG PZ (14–PIN)

12668 3 12671

FIGURE 9. CONTROL CARD CONNECTIONS

CONTROL CARD PLUGS 1. PLUG

2. RUBBER SEAL
(See FIGURE 10.) 3. PIN CONNECTOR
(REMOVED FROM PLUG)
4. LOCK PART NO. 897408
6
All control card connections are made at plugs A, B, Y 5. PIN CONNECTOR
or Z or at the six screws of TB terminals. If a wire of one (INSTALLED IN PLUG)
of the plugs must be replaced, the operation to remove a 6. TOOL (HYSTER PART
NO. 897408) (UNLOCKS
pin connector must be done carefully. A special tool PIN CONNECTOR FOR 1
(Hyster Part No. 897408), must be used to remove the REMOVAL)
pin connector from the plug. How the pin connectors are 5
held in the plug is shown in FIGURE 10. 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 re-
moved, 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 2

sure it is not damaged and is locked into the correct posi- 11559
tion in the plug. If the pin connection becomes loose
during operation of the lift truck, the malfunction is not 4
regular and is very difficult to find and repair. 3

8
FIGURE 10. CONTROL CARD PLUG

Brush Wear Indicators
The brush wear indicators illuminate when the motor
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 insulated from the brush
material. When the brush wears within approximately
1.5 mm (0.060 in) of the brush lead, the insulation be-
tween the sensor wire and the brush material is de-
stroyed. The connection between the brush and the sen-
sor wire causes the indicator 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 connected
for operation of the motors. See FIGURE 11. Discon-
nect the sensor wires from the outside of the motor case.
Touch the ends of the sensor wires together. The warn-
3
2 Tires” in the PERIODIC MAINTENANCE section
1 or the OPERATING MANUAL.
FIGURE 11. CONNECT THE BATTERY SO THAT THE MOTOR CAN BE OPERATED
Repairs
ing light will illuminate if the circuit is operating cor-
rectly. The thermal switch can be replaced if it is dam-
aged. However, the motor must be disassembled to re-
place the thermal switch.
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 connected
for operation of the motors. See FIGURE 11. Discon-
nect the sensor wires, one at a time, from outside of the
motor case. Touch the end of the sensor wire to battery
negative. The warning light will illuminate if the circuit
is operating correctly. The motor brushes must be re-
placed when they are worn. If equipped with brush wear
indicators, the condition of the commutator and the mo-
tor brushes must still be checked during periodic main-
tenance.
1. RAISE DRIVE WHEELS
2. JUMPER
3. BATTERY
1. 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 The Drive
9
 THEORY OF OPERATION

ELECTRONIC SPEED CONTROLS An electronic switch called an SCR is used to generate

NOTE: The description of the current flow in the elec-
trical circuits in this section uses the ”Conventional
Theory of Current Flow”. This theory describes the cur-
rent 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–100 series of motor controllers have solid–state
electronic circuits that control the operation of a DC mo-
tor. The speed of DC motors is controlled by the average
applied voltage. The higher the average applied voltage,
the faster the motor will rotate. If a switch is put in the
traction motor circuit, and the switch is changed to OFF
and ON quickly, the traction motor will rotate. See
FIGURE 1. The speed of rotation increases as the time
the switch is ON increases. The speed of rotation will
decrease if the switch is OFF for a longer time than it is
ON. The speed of the motor can be controlled using this
principle.
+ equal so that there is no current flow. The current
7 flow can be changed momentarily to charge a
6 the SCR is momentarily interrupted.
2 3 6 5
+ 1
– 6
4 flow through it.
– Part of a schematic that shows an SCR in a traction cir-
1. BATTERY
2. STEERING MOTOR
3. HYDRAULIC PUMP MOTOR
4. TRACTION MOTOR ARMATURE
5. TRACTION MOTOR FIELD
6. CONTACTOR
7. SCR 1 “SWITCH”
FIGURE 1. BASIC MOTOR CIRCUIT
the rapid ON and OFF times. It has no moving parts.
(An SCR is also called a thyristor in some countries.
“SCR” will be used in this manual.)
NOTE: In the following illustrations,
ÉÉÉ indicates positive voltage.
indicates battery negative.
The 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 electricity to
flow in only one direction. (See FIGURE 2.) A rectifier
or diode permits electricity to flow easily from the an-
ode to the cathode. An SCR is a rectifier that has an addi-
tional element called a gate. An SCR will only permit
electricity to flow when a positive signal voltage is ap-
plied momentarily to the gate. An SCR will permit elec-
tricity to flow from the anode to the cathode after the sig-
nal to the gate is removed. The following conditions
stop the flow of electricity through an SCR:
a. The signal voltage to the gate must be removed
and the current flow through the SCR must be
momentarily stopped.
b. The voltage at the anode and the cathode must be
large capacitor so that the current flow through
When the SCR is used as a switch:
a. The SCR is ON when electric current flows
through it.
b. The SCR is OFF when electric current cannot
A Motor Circuit That Operates With Pulses
cuit is shown in FIGURE 2. (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.

1
Theory Of Operation

3 SCR to the motor are very fast. The motor cannot follow
each pulse, but the motor runs smoothly on the average
2 voltage generated by the ON and OFF times. The aver-
age motor voltage applied to the traction motor is shown
in FIGURE 3. The frequency of the pulses also changes
5 the average motor voltage. As the frequency of the
+ 1 F R
pulses increases, the average motor voltage increases.

É The controller for the motor circuit has an oscillator that

É
– F R
controls the ON time by sending a gate signal to the SCR

É (begin the pulse).

