EV-100LXT/LX/LXP/LXD EV-200LXT/LX MOTOR CONTROLLER & DIAGNOSTIC HAND SET DESCRIPTION, CHECKS, REPAIRS, ADJUSTMENTS AND TROUBLESHOOTINGSAFETY PRECAUTIONS MAINTENANCE AND REPAIR ‘When lifting parts or assemblies, make sure that all slings, chains or cables are correctly fastened and that the load being lifted is balanced. Make sure that the crane, cables and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand. Use a lifting mechanism. Wear safety glasses, DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electriclift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See “How To Put The Lift Truck On Blocks” in the OPERATING MANUAL or the PERIODIC MAINTENANCE section. Keep the unit and working area clean and in order. Use the correct tools for the job. Keep the tools clean and in good condition. Always use HYSTER APPROVED parts when making repairs, Replacement parts must meet or exceed the specifications of the original equipment ‘manufacturer. Make sure that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when making repairs or if the unit needs repairs. Make sure you follow the WARNING and CAUTION notesin the instructions. Batteries generate flammable gas when they are being changed. Keep fire and sparks away from the area. Make sure the area has ventilation.CONTENTS INTRODUCTION GENERAL. DESCRIPTION . DIAGNOSTIC CONTROL CARD Status Codes HAND SET INSTRUMENT PANEL DISPLAY . Hourmeter Functions Battery Indicator Function . CONTROL CARD CONNECTION CHECKS AND ADJUSTMENTS GENERAL Function Codes... Connecting the Control Card for Bench Checks and Adjustments ‘Connecting the Hand Set to a Control Card Installed in a Lift Truck CHECKING AND ADJUSTING FUNCTION SETTINGS .. General a HOW TO CONNECT AND CHECK HAND SET . HOW TO CHECK AND ADJUST FUNCTIONS FUNCTION DESCRIPTIONS . Traction Control Cards (EV-100/200 LXTILX) Pump Control Card (EV-100/200 LXP) .. Dual Motor Traction Control Card (EV-100 LXM/LXDX/LXDT) ... FUNCTION TABLES . REPAIRS : TROUBLESHOOTING . GENERAL . ‘This section is forthe following models: E3,50-5.50 (E70-120XL) 325-35B J1.25-1.7SX1. 32.00-3.00XL (140-60XL) N40-45FR, R3OE/EAJEF, R30XM/XMA/XME/XMS, 11.60-2.00XMT (130-40XMT) E30FR, E40FR, and ESOFR E1.25-1.75XL (E25-35XL) E2.00-3,00XL (F40-60XL) ©HYSTER COMPANY 1995 4 “4 4 15 16 W W W 7 18 18 2 2 7 47 48.INTRODUCTION GENERAL ‘This section has the description, checks, adjustments and repairs of the control cards for the EV-100 LX/LXT/LXP/LXM/LXDX/LXDT and the EV-200 LX/LXT/LXP motor controllers. The LX/LXT/LXP/ LXM/LXDX/LXDTis the nomenclature toidentify the controllers that have the “LX” series of diagnostic con- trol cards. There is a description of the handset and how it is used to check and adjust the control cards. A de- scription and the replacement of the instrument panel display is also included. ‘The operation and most components ofthese controllers are basically the same as the EV-100 and EV-200 motor controllers. All of the power components used with this EV-100/200 “LX” series are the same as used with other EV-100/200 motor controllers. The control cards are the major differences. The “LX” series of diagnostic con- trol cards have the basic control features of the other EV-100/200 cards and some additional features. Not all control features are available onall ofthe different types of control cards of the series. Some control cards can have multiple features. These features include the fol- lowing: * Static Return to Off (SRO) (includes Start Sw.) ® Pulse Monitor Trip (PMT) (Traction Only) Pedal Position Plugging © Field Weakening (FW) Regenerative Braking (RB) © Creep Speed (C/S) Controlled Acceleration (C/A) © Current Limit (CL) © 1A Timed Pick Up (IA P.U,) © 1A Drop Ont (1A D.0.) © 1A Thermal Hold Off © Ramp Start Full Power Transition © ‘Stored Status Code (Diagnostics) Speed Limits Internal Resistance Compensation © Steer Pump Time Delay © Pump Motor Control (PX card only) Some of the differences between the EV-100/200 con- trol cards and the EV-100/200 “LX” series of diagnostic control cards are given in the following list * Contactor coil drivers within the control card © Diagnostics (automatic tests or checks) © Hourmeter function (control card display for the instrument panel is not installed on all units) Battery Discharge Indicator function (LXT and LXDT card only) (control card display forthe in- strument panel is not installed on all uaits) ‘The “LX” series of controllers have an outputio operate a digital display with four digits. A digital display unit (instrument panel display) is available for the instru- ment panel of some lift trucks. A hand set with a digital display is also available. All of the control settings are setusing the handset. There are NO manual adjustments, (trim pots) on these control cards. ‘The basic (motor speed and direction) operation of the EY-100/200 “LX” series of motor controllers is the same as the EV-100 controller. For an operational de- scription of the traction or pump motor controllers, see the section EV-100 MOTOR CONTROLLER, 2200 ‘SRM 287. For repairs, see the sections EV-100 MO- TOR CONTROLLER, 2200 SRM 288 or EV-200 MOTOR CONTROLLER, 2200 SRM 414. These ‘motor controllers are made for Hyster Company by the General Electric Company. Hyster electric lift trucks use a two-wire electrical sys~ tem, There is no common ground connection through the frame. Both the positive supply and the negative re- turn current flows are 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. DESCRIPTION DIAGNOSTIC CONTROL CARD ‘The control card is a printed circuit board with elec- tronic parts in a plastic case. The control card has four i plug connectors and a terminal strip with six screw con- nections. The control wires of the plugs and terminal-strips connect the control card to the lift truck circuits and the other circuits of the motor controller. The screw connections of the terminal strips are inputs from con- trol components of the lift truck. The plugs for the con- trol card are Plug A, Plug B, Plug Y and Plug Z. See FIGURE 3. Plugs A and B are six pin plugs. The pur- pose of the wires connected to these plugs can be differ- ent for different control cards. Plug Y is a 14 pin plug, that connects the instrument panel display or hand set to| the control card. Some pins of Plug Y are also used to connect the control card tothe Truck Management Mod- ule or other auxiliary control cards. Plug Z is also a 14 pin plug that connects the oscillator part of the control card to other circuit components. The 14 pins on Plug Z, have the same functions.as the pins of other EV-100/200 control cards. The pin numbers are also the same, for the ‘same function, for both the EV100/200"LX” series and the other EV-100/200 control cards. ‘TABLE 1 - STATUS CODES LIST DESCRIPTION ‘CARD INPUTS No input voltage to card andor display [No seat switch input * FWD switch closed on intial start EV switch closed on intial start Start switch input low after start Start or brake switch did not close Accelerator depressed ~ no direction selected ‘Accelerator input voltage too high Accelerator input voltage too low or power to ‘control card after key