É
6 4

É
ÉÉÉÉÉÉÉÉÉ
LOW
7 ON ON ON ON SPEED
SCR “ON” 100%

É OFF OFF OFF

9 50%
AVERAGE
MOTOR
BATTERY VOLTAGE
2 VOLTAGE (SPEED)
10%

0%
5
TIME
+ 1 F R LOW FREQUENCY

É
– F R OFF OFF OFF OFF
50% SCR

É
SPEED
100%
ON ON ON ON ON

É
AVERAGE
8 MOTOR

É
6 VOLTAGE
(SPEED)

ÉÉÉÉÉÉÉÉÉ
50%

ÉÉÉÉÉÉÉÉÉ
7 SCR “OFF” BATTERY

É
VOLTAGE

1. BATTERY 0%
2. SCR 1 “SWITCH” TIME
3. CURRENT FLOW THOUGH SCR 1 HIGHEST FREQUENCY
4. POSITIVE GATE SIGNAL
MAXIMUM
5. FIELD, TRACTION MOTOR OFF OFF OFF SCR SPEED
6. ARMATURE, TRACTION MOTOR 100% 96%
7. CURRENT SENSOR
ON ON ON
8. NO GATE SIGNAL
9. MOMENTARY INTERRUPTION OF AVERAGE
MOTOR
CURRENT FLOW 50% VOLTAGE
(SPEED)
FIGURE 2. SCR CONTROL BATTERY
VOLTAGE
When a signal is momentarily applied to the gate, the
SCR permits current flow from the battery through the 0%
motor. When the gate signal is removed and the current TIME
flow is suddenly changed to charge a large capacitor, the LOW FREQUENCY
SCR is changed to OFF. The battery voltage is applied FIGURE 3. AVERAGE MOTOR VOLTAGE
to the motor in pulses. The pulses of energy through the

2

The oscillator sends another signal to the special circuit
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 accelerator
pedal.
A potentiometer on the accelerator pedal sends a signal
(5 volts decreasing to 0 volts) to the controller. The con-
troller has a voltage controlled oscillator that increases
in frequency when the voltage decreases from the accel-
erator potentiometer. The oscillator controls the ON
time by sending a a gate signal to SCR 1 (begin the
pulse). The oscillator sends another signal 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 result
of a short ON time and a long OFF time. (See
FIGURE 3.) The minimum pulse that the controller can
give is one 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 av-
erage 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 milliseconds. This maximum
speed sends approximately 96% of the battery voltage to
the motor. Many EV–100 controllers for the traction
motor use a 1A by–pass contactor and a field weakening
contactor to increase the maximum travel speed of the
lift truck. These functions is described later in this sec-
tion.
See FIGURE 4. The pulse rate is approximately 50
Hertz at a low average motor voltage. When the pulse
rate increases to a maximum of 300 Hertz, the average
motor voltage increases. This increase in voltage 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 mini-
mum of 50 Hertz when the average motor voltage is
greater than 50%.
Theory Of Operation
300 Hz
FREQUENCY
150 Hz
50 Hz
5% 50% 96%
ON TIME ON TIME ON TIME
CREEP HALF SCR MAXIMUM
SPEED SPEED SCR SPEED
FIGURE 4. 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 connected and correctly
adjusted, the voltage is 3.5 to 3.7 volts when measured
between the accelerator potentiometer and battery nega-
tive. This voltage is measured at the slowest speed
(CREEP speed) of the lift truck and the accelerator po-
tentiometer is at its highest resistance. The accelerator
potentiometer decreases this voltage by decreasing the
resistance between the control card and battery nega-
tive. 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 by–pass circuit (1A) that is energized
when the accelerator voltage decreases to less than 1.0
volts. The 1A by–pass circuit disables the SCR control
and applies battery voltage directly to the traction mo-
tor.
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 circuit. These
changes in the resistance change the voltage that con-
trols the oscillator in the control card. The changes in
motor speed is controlled in three steps instead of the
continuous variation when the voltage is controlled with
a potentiometer.
3
Theory Of Operation

The SCR 1 “OFF” Circuit
A special circuit is necessary to generate a momentary
interruption in current flow to change SCR 1 to OFF.
The parts of this circuit are the capacitor C1, inductor as-
sembly L1, SCR 2, and SCR 5. SCR 2 discharges the ca-
pacitor 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–in-
duction is like a flywheel in a mechanical device. When
The operation of the SCR 1 “OFF” circuit is
described in the following steps:
+ scribed in the above paragraph.
C1
SCR 1
the torque is increased or decreased in a mechanical de-
vice, the flywheel gives a resistance to any change in
speed. Self–induction does the same function in an elec-
tric 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 proportional to
the current flow. At maximum current flow, this induc-
tion voltage can be greater than 300 volts when meas-
ured across the capacitor C1.
NOTE: The inductor L2 shown in step d of FIGURE 5.
is not a component in the motor controller. The inductor
L2 is the symbol for the inductance caused by the power
cables when electric current flows through them as de-
+
É
C1

É
SCR 2 –

É
+ SCR 1

É –
É
ÉÉÉÉÉÉÉÉ
SCR 2

É ÉÉÉÉÉÉÉÉ
É
+

É ÉÉ É
L1
–
É ÉÉ É
SCR 5

É ÉÉ É
TO MOTOR L1

ÉÉ É
CIRCUIT SCR 5

a. When the battery is first connected, the top

plate of C1 is connected to battery positive. The
direction contactor is closed in preparation to
ÉÉ TO MOTOR
CIRCUIT É
b. A signal is sent to SCR 2 to go ON, which
operate the lift truck. C1 can not charge
closes the electrical path to the bottom plate of
immediately to battery voltage because there is
C1. This action leaves the bottom plate of C1
no electrical path to the bottom plate. C1 will
equal to battery negative and C1 is charged to
slowly charge to battery voltage in approximately
battery voltage. When C1 is charged, SCR 2 goes
four minutes because there is a high resistance
OFF because there is no current flow.
path through the control card. The SCRs are not
ON. FIGURE 5. OPERATION OF THE SCR 1 “OFF”
FIGURE 5. OPERATION OF THE SCR 1 “OFF” CIRCUIT (2 OF 3)
CIRCUIT (1 of 3)

4
 Theory Of Operation

ÉÉ
– –
+ +
C1 C1

ÉÉ
+ +
– –

ÉÉ
SCR 1 SCR 1

ÉÉÉÉ
ÉÉ
ÉÉÉÉ
ÉÉ
+ SCR 2 +
B

É ÉÉ
ÉÉÉÉÉ É
– SCR 2

É ÉÉ É
–

É É
A
L1 L1

É É
SCR 5 SCR 5

É TO MOTOR
CIRCUIT
c. A signal is sent to SCR 1 and SCR 5 to go ON.
É TO MOTOR
CIRCUIT
e. The current flows through SCR 1 until a signal
Current flows through SCR 1, the motor circuit and is sent to SCR 2 to go ON. When SCR 2 goes
returns to battery negative. The polarity at point A is ON, the higher positive voltage moves from C1
now positive compared to the bottom plate of C1 and momentarily makes point B more positive
because SCR 1 is ON. than the battery. This momentary positive voltage
makes SCR 1 go OFF.
– –
+ + C1

SCR 1
É + +

É – –
C1

É
+ SCR 2
É
SCR 1

É É É
ÉÉÉÉÉÉÉÉ
É
SCR 5 SCR 2
– +

É A
É É
É É É
L1
–

É É É
É É É
TO MOTOR L2 L1
SCR 5

É É
CIRCUIT

d. 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 one
millisecond.
NOTE: The inductor L2 shown in step d 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.
É É
TO MOTOR
CIRCUIT
f. 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 control cards can not be repaired except
by the manufacturer. A service person must
replace a bad control card with a new or rebuilt
control card.

FIGURE 5. OPERATION OF THE SCR 1 “OFF” CIRCUIT (3 OF 3)

5
Theory Of Operation

INDUCTION CURRENT FROM THE
MOTOR
When a DC motor is controlled by a pulsed circuit, the
magnetic field in the armature and field is continuously
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.
2
+ 1 F R
voltage and current in the motor. (This current is often
called the “flyback current”). Diode D3, often called the
“flyback diode”, permits the current to flow through the
field and armature again to do work. At slower speeds
motor torque is high without a high current draw from
the battery. (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 cur-
rent comes from the battery at high speeds.
The graph in FIGURE 6. shows the typical induction
current during equal ON and OFF times of SCR 1.
4
CONTROL CARDS

ÉÉ F R
The control cards for the traction circuit and the hydrau-

ÉÉ
– lic circuit will be described separately in the following

ÉÉ
paragraphs.
5

ÉÉ
3
NOTE: The configuration of the controller divides the

ÉÉ base plate into three groups:

ÉÉ
6
a. Traction controller group

ÉÉÉÉ
ÉÉ1. BATTERY 5. MOTOR ARMATURE
b. Contactor group
c. Controller group for the hydraulic pump motor
2. SCR 1 (OFF) 6. MOTOR CURRENT The three groups of components are fastened to the rear
3. DIODE D3 SENSOR
4. MOTOR FIELD plate of the battery compartment. Typical controller
configurations are shown in NO TAG (If the SCR con-
OFF OFF OFF OFF MAXIMUM troller for the hydraulic pump motor is not used, a single
100% MOTOR
CURRENT contactor for the hydraulic pump motor is installed in
that position.)
ON ON ON ON
AVERAGE The control card makes checks as part of the logic se-
BATTERY
CURRENT quence. The control card only permits lift truck opera-
BATTERY tion during the correct conditions. The control card
CURRENT
checks and controls the functions described in the fol-
lowing paragraphs.
0%
TIME Pulse Monitor Trip (PMT)
(Traction Circuit Only)
FIGURE 6. INDUCTION CURRENT The PMT circuit is part of the control card function.
When SCR 1 goes OFF, the decreasing magnetic field When the SRO checks are complete, the control card
generates a voltage and current in the motor. Diode D3 senses the voltage across SCR 1. If the voltage across
permits the current to flow through the field and arma- SCR 1 stays at a low voltage, there is a fault in the trac-
ture again to do work. See FIGURE 6. The torque of a tion circuit. If the control card senses a short–circuit
DC motor is directly proportional to the amount of cur- (low voltage) across SCR 1, it will not permit a direction
rent flow through it. At slower speeds, the motor torque contactor to close. The PMT circuit also checks the trac-
is high, and SCR OFF time is relatively long. When tion circuit for faults during lift truck operation. If SCR
SCR 1 is OFF, the decreasing magnetic field generates a 1 stays ON for greater than 32 milliseconds, the PMT

6
 Theory Of Operation

circuit opens the direction contactor. The control card
immediately closes the contactor again. If the fault oc-
curs 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 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 will deenergize and
open the direction contactors. A PMT occurs when the
control card senses a malfunction in the operation of
SCR 1 and stops sending a signal to the direction contac-
tors.
SRO Circuit (Traction Circuit Only)
The lift truck is equipped with a safety circuit, called the
”Static Return to OFF” (SRO) circuit, that prevents the
operation of the lift truck if the starting sequence is not
correct. The function of the SRO circuit is to make sure
the operator is in the seat and ready to operate the con-
trols. The starting sequence:
a. The operator must be on the operator’s seat and
the seat switch closed. (The seat switch closes
when the weight of the operator is on the seat.)
b. Turn the key switch to the ON position. The key
switch supplies the battery voltage to the control
circuits.
c. Move the direction lever to FORWARD or RE-
VERSE. Move the accelerator pedal to close the
START switch after steps 1 and 2 are complete.
The operator’s foot must be removed from the
brake pedal so that the brake switch is closed.
If step 3 is done before steps 1 and 2, the lift truck will
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
will send a voltage signal to terminal TB3 on the control
card. The timer circuit has a six second delay if the seat
switch is opened. 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 momen-
tarily opened.
The control card must sense battery voltage at terminals
TB4 and TB3, then at TB2, then at TB6 (seat switch
closed) or the control card will not permit a direction
contactor to close.

Seat switch closed. Operator closes the
FORWARD direction
switch. The SRO circuit
checks that the START
switch and a direction
Key switch to the ON switch are not be closed
position. before the key switch.
Control card sends gate
signal to change SCR 1
and SCR 5 to ON.
Power pulse to traction
circuit.