sw. ON, Both FWD and REV switches closed at same time Both right and left steer angle switches are closed at same time Start switch is closed when the key is moved to tho ON position Battery volts too low Battery volts too high ‘Wrong card type selection CONTACTOR PANEL Forward or reverse contactor col current low Voltage at T2 too high 1A contactor does not open or opens too slowly ‘Shorted coil driver for RB, SP of FW contactor SCR PANEL (pen thermal protector or control over temperature ‘Motor sensor input missing (green wire) ‘Motor sensor input missing (yellow wire} SCA 1 did not turn off correctly ‘SCR 1 did not turn on correctly “Look ahead” (T2 volts high) ‘SCR 2 does not turn on correctly “Look ahead” (T2 volts low) ‘SCR 5 does not turn on correctly ‘C1 volts low Ct volts high with high motor current C1 volts high with low motor current ‘SCR 4 does not turn off during plugging Shorted F, Ror 1A driver Current sensor output voltage polarity check SNot used on all models of ft tracks. Status ‘codes in this group wil fash on the display. NOTE: Motor speed is decreased with @ Motor Over Tem- perature code at the normal function setting ‘STATUS DESCRIPTION REGENERATIVE BRAKING* Current sensor input missing (yellow wire) (Current sensor input missing (green wire) Regenerative braking contactor does, not energize Regenerative braking contactor does not deenergize or deenergizes slowly Regenerative braking contactor energizes too slovily SCR 1 does not tum off during regenerative braking Ct voltage too high during regenerative braking ‘TRUCK MANAGEMENT Traction Motor Over Temperature! x [ Loft} + [ Pump Motor Over Temperature*] 3 [Traction Motor Over Temperature/Pight ] ‘Pump Motor Over Temperature or > [ Traction Brush Wear/Right*} ‘Traction Brush Wear [Left] Pump Motor Brush Weart PUMP CONTROL* ‘Wrong card type selection Pump contactor col current low Voltage at T2 too high (Open thermal protector or control over temperature Motor sensor input missing (green wire) Motor sensor input missing (yellow wire) ‘SCR 1 did not tum off correctly ‘SCR 1 did not tur on correctly “Look ahead’ (T2 volts high) SCR 2 does not turn on correctly “Look ahead! (T2 votts low) ‘SCR 5 does not turn on correctly C1 volts ow C1 volts high with high motor current C1 volts high with low motor current Shorted #2 PUMP driver Current sensor output voltage polarity check %[_] for TRUCK MODELS J1.60, J1 LOXMT (J30XMT, JS5XMT and J4OXMT) only.The diagnostics circuits of the control card check the staticand operating conditions of the control and power Gircuits for the motor. The control card will show a status code on the display connected to Plug Y if the agnostic circuits find a condition that is not correct. The display connections are at Plug Y of the control card. Some lifttrucks can have a instrument panel display that will show the status codes from the traction and pump control cards. ‘Status Codes (See TABLE 1) ‘The Status Codes are code numbers for different symp- toms that the control card can sense. The control card will show this code number on the digital display of the instrument panel display (optional on some units) or the hand set. The control card will flash the status code on the display. Every third display will show the battery charge instead of the status code. The control card senses the following incorrect inputs: inputs that are too high or too low, inputs that have the ‘wrong polarity, inputs in the wrong sequence or correct, inputs that occur at the wrong time. NOTE: Astatus code display does not always mean that there is a malfunction. A temporary operating con- dition can cause a status code display. ‘The status codesall have a (-) before the numbers. Ifthe battery is disconnected, the “—” will be missing on the hand set display when a battery is connected again. Ifa status code number is flashing on the digital display, checks and adjustments cannot be done. Refer to TABLE 1 and Troubleshooting 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 1 has a short description of the different status codes. ‘TROUBLESHOOTING in this section has a table for each status code. The tables have a more complete de- scription ofthe status code, the circuit that has the incor- rect input, the symptom and the possible causes. HAND SET ‘The hand set isa tool with many functions. The tool can INLY with the EV-100 or 200 “LX” series ‘SCR motor controllers. The hand set is used to monitor traction or pump motor functions, show status codes (possible fault symptoms) and adjust the settings of the control cards. The hand set must be used to set the val- ues for the control card functions. It consists of a Light 3 Emitting Diode (LED) display, a keyboard for data en- try and an adjustment knob for changing function val- tues. See FIGURE 1. The purpose of the hand set isto al- low Authorized Personnel to monitor and adjust the following © Monitorsystem status codes for both tra: pump SCR systems mand ‘Monitor the intermittent status codes ‘Monitor the state of charge of the battery on sys- tems with LXT control cards ‘Monitor the hourmeter readings on the traction and pump SCR systems NOTE: These first four function values above will also show on the instrument panel display. PLUG WRING Moo. | PLUG Bug | “ 4. ADJUSTMENT KNOB 2. LED DISPLAY 3. KEYBOARD 4. COIL.CORD 5. PLUG Y (14PIN) 6. MODULAR PLUG. (8 PIN HAND SET) FIGURE 1 - HAND SETMonitor or adjust the following control func- tions: + Creep Speed ‘+ Controlled Acceleration and LA Time © Current Limit * Steering pump time delay and define signal input (seat sw. or directional sw. ‘+ Plugging distance (Current) 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 with Field Weakening, * Traction with Speed Limits + ‘Traction with Regenerative Braking and Field ‘Weakening High or low current limit for all of the above NOTE: The vehicle will operate with the hand set connected, however, the adjustment knob MUST be set fully clockwise to make sure the control can operate at top speed. INSTRUMENT PANEL DISPLAY (Optional on Some Units) ‘The instrument panel display, for these control cards, is a display unit with four digits and three indicators. See FIGURE 2. The indicators show which function value is displayed by the digits. The unit is available forthe in- strument panel of some lift trucks. Not all functions are available on all lft truck models. The following func~ tions are available: Battery Indicator, Status Codes, ‘Traction Hourmeter and Pump Hourmeter. ‘The digits show the operating hours when the function indicator (FIGURE 2) on the left-hand side is ON. ‘When the middle indicator is ON, the digits show the charge condition ofthe battery. The right-hand indicator is ON when the digits show the status code. Hourmeter Functions ‘The hourmeter function of the instrument panel display is controlled by the EV-100/200 “LX” series control card. There can be a display for the operating time of the traction circuit. On some units, there can a'so be a dis- play for the operating time of the pump circuit. Only those units that have the EV-100“LX” series pumpcon- trol card can have the optional pump hourmeter func- tion, ‘The