Control card checks for FORWARD contactor C1 fully charged with

battery voltage across
SCR 1.
Control card energizes
the PMT electronic driver
so that the direction
contactors can close.
closes.
PMT check.
Control card sends gate
signal to SCR 2. SCR 2
goes ON and connects
capacitor C1 to the
battery. SCR 2 goes OFF
when C1 is charged.
reverse voltage. SCR 5
goes OFF.
Control card sends gate
signal to SCR 2. SCR 2
goes ON and discharges
C1 to cathode of SCR 1.
SCR 1 goes OFF. Control
card repeats cycle.

FIGURE 7. SEQUENCE OF OPERATION

7
Theory Of Operation

SEQUENCE OF OPERATION
1
The sequence of operation describes a complete cycle of
the SCR traction circuit in FIGURE 7.

Control Card Adjustments (Traction Circuit)

The control card checks the current in the traction circuit 2
and controls the current to prevent damage. The control 1. SENSOR WIRES
2. SENSOR SHUNT
card has several control adjustments.
FIGURE 8. MOTOR CURRENT SENSOR
The control card for the traction circuit has a control ad-
The 1A or By–pass Circuit permits the battery to be
justment called “CREEP”. This adjustment controls
connected directly to the traction motor. This circuit dis-
the minimum current level in the traction circuit when
connects the control of the SCR circuit and is used for
the direction contactors are closed. This adjustment can
maximum power from the traction motor. When the bat-
be changed to meet the needs of a specific application.
tery is connected to the traction motor through the 1A
The CREEP adjustment controls how far the accelera-
circuit, the maximum voltage available to the traction
tor pedal moves between the closing of the START
motor is increased by approximately 10%.
switch and the application of enough power to move the
lift truck. This adjustment is only made after the adjust-
ment between the accelerator pedal and the accelerator
2
potentiometer is correct.
7
The “C/A” (Controlled Acceleration) adjustment con-
trols the maximum rate that the average voltage is in- 4
+ 1 F R
creased by the controller to accelerate the traction mo-
tor. This maximum rate is not controlled by the rate that
ÉÉ F

ÉÉ
– R
the accelerator pedal is pushed down for maximum ac-
celeration. A high rate of acceleration increases the wear
ÉÉ
ÉÉ
3 5
on the brushes of the traction motor. The acceleration

ÉÉ ÉÉ
time can be adjusted for the operating conditions of the

ÉÉ ÉÉ
user. The acceleration rate can be adjusted to give a 6

ÉÉÉÉÉÉÉÉ
ÉÉ ÉÉ
smooth acceleration for better load handling.

The “C/L” (Current Limit) adjustment will control 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 traction 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 connected. See FIGURE 8. The
metal of the shunt has a small resistance between the two
sensor wires. This small resistance sends a signal volt-
age to the control card. This signal voltage increases as
the motor current increases. The control card compares
the signal voltage with the C/L current limit adjustment.
When the signal voltage reaches the limit set on the C/L,
the control card reduces the pulse rate. The current sen-
sor is found connected between the heat sink for D3 and
D4 and the terminal for a power cable.
1. BATTERY
2. SCR 1 (OFF)
3. DIODE D3
4. MOTOR FIELD
5. MOTOR ARMATURE
6. MOTOR CURRENT SENSOR
7. CONTACTOR 1A
FIGURE 9. 1A BY–PASS CIRCUIT
The control card controls the operation of the 1A circuit.
A 1A TIME adjustment permits the SCR control to be-
gin the operation of the traction motor before 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

8
 Theory Of Operation

motor and wastes battery energy.) This adjustment also
permits smoother operation 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 seconds. The full battery power is available to the
traction motor through the 1A circuit after the time de-
lay 1A TIME.
“PLUG”. Plugging uses the traction motor as a brake to
slow or stop a lift truck. When a lift truck is being
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 motor.
lift truck will stop very quickly if the induction current is
not controlled. A diode D4 permits part of the induction
current from the armature to flow with the battery cur-
rent through the armature again. This reduction of the
opposite induction current permits the lift truck to stop
more smoothly.
The control card for the traction circuit has a PLUG ad-
justment. This adjustment controls the maximum appli-
cation of the plugging current. The position of the accel-
erator pedal controls the plugging distance up to the
maximum application. This adjustment can be changed
as needed for an operator. The shorter the plugging dis-
tance, the faster is the wear on the traction motor
brushes.

Regenerative Braking. When a lift truck is being

stopped, energy is generated by the traction motor. The
lift truck causes the traction motor to rotate and operate
2
like a generator. Plugging uses battery energy in opposi-
7 tion to the energy generated by the traction motor. This
energy generates heat in the traction motor. Lift trucks
+ 1 F R 4 used in heavy duty operations can generate enough heat

ÉÉ
to damage the traction motors and cause the motor
F

ÉÉ
– R brushes to wear rapidly.

ÉÉ Regenerative braking returns the energy generated by

ÉÉ
3 8 5
the traction motor to the battery. The regenerative brak-

ÉÉ ing contactor opens during regenerative braking. When

ÉÉ
ÉÉÉÉÉÉ
6 the voltage generated by the traction motor is less than

ÉÉ 1. BATTERY
the battery voltage, the lift truck will be moving slowly.
The contactor for regenerative braking then closes and
plugging is used to stop the slowly moving lift truck. Re-
2. SCR 1 (OFF) generative braking generates less heat in the traction
3. DIODE D3
4. MOTOR FIELD motor and reduces brush wear. Another electric circuit
5. MOTOR ARMATURE must be added to the motor controller to control this op-
6. MOTOR CURRENT SENSOR eration. The energy generated during regenerative brak-
7.CONTACTOR 1A ing must be controlled within limits so that the parts of
8. DIODE D4
the electric circuit are not damaged. The adjustments
FIGURE 10. PLUGGING CIRCUIT used to control regenerative braking are:
REGEN C/L (Regenerative Braking Current Limit)
Plugging is energized when the direction switches in the REGEN D.O. (Regenerative Braking Drop Out)
direction control lever is moved to the opposite direc-
tion from which the lift truck is traveling. The direction The “regenerative braking current limit” controls the
contactors will change to their opposite positions and re- maximum application of regenerative braking during
verse the current flow through the motor field. The in- operation. The position of the accelerator pedal by the
duction current generated in the traction motor now operator controls the plugging distance up to the limit
flows opposite to the current flow from the battery. The set by the REGEN C/L adjustment.