instrument panel display shows the operating time of 0000 to 9999 hours. The traction time is shown for four seconds after the lift truck has been operating and the key is turned to the OFF position. If there is a pump hourmeter, the pump time will now be shown for an- other four seconds, Battery Indicator Function This battery indicator uses the traction control shunt to ‘measure the current during operation. This current and battery voltage are checked at the same timeforan accu- rate reading of battery voltage with a load (during use). ‘This method is much more accurate than other battery indicators used on earlier lift tricks. This method can also make operation of the lift truck different when the battery is low or a different battery is connected. This method allows more usage of the battery. ‘The battery indicator function shows the battery charge represented by numbers between 100 and.) The digital display will flash when the digital display weads 19. Ata display of , the control wil disable the lift pump circuit ‘After the circuit has disabled the lift pump, charge or change the battery. Battery Indicator Battery State of Charge / Value Condition 700 700% / Fully Charged Battory 15 "30% [Display Begins Flashing 3 20% 7 Lift Interrupt Occurs ‘The control also checks the battery voltage each time a battery is connected. The traction control will prevent lift truck operation ifthe battery voltage isnot correct as set by traction Function 15. A status code of -16 (too high) or -15 (too low) will show on the instrument panel display. The battery can have a voltage that is too high or too low. A battery with the correct voltage can also be over discharged from use or other reasons and have a voltage that is less than the minimum of the voltage range.EARLY SitDrive® UNITS LATER SitDrive® UNITS 14 10 BOTTOM VIEW ‘SIN CONNEGTOA WIRING PARE] _connecrionruncTion 9 _| Traction Motor Over Temperatura '96_| Pump Motor Over Temperature ‘93 | Traction Motor Brush (A) Wear ‘94 Traction Motor Brush 6) Wear 98 Pump Motor Brush (A) Wear 29 | Pump Motor Brush (B) Wear = [Not Used 73_[ Battery Negative 710” [ Baery Possive for Key Switch *TRACTION CARD PLUG ONLY DISPLAY UNIT BRUSH WEAR INDICATOR, HYDRAULIC MOTOR (YELLOW LED) TEMPERATURE ALARM, HYDRAULIC MOTOR (RED LED) ‘TEMPERATURE ALARM (RED LED) (ILLUMINATES WITH ITEM 3 OR 5) ‘TEMPERATURE ALARM, TRACTION MOTOR (RED LED) BRUSH WEAR INDICATOR, TRACTION MOTOR (YELLOW LED) STATUS CODE FUNCTION INDICATOR, (GREEN LED) 8, HOUR METER FUNCTION INDICATOR (GREEN LED) 9, FOUR DIGIT DISPLAY 10. BATTERY FUNCTION INDICATOR (GREEN LED) 41, MOUNT BRACKET 12, MOUNT NUTS 13, 9-PIN MOTOR CONNECTOR 14, TRACTION CARD CONNECTOR 15. PUMP CARD CONNECTOR 16. INSTRUMENT PANEL, 17. TO CONTROL CARD PLUG Y NOTE: For truck models JSOXMT, J35XMTand J4OXMT see ELECTRICAL SYSTEM, 2200 SRM ‘577 for instrument panel display. NOTE: For truck models 1.60, J1.80XMT and J2.00XMT see ELECTRICAL SYSTEM, 2200 SRM 585 for instrument panel display FIGURE 2 - INSTRUMENT PANEL DISPLAY Batteries that have different amp 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 Adjustments. 5 CONTROL CARD CONNECTION All connections between the control card or control cards and any otherelectrical component are made at the ‘edge of the card. See FIGURE 3. These connections are made at the four connector plugs: Plug A (PA 1 through6), Plug B (PB 1 through 6), Plug Y (PY 1 through 14) or Plug Z (PZ 1 through 14). There are also six screw ter- minals for connections (TB 1 through 6). Plugs A and B and the screw terminals have some of the same function ason the earlier EV-100. and EV-200con- ol cards. ‘The Plug Z has basically the same connec- tions as the Plug C on the earlier (before “LX”) control cards. Plug Y is an additional plug and has the connec- tions for the diagnostics and digital display signals. ‘TABLE 2 through TABLE 8 show the connections for the single motor control card, the pump cortrol card and the dual motor control card. SEE TABLE2 THROUGH TABLE 8 FOR WIRE CON- NECTIONS. CONTROL CARD (TRACTION OR PUNP) TB SCREW TERMINALS PLUG GUIDES PLUG A (6 PINS) (WIDE GUIDES) PLUG B (6 PINS) (CLOSE GUIDES) PLUG Y (14 PINS) PLUG Z (14 PINS) FIGURE 3 - CONTROL CARD CONNECTIONS,TABLE 2 - TERMINAL AND PLUG WIRE CONNECTIONS FOR SINGLE MOTOR ‘TRACTION CIRCUIT Not used PAZ 30 | BDI pump interrupt signal PAS 7 | Auxiliary hourmeter input PAS + | Not used with standard control ~ Speed Limit 2 input or regen. sensor 2 (YEL) PAS * | Not used with standard control - Speed Limit 3 input or regen. sensor 2 (GRN) PAG = Not used with standard control - Speed Limit 1 input or motor A2 input (wiregen.) PBI 37 _| Field weakening contactor coil driver PB2 31 | Regenerative braking contactor coil driver (with regenerative braking only) PBS 60 | Steering pump motor coil driver PBS 27 | Forward contactor coil driver PBS 23 | Reverse contactor coil driver PB6 41__| 1Acontactor coil driver Tet 29 | Accelerator potentiometer input Te2 15A__| Start switch input TB3 7 | Seat switch input - Voltage input from timer circuit Ba 10 | Key switch input - Battery voltage supply from key switch TBS 6 | FORWARD direction switch input TB6 8_| REVERSE direction switch input PY WHT | Instrument panel display number 4 input Py2 BLK _| Instrument panel display number 3 input Pys GRN | Instrument panel display number 1 input PYa BAR | Instrument panel display number 2 input PYS E | Instrument panel display number 6 input, PY6 RED | Notused PY7 Not used Pys 90 | Truck Management Module (TMM) 1 9 - Not used on all models of lit trucks PyY9 91 | Truck Management Module (TMM) 1A 7 - Not used on all models of lift trucks PYi0 92 | Truck Management Module (TMM) 1A 2 ~ Not used on all models of lft trucks PYtt Not used PYi2 Not used PY13 Not used Pyia Not used Pz BLK | Signal wire from SCR 1 thermal protector Pz2 BAN | Battery negative Pz YEL | Signal wire from current sensor Pza GAN | Signal wire from current sensor Pzs GRY _| Signal wire from SCR 1 thermal protector Pz6 -__ | Notused Pz WHT _| Battery positive ze |BLUMWHT| Signal wire to SCR 1 gate Pz9 BLU_ | Signal wire from SOR 1 cathode PZ10 |WHT/RED| Signal wire to SCR 2 gate Pzit RED | Connection between filter for SCR 2 and control card PZ12__ \WHT/PUR| Signal wire to SCR 5 gate Pzi3_| PUR | Connection between fter for SCR 5 and control card ORN | Sensor wire for voltage check across capacitor C1 * See the DIAGRAMS SRM section for your lift truck model for the correct wire number.