9
Theory Of Operation

contactor closes when the key switch is turned to ON.

During regenerative braking, the contactor opens and
2 the energy generated by the traction circuit is sent to the

É
ÉÉÉÉ
7 battery. When the voltage level is less than the level set

ÉÉÉÉÉ
by the REGEN D.O., the regenerative braking contac-
11 tor closes and the remainder of the lift truck speed is de-
É
+ 1 R 4
F
creased by plugging. When the plugging function is in

É É É R operation, the voltage generated by the traction motor is

É É É
– F 10
normally less than battery voltage.

É É É
É É É
5 Field Weakening. Some 36–48 volt lift trucks and
some 72–80 volt XM series lift trucks have a “field

É É É3 8 weakening” circuit. The field weakening circuit permits

É É É a faster travel speed than the 1A circuit. The traction

ÉÉÉÉÉÉÉÉ
É
9 motor must be operating during 1A conditions of high

ÉÉÉÉÉÉÉÉ
É É 6 speed and small load before the field weakening circuit

É É É
is used.

1. BATTERY The field weakening contactor connects a by–pass shunt

2. SCR 1 (OFF)
3. DIODE D3
4. MOTOR FIELD
5. MOTOR ARMATURE
6. MOTOR CURRENT SENSOR
7. CONTACTOR 1A
8. DIODE D4
9. REGENERATIVE BRAKING (RB)
CONTACTOR
10. DIODE D7
11. CURRENT SENSOR,
REGENERATIVE BRAKING
When the regenerative braking function is started,
the controller begins the plugging function first.
The controller checks the voltage in the plugging
circuit during three pulses of SCR 1. If the voltage
in the plugging circuit is greater than the battery
voltage, the controller opens the regenerative
braking contactor. The current generated in the
traction motor flows through diode D7. SCR 1
continues to operate as selected by the operator
(accelerator position).
When SCR 1 is ON, the current flows through
SCR 1 and then through the field and armature
again.
When SCR 1 is OFF, the current flows through the
battery, diodes D3 and D4 and then to the fields
and armature again. The energy generated during
regenerative braking is used to charge the battery.
FIGURE 11. REGENERATIVE BRAKING
The “regenerative braking drop out” adjusts the voltage
level where the regenerative braking contactor closes
during regenerative braking. The regenerative braking
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 12. 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 avail-
able from the traction motor to increase the travel speed.
The field weakening contactor is controlled by two ad-
justments on the control card:
F.W.P.U. (Field Weakening Pick Up)
F.W.D.O. (Field Weakening Drop Out)
When the lift truck is operating at high speed with a
small load, the armature current will decrease to a mini-
mum 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 arma-
ture current. The field weakening shunt is a strip of
metal that connects the field weakening contactor 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 con-
tactor closes. The 1A contactor closes after the accelera-
tor 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 armature
current will increase. When the armature current in-

10
 Theory Of Operation

creases 2.75–3.0 times the minimum armature current, Accelerator Control

the F.W.D.O. will open the field weakening contactor. If The control card supplies approximately 5.0 volts at ter-
the accelerator pedal is moved to a slower speed, the minal TB1 of the control card. The accelerator potenti-
control card will open the field weakening contactor. ometer decreases the voltage between TB1 of the con-
trol card and battery negative. This voltage controls the
frequency of the oscillator which controls the SCR
speed of the lift truck.
2
The voltage signal from the accelerator potentiometer is
7 0–5 volts. The voltage is normally adjusted to 3.5–3.7
4 volts. At 3.50–3.7 volts, the lift truck will move at
+ 1 F R

ÉÉ
CREEP speed. The 1A TIME will begin its cycle at 1.0

ÉÉ
9 volts so that the 1A contactor can close. The maximum
– FW

ÉÉ
RES speed of the lift truck when operating in the SCR range
F R occurs when the voltage is 0.0–0.2 volts. The 1A contac-

ÉÉ tor applies battery voltage directly to the traction motor.

ÉÉ ÉÉ
5

ÉÉ
3 SCR CONTROL
8

ÉÉ ÉÉ
(HYDRAULIC PUMP MOTOR)

ÉÉÉÉÉÉÉ
ÉÉ ÉÉ
6 The control card for the hydraulic pump motor is not the

ÉÉÉÉÉÉÉ
ÉÉ ÉÉ
same as the control card for the traction circuit. This
control card has a different label. The SCR function for
1. BATTERY speed control is the same, but the many functions neces-
2. SCR 1 (OFF) sary for control of a traction circuit are not needed for
3. DIODE D3 the hydraulic pump motor. A contactor is not used in the
4. MOTOR FIELD power circuit. The 325 ampere fuse for the hydraulic
5. MOTOR ARMATURE
6. MOTOR CURRENT SENSOR pump circuit is found between the (+) bus bar and the
7. CONTACTOR 1A SCR 1 anode of the controller.
8. FIELD WEAKENING (FW)
CONTACTOR This control card does not have an SRO check nor a
9. FIELD WEAKENING (FW) PMT check. If SCR 1 has a short–circuit, the hydraulic
RESISTOR pump motor will run until the battery is disconnected.
The main control valve is an open center valve and the
FIGURE 12. FIELD WEAKENING CIRCUIT
hydraulic function will stop when the hand lever is re-
“RAMP START” is a function of the EV–100LX con- turned to the NEUTRAL position. The SCR controller
trol card for the traction circuit. This function permits an for the hydraulic pump motor controls the motor at three
operator to stop a lift truck with a load when going up a speeds:
slope. If the operator does not change the direction con- Speed 1 is for the TILT function and for optional func-
trols, the lift truck can be started again on the slope. A lift tions that require the third or fourth spool of the main
truck will often roll backward a little distance when control valve (slow speed for some attachments).
starting again on a slope. If the operator does not change Speed 2 is for the low speed LIFT function and high
the direction controls, the control card will not sense the speed operation of an optional function that requires the
reverse operation of the motor armature and will apply third spool of the main control valve.
enough power to go up the slope. If the operator has
Speed 4 is only for the high speed LIFT function. This
changed the direction controls, the control card will
speed applies full battery voltage across the hydraulic
sense that the expected operation is PLUGGING when
pump motor. The SPD 3 adjustment is not used.
the lift truck rolls backward. The control card will not
apply enough power during PLUGGING to make the The control card sends three reference voltages to the
lift truck go up the slope. switches controlled by the linkage to the main control