‘TABLE 3 - TERMINAL AND PLUG WIRE CONNECTIONS FOR SINGLI WITH SCR PUMP MOTOR CONTROLLER MOTOR TRACTION CIRCUIT PLUG OR TERME NO! FUNCTION Not used Status code 93 input ‘Status code 90 input ‘Status code 94 input ‘Status code 94 input Status code 91 input Status code 95 input Status code 95 input Battery Discharge Indicator enable signal input Pump (PMT) coil driver 1A coll driver Status code 92 input ‘Accelerator potentiometer input SLI input SL2 input Key switch input ~ Battery voltage supply from key switch S13 input SL input Instrument panel display number 4 input Instrument pane! display number 3 input Instrument panel display number 1 input Instrument panel display number 2 input Instrument panel display number § input, Not used Not used Signal wire between Traction and Pump cards - From Pump card PY12 Signal wire between Traction and Pump cards - From Pump card PY1t ‘Signal wire between Traction and Pump cards - From Pump card PY10 Not used Not used Not used Not used Signal wire from SCR 1 thermal protector BRN | Battery negative YEL | Signal wire from current sensor GRN_ | Signal wire from current sensor GRY _| Signal wire from SCR 1 thermal protector - | Notused at Traction Card - No color or number shown for Pump Card WHT _| Battery positive BLUWHT| Signal wire to SCR 1 gate BLU _ | Signal wire from SCR 1 cathode WHT/RED] Signal wire to SCR 2 gate RED | Connection between filter for SCR 2 and control card WHT/PUR] Signal wire to SCR 5 gate PUR | Connection between filter for SCR 5 and control card CORN _| Sensor wire for voltage check across capacitor C1‘TABLE 4 - TERMINAL AND PLUG WIRE CONNECTIONS FOR ‘SCR PUMP MOTOR CONTROLLER EXCEPT TRUCK MODELS 31.60, J1.80 and J2.00XMT (J30XMT, J3SXMT and J40XMT) PLUG OR, TERM. NO, ee Not used Status code 99 input Status code 90 input Status code 94 input Status code 94 input Status code 91 input Status code 95 input Status code 95 input Battery Discharge Indicator enable signal input Pump (PMT) coil driver 1A coil driver (Not used) Status code 92 input Not used. SLI input SL2 input Key switch input - Battery voltage supply from key switch SL3 input SL4 input Instrument panel display number 4 input Instrument panel display number 3 input Instrument panel display number 1 input Instrument panel display number 2 input Not used Not used Not used Not used Not used ignal wire between Traction and Pump cards - To Traction card PY10 Signal wire between Traction and Pump cards - To Traction card PY Signal wire between Traction and Pump cards - To Traction card PY. Not used Not used Signal wire from SCR 1 thermal protector BRN | Battery negative YEL | Signal wire from current sensor GRN | Signal wire from current sensor GRY _| Signal wire from SCR 1 thermal protector ~ | Not used at Traction card - No color or number shown for Pump card WHT _| Battery positive BLUMHT| Signal wire to SCR 1 gate BLU_ | Signal wire from SCR 1 cathode WHT/RED) Signal wire to SCR 2 gate RED _| Connection between fter for SCR 2 and control card WHT/PUR] Signal wire to SCR 5 gate PUR | Connection between filter for SCR § and control card ORN_| Sensor wire for voltage check across capacitor C1‘TABLE 5 - TERMINAL AND PLUG WIRE CONNECTIONS FOR DUAL MOTOR CONTROLLER TRACTION CARD TYPE LXM EXCEPT TRUCK MODELS J1.60, J1.80 and J2.00XMT (J30XMT, J3SXMT and J40XMT) FUNCTION Power steering contactor coil driver Not used ‘Auxiliary hourmeter input Inside motor reverse switching signal light motor drop out switching signal Left motor drop out switching signal Forward right motor contactor coil driver Forward left motor contactor coll driver Reverse right motor contactor coil driver Reverse left motor contactor coil driver 1A contactor coil driver D contactor coil driver ‘Accelerator potentiometer input Start switch input ‘Seat switch input ~ Voltage input from timer circuit Key switch input - Battery voltage supply from key switch FORWARD direction switch input REVERSE direction switch input Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used, Not used Not used Not used Not used BLK _ | Signal wire from SCR 1 thermal protector BRN | Battery negative YEL | Signal wire from current sensor GAN _ | Signal wire from current sensor GRY | Signal wire from SCR 1 thermal protector = | Notused WHT _| Battery positive BLU/WHT| Signal wire to SCR 1 gate BLU _| Signal wire from SCR 1 cathode IWHT/RED] Signal wire to SCR 2 gate RED | Connection between fiter for SCR 2 and control card |WHT/PUA} Signal wire to SCR 5 gate PUR | Connection between filter for SCA 5 and control card ORN | Sensor wire for voltage check across capacitor C1 * See the DIAGRAMS SRM section for your it ruck model for the correct wire number. 10‘TABLE 6 - TERMINAL AND PLUG WIRE CONNECTIONS FOR DUAL TRACTION MOTOR CONTROLLER ‘TRACTION CARD TYPE LXDX, LXDT ‘TRUCK MODELS J30XMT, J3SXMT and J40XMT (J1.60, J1.80 and J2.0XMT) PLUG OF. TERMINAL ‘NO. FUNCTION Power stesring contactor coil driver Battery Discharge Indicator pump interrupt signal Not used (auxiliary hourmeter input) Inside motor reverse switching signal (leftright 90° turn) Fight traction motor cut-out switching signal (60° turn) Left traction motor cut-out switching signal (60° turn) Forward contactor coll driver - right motor Forward contactor coil driver - left motor Reverse contactor coil diver - right motor Reverse contactor coil driver - left motor A contactor coll driver ‘AC contactor coil driver ‘Accelerator potentiometer input Start switch input Seat switch input Key switch input ~ Battery voltage supply from key switch Forward direction switch input Reverse direction switch input WHT | instrument panel display number 3 input BLK | Instrument panel display number 4 input GAN [instrument panel display number 5 input BARE | instrument panel display number 9 input RED —_| instrument panel display number 1 input Not used . Not used 109 | Signal wire between traction and pump cards or traction card and TMM 1 module 110 _| Signal wire between traction and pump cards or traction card and TMM 1 module 111 | Signal wire between traction and pump cards or traction card and TMM 1 module - Not used pyi2 2 Not used Pvia - Not used Pyia . Not used Pzt BLK [Signal wire from SCR 1 thermal protector P22 BRN | Battery negative Pz3, YEL | Signal wire from current sensor Pza GRN | Signal wire from current sensor P25, GRY —_| Signal wire from SCR 1 thermal protector P26 - Not used P27 WHT | Battery positive Pz BLUWHT | Signal wire to SCR 1 gate P29 BLU___ | Signal wire from SCR 1 cathode Pz10 WHT/RED | Signal wire to SCR 2 gate pzit RED __ | Connection betwoon fer for SCR 2 and control card p22 WHT/PUR | Signal wire to SCR 5 gate P213 PUR | Connection between filter for SCR § and control card Zia ORN | Sensor wire for voltage check across capacitor Ct NOTE: _Not all connections are used on all models or with all options: un‘TABLE 7 - TERMINAL AND PLUG WIRE CONNECTIONS. FOR SCR PUMP MOTOR CONTROLLER LIFT PUMP CARD TYPE PX or TMM 1 MODULE ‘TRUCK MODELS J30XMT, J35XMT and J40XMT (J1.60, J1.80 and J2.0XMT) PLUG OR TERMINAL } PLUG OR FUNCTION Right traction motor brush wear indicator (Status code 98 input) Fight traction moter brush wear indicator (Status code 98 input) Left traction motor hi temperature indicator (Status code 90 input) [Left traction motor brush wear indicator (Status code 94 input) Leftraction motor brush wear indicator (Status code 94 input) Lit pump motor hi temperature indicator (Status code 91 input) Lift pump motor brush wear indicator (Status code 95 input) Litt pump motor brush wear indicator (Status code 95 input) Battery Discharge indicator enable signal input Pump (PMT) col driver Not used (1A coil diver) Right traction motor hi temperature indicator (Status code 92 input) Not used SLI input (Slow hoist / Auxiliary # 2) 'SL2 input (Tit) ‘Key switch input Battery voltage