11
Theory Of Operation

valve. When a contact on a switch is closed, the refer-

ence voltage is connected with battery negative and the 2
1
control card senses the change in the reference voltage.
The voltage controlled oscillator in the control card 3 6
causes SCR 1 to operate at a certain frequency (see the
paragraphs that describe Electronic Speed Controls).
The speeds of operation can be adjusted for an operating
application. 4

CONTACTORS
2 1
Contactors are switches, controlled by electromagnets, 5
that close and open a power circuit. The control card has 1. POWER TERMINALS
2. CONTACTS
internal electronic drivers and the electronic drivers
3. SUPPRESSOR
control the current to the coils of the electromagnets for 4. COIL TERMINALS
the contactors. The electromagnetic field in the coil 5. MOUNT BRACKET
moves the armature against spring pressure to close the 6. COIL
contact. When the coil is deenergized, the spring pres- FIGURE 13. TYPICAL CONTACTOR
sure moves the armature and opens the contacts. When a ASSEMBLY (REGENERATIVE BRAKING
spring holds the contacts of a switch open, the switch is SHOWN)
called normally open (NO). If a spring holds the con-
tacts of a switch closed, the switch is called normally 1 3 1
closed (NC).

Some lift trucks have an SCR control for the hydraulic

pump motor. Some lift trucks also have an electronic 1
driver that energizes the coil for the hydraulic pump
contactor. 4 4

Lift trucks equipped with regenerative braking, 1A, and

field weakening circuits have contactors with one set of 5
normally open contacts. See FIGURE 13. When the lift 2 2
12180
truck does not have an SCR controller for the hydraulic
pump motor, the hydraulic pump contactor also has one
set of NO contacts.
6
1. POWER TERMINALS
A typical set of direction contactors are shown in
2. NC CONTACTS
FIGURE 14. The direction contactors (FORWARD 3. NO CONTACTS
and REVERSE) each have two sets of NC and NO con- 4. COIL TERMINALS
tacts. When a coil for a direction contactor is energized, 5. MOUNT BRACKET
6. COIL (THE SUPPRESSOR IS ADDED
the NO contacts close and the NC contacts open. This
TO THE OUTSIDE OF THE COIL)
design prevents the contacts from being closed in the
wrong sequence. FIGURE 14. DIRECTION CONTACTOR

12

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 an-
ode 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 will fail.
Current Limit
SCR 1 will become damaged from heat unless the cur-
rent flow has limits. A current sensor is installed in the
traction circuit between the armature and battery nega-
tive. The current sensor sends a voltage signal to the
control card. The control card compares the adjustment
C/L with the signal from the current sensor. If the cur-
rent flow reaches the limit, the control card overrides the
other signals to the oscillator. The pulse width and fre-
quency are decreased to decrease the average motor cur-
rent.
NOTE: Dotted Lines Indicate Internal Connections
FIGURE 15. SUPPRESSOR MOUNT
Thermal Protection
The parts of the traction circuit will be damaged by too
much heat. A heat sensor is connected to the SCR 1 heat
sink. When the temperature increases towards the de-
sign limit [85°C (185°F)], the resistance in the sensor in-
Theory Of Operation
creases. This increase in resistance decreases the SCR 1
ON time by decreasing the the pulse width and fre-
quency to SCR 1. The average motor current is de-
creased to prevent damage. When the heat sink cools,
the thermal protection will return the control to normal
operation. This input signal overrides all other input sig-
nals (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. Electrical noise
will 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 ca-
pacitors in a small plastic block. They are installed on a
mount as shown in FIGURE 15.
FIGURE 16. TRUCK MANAGEMENT
MODULE (TMM1)
TRUCK MANAGEMENT MODULE (TMM1)
The Truck Management Module is a multi–function ac-
cessory card that can be used to give additional status
codes or operator warnings on the display panel display.
If a lift truck has brush wear indicators and motor tem-
perature switches and does not have an SCR controller
for the hydraulic pump motor, a TMM1 card is added to
the controller. The TMM1 receives the signals from the
brush wear sensors and motor temperature switches and
sends the signals through the traction controller to the
display panel.
13
Theory Of Operation

TABLE 1. Terminal And Plug Wire Connections For TMM1 Module

Input Output
Terminal Function Terminal Actuation Output Fault
No. No. Voltage Code

TB1 Signal wire for temperature switch, traction motor. TB7 Battery – 0.6 volts 90
TB2 Not Used. — — — —
TB3 Signal wire for temperature switch, hydraulic pump motor. TB7 Battery – 1.6 volts 91
TB4 Not Used. — — — —
TB5 Signal wire for brush wear indicator,steering pump. TB9 Battery – 0.6 volts 93
TB6 Signal wire for brush wear indicator,steering pump. TB9 Battery – 0.6 volts 93
TB7 Not Used — — — —
TB8 Signal wire for brush wear indicator, traction motor. TB9 Battery – 1.6 volts 94
TB9 Not Used — — — —
TB10 Signal wire for brush wear indicator, traction motor. TB9 Battery – 1.6 volts 94
TB11 Signal wire for brush wear indicator, hydraulic pump motor. TB9 Battery – 2.3 volts 95
TB12 Signal wire for brush wear indicator, hydraulic pump motor. TB9 Battery – 2.3 volts 95
TB13 5–volt supply
TB15 Battery negative

DISPLAY PANELS
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 adjustments for the instrument
panel display without using the procedures in the
section EV–100/200ZX MOTOR CONTROLLER
Parameter Tables, 2200 SRM 595.
Display Panel
There are two display panels available on lift trucks with
the EV–100ZX SCR motor controller. Some lift trucks
can only have one of the two panel displays:
• a basic display that gives the operator basic in-
formation about the operation of the lift truck
• a performance display that includes diagnostic
capabilities similar to the Hand Set.
Basic Display (See FIGURE 17.)
The EV–100 “ZX” Series motor controller can have two
Basic display panels that includes one of two types of
Battery Indicators.
EARLY DISPLAY PANEL
for the traction circuit is shown for four seconds
after the lift truck has been operating and the key
is turned to the OFF position.
(2) Voltmeter. The earlier Basic Display Panel has a
battery indicator without lift interrupt (volt-
meter). 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.
Operating the lift truck with the needle in the red
band can decrease battery life. Continued opera-
tion with a discharged battery can damage the
battery, motors or the contactors.
(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.

When the key switch is turned to the ON position, a start
program will cause each warning light to illuminate to
show that the function is operating. This early display
panel has the following functions:
(1) Hourmeter. The hourmeter display shows the
operating time of 0000 to 9999 hours. The time
(4) Warning light, brake fluid reservoir is low
(Early Only). The red light is ON for one second
when the key switch is turned to the START posi-
tion and must go OFF after one second. If the
warning light is ON during operation, the brake
fluid level in the reservoir is too low.

14
 Theory Of Operation

STANDARD DISPLAY 3 4 5 EARLY DISPLAY PANEL

18 PIN CONNECTOR
1
PIN FUNCTION
1–11 No Connection
12 Battery Negative (–)
13 Parking Brake Switch
14 Brake Fluid Switch
15 Hyd. Contactor Coil
16 Seat Switch
17 Key Switch (IGN)
18 Battery Positive (+) KEY
(from Fuse 6) SWITCH
LEADS
2
RED/BRN
BRN “IGN”
“BAT” TERMINAL
TERMINAL

1. HOURMETER 1364435
2. BATTERY METER
3. PARKING BRAKE INDICATOR
4. BRAKE FLUID TOO LOW INDICATOR
5. SEAT BELT INDICATOR
1 2 3 4

LATER DISPLAY PANEL

1. BATTERY DISCHARGE
INDICATOR
2. PARKING BRAKE
SYMBOL AND LED
3. FASTEN SEAT BELT
SYMBOL AND LED
4. DIGITAL DISPLAY
504305778 R2

FIGURE 17. BASIC DISPLAY PANEL AND PLUG CONNECTOR

(5) Warning light, fasten seat belt. The red light is
ON for eight to ten seconds after the key switch is
turned to the ON position.
LATER DISPLAY PANEL
When the key switch is turned to ON, a start program
will cause each warning light to illuminate to show that
the function is operating. This early display panel has
the following functions:
(1) Battery Charge Indicator With Lift Interrupt.
Later Basic display panels have a battery indica-
tor that is a scale with a series of 5 round LEDs in
three colors (green, orange, red). See
FIGURE 17. 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 bat-
tery 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 discharges during operation, the
LEDs illuminate from top to bottom (green to
red). The red LED indicates that the battery is dis-
charged. 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 op-
eration. 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 dif-
ferent when the battery is low or a different bat-

15
Theory Of Operation
tery 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 will prevent lift truck operation if the bat-
tery voltage is not correct as set by traction func-
tion 15. A status code of –16 (voltage too high) or
–15 (voltage too low) will indicate on the display
panel. The battery can have a voltage that is too
high or too low. A battery with the correct 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
traction Function 14 so that the weakest battery is
not damaged. Follow the procedure for adjusting
traction function 14 in the Checks And Adjust-
ments.
(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 eight to ten 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 will be shown with a dash (–) in the left digit
position. The warning light, Service Interval (11)
will also be illuminated when a fault occurs.
When it is time for periodic maintenance, the
warning light, Service Interval (11) will be illu-
minated and a status code –99 will be indicated.
The register in the controller card must be reset
by the service person before this warning light
will go OFF.
The hourmeter display shows the operating time
of 0000 to 9999 hours. The time for the traction
circuit is shown for four seconds after the lift
truck has been operating and the key is turned to
the OFF position. The indicator lights for the
traction motor (8) and for the hourmeter (12) 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 hourmeter for
16
another four seconds. The indicator lights for the
hydraulic motor (9) and for the hourmeter (12)
will also be illuminated during this time.
Performance Display ( See FIGURE 18.)
When the key switch is turned to the ON position, a start
program will cause each warning and indicator light to
illuminate to show that the function is operating. The
functions and operation of the indicators for these early
and later display panels is the same. These display pan-
els have the following functions:
(1) Battery Charge Indicator With Lift Interrupt.
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 sequen-
tially from the top green bar through the orange
bars to the red bars. When the battery is dis-
charged to the red LED bars, the battery is 73%
discharged and the lift interrupt function will not
permit operation of the hydraulic motor. The bat-
tery must be charged or a charged battery must be
installed before lift truck operation can continue.
The top green bar will be illuminated when the
battery is more than 90% charged.
The battery charge indicator uses the traction
control shunt to measure the current during op-
eration. 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 dif-
ferent when the battery is low or a different bat-
tery 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 will prevent lift truck operation if the bat-
tery voltage is not correct as set by traction func-
tion 15. A status code of –16 (voltage too high) or
–15 (voltage too low) will indicate on the display
panel. The battery can have a voltage that is too
high or too low. A battery with the correct 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
 Theory Of Operation

traction Function 14 so that the weakest battery is
not damaged. Follow the procedure for adjusting
traction function 14 in the Checks And Adjust-
ments.
(2) Digal 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 will be shown with a dash (–) in the left digit
position. The warning light, Service Interval (11)
will also be illuminated when a fault occurs.
The hourmeter display shows the operating time
of 0000 to 9999 hours. The time for the traction
circuit is shown for four seconds after the lift
truck has been operating and the key is turned to
the OFF position. The indicator lights for the
traction motor (8) and for the hourmeter (12) will