supply from key switch 'SL3 input (Auxiliary #1) SLA input (Fast hoist) Instrument panel display number 6 input Instrument pane! display number 7 input Instrument panel display number 8 input Instrument pane! display number 10 input Not used Not used Not used ‘Signal wire between traction and pump cards or traction card and TNM 1 module ‘Signal wire between traction and pump cards or traction card and TMM 1 module Signal wire between traction and pump cards or traction card and TMM 1 module Not used Not used Not used Not used BLK [Signal wire from SCR 1 thermal protector BRN | Battery negative YEL | Signal wire from current sensor GAN | Signal wire from current sensor GRY —_| Signal wire from SCR 1 thermal protector ~ | Not used attraction card - No color or number shown for Pump card WHT | Battery positive BLUMWHT | Signal wire to SCR 1 gate BLU | Signal wire from SCR 1 cathode Pzi10 WHT/RED | Signal wire to SCR 2 gate pai REO | Connection between filter for SCR 2 and control card P12 WHT/PUR | Signal wire to SCR'5 gato Pz13 PUR | Connection between filter for SCR 5 and control card Pzia ORN | Sensor wire for voltage check across capacitor C1 NOTE: Not all connections are used on all models or with all options. 2‘TABLE 8 - TERMINAL AND PLUG WIRE CONNECTIONS. FOR TRACTION CARD TYPE ‘TRUCK MODELS E30ER, E40ER and ES0ER WIRE NO. ‘OR COLOR Power steering contactor oll ver Battery Discharge Indicator pump interupt signal ‘Auxiary Rourmeter input Speed limit traction motor over temp. Right traction motor dropout svstch (96° Turn) Left traction motor dropout switch (36° Turn) Forward contactor coll diver - right motor Forward contactor coll driver ~ left motor Reverse contactor coil driver ~ right motor Reverse contactor coil driver - left motor ‘1A contactor coil driver D contactor coll driver ‘Accelerator potentiometer input Start switch input Not used Key switch input ~ Battery voltage supply from key switch Forward direction switch input Reverse direction switch input Instrument panel display number 4 input Instrument pane! display number 3 input Instrument panel display number 1 input Instrument panel display number 2 input Insuument panel display number 5 input Not used Not used Brush wear indicator Notused Pyi0 Not used Pyit Not used Pyi2 Not used Pyi3 Not used Pyta Not used zt BLK | Signal wire fom SCR 1 thermal protector P22 BRN | Battery negative Pz3. YEL | Signal wire from current sensor Pza GRN | Signal wire from current sensor PzS GRY —_| Signal wire from SCR 1 thermal protector Pz6 2 Not used Par WHT | Battery positive Pz BLUMHT Signal wire to SCR 1 gate zo BLU | Signal wire from SCR 1 cathode Pz10 WHT/RED | Signal wite to SCR 2 gate a RED | Connection between fiter for SCR 2 and control card pzi2 WHT/PUR | Signal wire to SCR 5 gate Pz13 PUR —_| Connection between fle for SCR 5 and control card pzia ORN | Sensor wire for volage check across capacitor C1 NOTE: Not all connections are used on all models or with all options. BCHECKS AND ADJUSTMENTS GENERAL A WarNiNG ‘When a replacement card is installed, it must be adjusted using the procedures and settings shown in this section. Do NOT operate the lift truck before checking and adjusting the setting for each function. Setting numbers that are not correct for your lift truckcan damage the electrical system and cause the truck to operate differently than normal. This different operation of the truck can result in personal injury. If function settings are changed, tell all operators of the lift truck that the truck can operate differently now. This section has the control card checks and adjustments that can be made using the hand set. The control card checks and adjustments are usually made with the con- trol card installed inthe lift truck. Bench checks and ad- jjustments can also be made with the control card con- nected as shown in FIGURE 4. The checks show the stored setting numbers that have been stored for the dif- ferent control card functions. This section also includes a description of each of the different functions. The function settings can be adjusted using the adjustment ‘knob of the hand set. See FIGURE 1. ‘There are no checks oradjustmentsin this section for the other traction control components. To check, adjust or repair these other components, see the sections EV-100 MOTOR CONTROLLER, 2200 SRM 288 or EV-200 MOTOR CONTROLLER, 2200 SRM 414. Function Codes ‘The Function Codes are code numbers for the different functions that can be set for the “LX” series control cards. The hand set must be used to adjust the settings for the control card functions. There is a description of the function settings for the different control cards in CHECKING AND ADJUSTING FUNCTION SET- TINGS of this section. TABLE 9 also has a list and a short description of the different functions. TABLE 10 through TABLE 28have the correct setting numbers for the different functions on each control card. TABLE 9 - FUNCTION CODES. FUN CODE eoransen+ side] DESCRIPTION FOR CARDS - EV-100/200 LXT & LX’ Stored Status Code Creep Speed Controlled Acceleration and 18 Time ‘Current Limit Plugging Distance (Current) 4A Drop Out Current Field Weakening Pick Up (Curtent) Field Weakening Drop Out (Current) Regen. Braking Current Limit Regen. Start ‘Speed Limit 1 (SL1) ‘Speed Limit 2 (SL2) Speed Limit 3 (SL3) Internal Resistance Compensation BDI Battery Volts - BDI Pedal Position Plug Card Type Selection - Nominal Battery Volts Stoor Pump Time Dela FOR CARD - EV-100 LXM Stored Status Code Creep Spood Controlled Acceleration and 1A Time Current Limit Plugging Distance (Current) 4A Drop Out Current PAA Input Switch Function Selection ‘Speed Limit 1 (PAS or PAB) ‘Speed Limit 2 (PA4) ‘Speed Limit 3 Internal Resistance Compensation BDI Battery Volts Pedal Position Plug Card Type Selection - Nominal Battery Volts ‘Steer Pump Time Delay FOR GARD - EV-100/200 LXP Stored Status Code Internal Resistance Compensation Start (Current) Controlled Acceleration and 1A Time ‘Current Limit ‘Controlled Acceleration Compensation Speed Limit 1 (SL1) ‘Speed Limit 2 (SL2) ‘Speed Limit 3 (SL3) ‘Speed Limit 4 (SL4) Internal Resistance Compensation Card Type Selection - Nominal Battery Votts 4TABLE 9 - (Continued) FUNCTION cone DESCRIPTION TRUCK MODELS J1.60XMT, J1.80XMT and ‘J2.0XMT (J30XMT, JO5XMT and J40XMT) FOR CARD - EV-100 LXDX and LXDT Stored Status Code Creep Speed Controlled Acceleration and 1A Time (Current Limit Plugging Distance (Current) 1A Drop Out Current Field Weakening ‘Speed Limit 1 (PAS or PAB) ‘Speed Limit 2 (PA4) NA Internal Resistance Compensation BD! Battery Volts Pedal Position Plug Card Type Selection - Nominal Battery Volts Steer Pump Time Delay TRGESEtNeaeen+ FOR CARD - EV-100 LXPX 1 |Stored Status Code 2 | Internal Resistance Compensation Start (Current) 3 | Controlled Acceleration and 1A Time 4 {Current Limit 7 {Controlled Acceleration Compensation 1 | Speed Limit 1 (SL1) Slow Lift + 4th Function (Auxiliary # 2) 412 | Speed Limit 2 (SL2) Tit 13 | Speed Limit 3 (SL3) 8rd Function (Auxiliary # 1) 14 | Speed Limit 4 (SL4) Fast Lift 16 | Internal Resistance Compensation 17 | Card Type Selection - Nominal Battery Votts A warnina NEVER attempt to adjust any of the function set- tings without using the procedures and setting aum- bers given in this section, 15 Connecting the Control Card for Bench Checks and Adjustments (See FIGURE 4) A cauTION The control card can be damaged if power is not cor- rectly connected or disconnected. Always disconnect the battery connector before connecting or discon- necting the control card plugs. NOTE: The bench supply voltage does not need tobe the same as the voltage of the lift truck. ‘The hand set can also be used to check and adjust the functions of the control card when it is connected to a bench power supply for bench checks and adjustments. ‘The following parts are required: (1) a powersource to supply a minimum of 24 DC volts at 0.5 Amps (two 12 volt automotive batteries connected in series will work) (amax. of 84 VDC @ 0.5 amps can also be used), (2) an electrical plug to connect to the Plug Z. connector of the control card, (3) a switch for the circuit, (4) approxi- ‘mately 45 cm (18 inches) of 18 gage wire and (5)a hand set. Ifbatteries are not used, the power supply must have a full bridge rectifier with filter. Make the connections, for the bench checks and adjustments as follows: 1. Connect the switch and a Plug Z.(Hyster part number 1308651) tothe powersource using the wire asshown in FIGURE 4. 2, Make sure the switch is in the OFF position and con- nect the wire to TB4 as shown in FIGURE 4 3. Connect Plug Z.to the control card Plug Z connector and the hand set to the Plug Y connector. NOTE: There are no connections to the Plug A or B connectors of the control card. NOTE: The bench checks and adjustments are done using the same procedures described in the following, pages.CONTROL CARD PLUG A & B CONNECTORS 8 TERMINALS, PLUG Y CONNECTOR PLUG Z CONNECTOR PLUGZ ‘SWITCH 24 TO 84 VOLT DC 0.5 AMP POWER SUPPLY OR BATTERIES PIN PZ7 (B+) PIN Pz2 (B-) TERMINAL TB4 (B+) FIGURE 4 - BENCH CHECKS AND ADJUSTMENTS. Connecting the Hand Set to a Control Card Installed in a Lift Truck (See FIGURE 1 and FIGURE 3) A WARNING Before connecting or disconnecting the hand set to a control card installed in a truck, make sure to raise the drive wheel(s). Turn the key to the OFF po- sition, disconnect the battery and discharge capaci- tors Cl. Make sure the power is off as described in the WARNING. Disconnect Plug Y at the SCR control card (Traction or Pump) if the display is connected. See FIGURE 3. Connect the hand set plug at the location Y onthe control card, Connect the battery andturn the key to the ON positions. Following is the that will occur: lay sequence * Display of 8888 for one second to check the dis- play segments. * Status Code display of -01 ifseatisinthe up posi- tion, * Another Status Code will be displayed if there is, or has been, a possible fault * Blank display if the operator is on the seat and there is no Battery Indicator function installed. * Battery state of charge if the operator is om the seat and there is a Battery Indicator function in- stalled. ‘Turn the key to the OFF position. Following is the dis- play sequence that will occur: * Display shows the traction hourmeter reading for four seconds. © Display shows the pump hourmeter reading for fourseconds. Ifthere is no pump SCR control, the display will be blank. 16CHECKING AND ADJUSTING FUNCTION SETTINGS General A WARNING Each function of each control card has range of set- ting numbers so that the control card can be used on different models of lift trucks. This variation needed for lift trucks of different sizes and operating voltages. However, adjusting the function setting to the wrong number for your lift truck model can cause the truck to operate differently than normal. This different operation of the truck can result in personal injury. Do NOT adjust any of the function settings without using the procedures and the settings in TABLE 10 through TABLE 28. NOTE: TABLE 10 through TABLE28 show the range of settings allowed and the correctsetting foreach control function. The Factory Setting numbers are the recommended settings for new units as set by the facto- ty. These settings will provide satisfactory performance for most applications Some functions can be adjusted within the allowed range to change truck operation for specitic applica- tions. Adjusting a setting number to one thatis different than the factory setting is allowed, but follow the in- structions closely and stay within the minimum and ‘maximum settings. Settings other than the factory set- ‘tings will cause the lift truck to operate differently and can cause increased wear of parts. How to Connect and Check Hand Set A WARNING Before connecting the hand set to the control card, make sure to raise the drive wheel(s). Turn the key to the OFF position, disconnect the battery and charge capacitors C1. ‘The functions can be set when sitting on the seat or when off the lift truck, Disconnect Plug Y at the SCR control card (Traction or Pump) if the display is connected. See FIGURE 3. Connect the hand set plug at the location Y onthe control card (Traction or Pump). Connect the bat= tery. Push and hold the CONT button of the hand set so that tis depressed when power is applied. Turn the key to the ON position or move the power switch of the bench setup to the ON position. The display will show 7 “8888” to check that all segments of the display are working. The Function settings can now be checked or changed, How to Check and Adjust Functions ‘To check or adjust the setting for a function, do the fol- lowing steps: 1. Push the keyboard numbers for the desired function, See TABLE 9 for the functions and function numbers. For functions 16 or more, think of the CONT key equaling 15. Push and hold the CONT key plus the additional key number above 15 to total therequired function number. Example: for Function 18, push CONT and key 3 (15+3=18). The display will show the selected function. After one second, the display will show the number that has been set for that function, 2. Push and hold CONT for one second, The display number will blink, 3. To change the setting number, check for the correct setting for that function in TABLE 1 BLE 28. Change the setting number by turning the ‘Adjustment Knob on the hand set. The display will con- Gnue (o blink as the setting el 4, Push and hold the STORE key forone second. When the new setting number is set (stored), the display will stop blinking. 