ENHANCED DISPLAY
18 PIN CONNECTOR 3 4 5 6 7 8 9 10 11 12
PIN FUNCTION
1 Traction Card PY 5
2 Pump Card PY 5
3 No Connection
4 Traction Card PY 14
5 Traction Card PY 13
6 Pump Card PY 14
7 Pump Card PY 13 KEY
8 No Connection SWITCH 2
9 Traction Card PY 4
10 Pump Card PY 4 1 LEADS 13
11 Brush Wear Indicator &
Temperature Jumper* RED/BRN
15
12 * BRN “IGN”
13 Parking Brake Switch “BAT” TERMINAL 14
14 Brake Fluid Switch TERMINAL
15 No Connection EARLY DISPLAY PANEL
16 No Connection 1340960
17 Key Switch (IGN)
18 No Connection
LATER DISPLAY PANEL
1 5 4 3 12 2

13

15
* PIN 11 TO 12 JUMPER (IN
WIRE HARNESS). BWI
AND TEMPERATURE
LED’s DISABLED IF CUT.

504249713

1. BATTERY DISCHARGE INDICATOR 6 7 8 9 10 11 14

2. DIGITAL DISPLAY
3. FASTEN SEAT BELT INDICATOR 10. MOTOR TEMPERATURE
4. BRAKE FLUID TOO LOW INDICATOR INDICATOR
5. PARKING BRAKE INDICATOR 11. STATUS CODE/MAINTENANCE
6. STEERING PUMP MOTOR INDICATOR
INDICATOR 12. HOURMETER INDICATOR
7. BRUSH WEAR INDICATOR 13. STATUS CODE BUTTON
8. TRACTION MOTOR INDICATOR 14. PERFORMANCE LEVEL BUTTON
9. LIFT PUMP MOTOR INDICATOR 15. PERFORMANCE LEVEL LEDS

FIGURE 18. PERFORMANCE DISPLAY PANEL AND PLUG CONNECTOR

17
Theory Of Operation
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 hourmeter for
another four seconds. The indicator lights for the
hydraulic motor (9) and for the hourmeter (12)
will also be illuminated during this time.
(3) Warning Light, Fasten Seat Belt. The red light
is ON for eight to ten 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 one second
when the key switch is turned to the START posi-
tion 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 will make a noise if the opera-
tor leaves the seat (key switch ON) and the park-
ing brake is not applied.
(6) Indicator Light, Steering Pump Motor. This
light will illuminate 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 (7) will go ON and the
indicator light for the steering pump motor will
show which motor has the problem.
(7) Warning Light, Motor Brushes Are Worn.
When the sensor for brush wear closes, this warn-
ing light and the indicator light for the motor that
has the problem will both illuminate.
(8) Indicator Light, Traction Motor. This light will
illuminate with another warning light if a fault
occurs in the traction motor. Example: If the
brush wear sensor is activated in the motor, the
warning light, brush wear (7) will go ON and the
indicator light for the traction motor will show
which motor has the problem.
(9) Indicator Light, Hydraulic Motor. This light
will illuminate with another warning light if a
fault occurs in the hydraulic pump motor. Exam-
ple: If the temperature over limit switch closes in
the motor, the warning light, motor temperature
18
over limit (10) will go ON and the indicator light
for the hydraulic motor will show 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 (8) or for the hydraulic motor
(9) will show 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 (14), performance
level will increase by one step. At the maximum
(rabbit) level, the performance levels will begin
at the lowest (turtle) level again. The four perfor-
mance 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 ei-
ther the PC or the Hand Set (Functions 11, 12, and
13).
The four performance levels can be set to any lev-
el up to the maximum limits. Two or more adja-
cent performance levels can be set to the same
limits. The performance levels must be set at the
same or in ascending 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.
Fault Code Memory. The control cards for the traction
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 will be indicated on the Sta-
tus Code Indicator (2). If the key switch is turned to
OFF, the status code will be removed from the four digit
display.
The push button (13) will cause the status codes for the
for the faults to be shown on the Status Code Indicator
(2). When the button is pushed and held down, the indi-
cator light for the traction motor (8) will illuminate. The
status codes in memory for the detected faults will be
displayed, starting with the most recent fault. If the push
button is released, the display will stop. If the button is
pushed again, the display will start from the beginning
again. The hourmeter time and the battery charge at the
time of the fault will not be shown. A Hand Set or a PC
must be used to show this additional information. A
Hand Set 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 in-
dicator light for the hydraulic pump motor (9) will illu-
minate. The status codes in memory for the detected
faults will be displayed, starting with the most recent
fault. If the push button is released, the display will stop.
If the button is pushed twice to start the sequence again,
the display will start from the beginning. The hourmeter
time and the battery charge at the time of the fault will
not be shown. A Hand Set or a PC must be used to show
this additional information. A Hand Set or a PC must be
used to clear the status code from the register.
Theory Of Operation
There can be 16 status codes in the memory for each sys-
tem (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 Traction Motor Indica-
tor will be 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 will start over
showing all the status codes for the traction system.
Push the button twice and hold the push button to dis-
play all the status codes in the memory for detected
faults of the lift system. The Lift Pump Motor Indicator
will be ON to show that the status codes are for the lift
system. If the push button is released then pushed twice
and held again, the digital display will start over show-
ing all the status codes for the lift system.
Brush Wear Indicators
The brush wear indicators illuminate when the motor
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 insulated from the brush
material. When the brush wears within approximately
1.5 mm (0.060 in) of the brush lead, the insulation be-
tween the sensor wire and the brush material is de-
stroyed. The connection between the brush and the sen-
sor wire causes the indicator 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.
19