5. Push and hold the ESC key for one seconé. The dis- play will show “8888”. To check or set another function, 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 o the status code mode or display the state of battery charge if the operator isin the seat. The display can also be blank (no status codes and battery indicator is not installed). NOTE: Make sure the control is in the run mode be- fore disconnecting the hand set. If not, the battery must be disconnected and connected again to reset the sys~ tem. ‘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 connected, make sure to set the Adjustment Knob fully clockwise to make sure the control can operate at top speed.A warnina Before disconnecting the hand set from the control card, make sure to raise the drive wheel(s). Turn the key to the OFF position, disconnect the battery and discharge capacitors Cl. Disconnect the plug at the Y connector on the control ‘card to disconnect the hand set. Connect the plug for the instrument panel display plug at the Y connector. Function Descriptions ‘The following pages have descriptions for the different functions. The setting for each function is specific for each control card. To identify the control card, check the label at the top edge of each card case. There are some painted letters and numbers followed by letters on the lower part of the label. The last two letters identify the type of card installed. The following types of control cards are used: EV-100 or 200 LXT - Traction (with Regen) EV-100 or 200LX - Traction (with & without Regen. & without BDI) EV-100 LXM - Dual Motor Traction (without BD!) EV-100 or 200 LXPX ~ Pump Control EV-100 LXDX - Dual Motor Traction (without BDI) EV-100 LXDT - Dual Motor Traction (with BDI) NOTE: EY-100 LXDX_and_EV-100 LXDT are used on TRUCK MODELS J1.60XMT, J1.80XMT and J2.00XMT (J30XMT, J35XMT and J40XMT) ONLY. ‘The same nomenclature is also shown on TABLE 10. through TABLE 28 and in the following section head ings for the traction and pump control cards. Traction Control Cards (EV-100/200 LXT/LX) NOTE: These control cards are used with the motor controllers that control the speed of the traction mo- tors). A WARNING Ifany of the function settings are changed, the opera- tors must be told that the lift truck will operate dif- ferently. Do not adjust the function settings outside of the range of setting numbers shown in the TABLE 10 through TABLE 27. Settings out side the ranges can cause damage to the components of the traction sys- tem and can cause the truck to operate differently than normal. This different operation of the truck can result in personal injury. FUNCTION 1 STORED STATUS CODE (Push 1) ‘This function memory contains the last status code of the possible PMT fault that caused the lifttruck to stop operation. These codes can be removed from the display by turning the key tothe OFF position. The code will be stored in memory in the control card. This status code will be written over if a new possible PMT fault occurs. ‘The status code can be cleared from memory by adjust- ing the setting number to zero. The setting number must be stored by pushing the STORE key for one second. Adjustment of this function does not change the opera- tion of the lift truck. FUNCTION 2 CREEP SPEED (Push 2) ‘This function 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 ereep speed frequency will be main- tained when the accelerator input voltage is between 3.7 and 3.5 volts (an ohm value between 6K and 4.7K, ohms). FUNCTION 3_ CONTROLLED ACCEL- ERATION AND 1A TIME (Push 3) This function permits the adjustment of the maximum rate of acceleration. The setting determines the time al- owed to reach maximum SCR speed after the accelera- tor is set formaximum speed from stop. The control will stay in SCR acceleration for between 0.77 second (8) and 21.5 seconds (255) before the 1A contactor will ‘lose. The numbers in ( are the setting numbers 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). Donot adjust the function forasetting less than the minimum setting of 8. FUNCTION 4 CURRENT LIMIT (Push 4) ‘This function permits the adjustment ofthe current limit of the control. The rating of the control will determine the range of adjustment for this fmction. See 18‘TABLE 10 through TABLE 27. Do not adjust the set- ting to any number other than the factory setting. FUNCTIONS PLUGGING DISTANCE (CURRENT) (Push 5) This function permits the adjustment of the distance it takes to stop the lift track when plugging by controlling the current. Settings of higher numbers makes the lift truck stop faster. Lower numbers decreases the stopping rate for a longer stopping distance. A caution ‘Traction motor or controller damage will occur if the setting is above the maximum setting of TABLE 10 through TABLE 26. ‘The number for the setting for the current value of this function must be found if the Pedal Position Plug (Func- tion 16) will not be used. To find the number for the cur- rent value, use the following information: Range 200 to 1000 amps (EV-100) 300 to 1500 amps (EV-200) 010 255 3.14 amps per set unit (EV-100) 4.7 amps per set unit (EV-200) Setting Range Resolution Example: Setting of 20=263A (EV-100) 20 X 3.14A = 628A oF 63A 63A + 200A (range min.) = 263A FUNCTION6 1A DROP OUT CURRENT (Push 6) ‘This function permits the adjustment of the setting for the current value at which the 1A contactor will de- energize (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 setting of 255 will dis- able the 1A Drop Out. 19 FUNCTION7 FIELD WEAKENING PICK uP (Push 7) & CAUTION A setting HIGHER than the setting shown in TABLE 13, TABLE 17, TABLE 18, or TABLE 23 will make the Field Weakening Contactor energize too soon. This aperation can damage the traction motor, ‘This function permits the adjustment of the setting for the current value at which the FW contactor will ener- ize (close). This setting permits the FW contactor to close when the lift truck has returned to approximately 150% of its running current with a full load on a level surface. FUNCTIONS FIELD WEAKENING DROP OUT (Push 8) & cauTION A setting HIGHER than the setting shown in TABLE 13, TABLE 17, TABLE 18, or TABLE 23 will make the Field Weakening Contactor remain energized at high currents. This operation can cause motor heating and damage the traction motor. Do NOT set this function toa setting greater than the setting of Function 7. ‘This function permits adjustment of the setting for the current value at which the FW contactor will deenergize (open). This setting permits the FW contactor to open ‘when the lift truck requires more than 300% of the run- ‘ning current with a full load on a level surface. FUNCTIONS REGEN. BRAKING C/L (Push 9) & warnina A setting greater than the setting shown in TABLE 10, TABLE 13, TABLE 14, TABLE 17, ‘TABLE 18, or TABLE 23 will make the lift truck slow ata rte faster than normal A setting Iss than the number shown will make the lift truck slow at a. slower rate for less braking effect. This diferent op- eration of the truck can result in personal injury. A faster slowing rate can also damange the control eye- tem or traction motor.This function 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 10 REGEN. START (Push 10) A setting greater than the setting shown in TABLE 10, TABLE 13, TABLE 14, TABLE 17, ‘TABLE 18, or TABLE 23 can prevent regenerative braking. The lift truck will remain in the plugging mode longer and increase brush wear in the traction motor. ‘This function permits adjustment of the percent ON time at which the control will start toenergize the regen- erative braking circuit. The percent ON time can be be- tween0% and 95%. This adjustment setsthe speed point where regenerative braking will start. This prevents control from trying to energize the regen. circuit when motor current is too low. FUNCTION 11 SPEED LIMIT 4 (SL1) (Push 11) ‘This function is the same as Function 13, butuses a SL1 imit switch for an input. Some series of trucks do not use this function, FUNCTION 12 SPEED LIMIT 2 (SL2) (Push 12) ‘This function is the same as Function 13, but uses aSL2 limit switch for an input. Some series of trucks do not use this function. FUNCTION 13 SPEED LIMIT 3 (SL) (Push 13) This function permits adjustment of the speed limit (maximum battery volts to the motor). The range is 0% t0.96%. The adjustment sets the speed limit for the time when the input signal from the SL3 limit switch is received by the control card. This signal can be a signal from the sensor in the traction or pump motor. If the sensor shows that a motor is too hot, the control will limit maximum motor speed to this speed setting. SL3 limit switch is a normally closed switch connected to battery negative. When the switch opens, it enables the speed limit function. Asetting of Owill 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 sensorand can damage the motor. Some series of trucks donot use this function. FUNCTION 14 INTERNAL RESISTANCE COMPENSATION (Push 14) Adjusting this function setting to the wrong number can cause battery damage. ‘This function is used when the control card has the Bat- tery Discharge Indicator (BDI) function. Control cards that have BDI are type “LXT” control cards. TABLE 10, TABLE 1, TABLE 13, TABLE 14, TABLE 15, TABLE17, TABLE 18, TABLE 21, TABLE 22, TABLE 23, TABLE 26 and TABLE 27 show the settings for a battery in average condition. You can doa quick check to see if the function setting is accurate for your battery. Operate the lift truck uatil the battery indicator function has a display of approxi- mately 60 (1/2 discharge). Stop the lift truck for 5 min- utes. Disconnect the battery connector then connect the battery connector again and check the display for the battery indicator. If the change of display numbers is, Jess than 10, the setting number for this Function (14) is, correct, For the best use of yourbattery energy, the setting can be adjusted using the following procedure. However, you must use the procedure to change the setting as the bat- tery ages or battery damage can occur. Setting the num- ber too low for your battery can allow the kattery to dis- charge below the minimum specific gravity value. This ‘minimum specific gravity is specified by the battery manufacturer to prevent battery damage. A caution ‘Iftwo or more batteries are normally used in this lift truck, use the oldest battery to make this adjust- ment. Making this adjustment using a new battery ‘can result in a setting too low for an older battery that is not in as good a condition. Adjust the setting using the following procedure: 1. Operate the lift truck on a normal work cycle, Travel at medium speeds. 2. When lift interrupt occurs, park the lift truck and wait for approximately 10 minutes. 3. Check the specific gravity of several battery cells. If the specific gravity is between 1.140 and 1.150, the set- ting is correct for that battery. If the spocific gravity 20reading is high, adjust the function setting for a lower number. If it is low, adjust the setting fora higher num- ber. NOTE: It canbe necessary to charge the battery and do Steps 1 through 3 again to get an accurate setting for ‘your battery. FUNCTION 15 BATTERY VOLTS (Push 15) This function permits adjustment for the operating volt- age ofthe lift track, The adjustment also permits correct operation of the Battery Discharge Indicator function for controls equipped with BDI. For the controller and BDI to operate correctly, the setting number shown in TABLE 10, TABLE1, TABLE 13, TABLE 14, TABLE 15, TABLE17, TABLE 18, TABLE 21, TABLE 22, TABLE 26, and TABLE27 must be en- tered. Battery Volts Setting volts Between 0 and 31 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 NoBDI Between 251 and 255 NOTE: Adjusting the function setting to a number other than the number shown for your lift truck in TABLE 10, TABLE, TABLE13, TABLE 14, TABLE 15, TABLE 17, TABLE 18, TABLE 21, TABLE 22, TABLE 26, and TABLE 27 will cause a status code of ~15 or -16, Make sure the battery is fully charged and battery connector has good connectionsbe- fore making this adjustment. This is especially impor- ‘tant when adjusting for 36/48 volt operation (aumbers 184 to 250). FUNCTIONS GREATER THAN 15 NOTE: ForFunctions 16or more, think ofthe CONT key equaling 1 I INT key plus the litional key m we 1 the function_number. Example: for Function 18, push CONT key and key 3 (15+3=18). The display will show the selected function. After one second, the display will show the setting number that has been set for that func- tion, mn FUNCTION 16 PEDAL POSITION PLUG (Push CONT and 1) This function permits adjustment of the pedal position plug range. Pedal position will reduce the plugging cur- rent tothe current value set by this function as the accel- erator is returned to the creep speed position. There is ‘maximum plug current when the accelerator isin the top speed position. To disable the pedal position plug func- tion, adjust the current value tothe same current value as the plug distance current. See the description of Func- tion 5. Example: If Plug Distance Current (Function 5) is set at 500 amps, then set pedal plug current at 500 amps. With this setting, pedal position will have no effect on the plugging distance. Use the following information to adjust the current value: Range 100 to 930 amps (EV-100) 150 to 1425 amps (EV-200) Setting Range Oto 255 Resolution 3.2 per set unit (EV-100) 5.0A per set unit (EV-200) Example: Setting of 20 = 164 amps 20 x 3.2A = 64A EV-100) (644+ L00(range min)= 164A, FUNCTION 17 CARD TYPE SELECTION (Push CONT and 2) A WARNING Incorrect settings of Function 17 can cause the truck to operate differently than normal. This different operation ofthe truck can result in personal injury. NEVER set Function 17 toa setting that is notshown for your lift truck, This function permits the selection of the cardtype used for your lift truck application, FUNCTION 18 STEER PUMP TIME DELAY (Push CONT and 3) A WARNING setting lower than the setting shown in TABLE 10, TABLE li, TABLE 13, TABLE 14, TABLE 15, TABLE 17, TABLE 18, TABLE 21, TABLE 22, ‘TABLE 26, or TABLE 27 canlet the steer pump stop if the seat switch opens momentarily during normal operation. There is no power steering if thishappens. ‘The sudden and difficult steering effort that is notexpected can result in personal damage. jury or property ‘This function permits the selection of the input for the steering pump contactor. Either the seat switch or FWD/ REV switch closing can be the input. The setting also sets the time delay for the contactor to drop out after the switch opens, NOTE: | There is no delay time for contactor closing after getting the input signal from the closing of the seat or FWD/REV switches. Settings in the 0-128 range ad- just the delay after the seat switch opens. Settings in the 129-255 range adjust the delay afier the EWD/REV switch opens. Adjust the setting to the number shown in TABLE 1 TABLE 13, TABLE 14, TABLE 15, TABLE 18, TABL TABLE 22 , TABLE 24. TABLE 26 or TABLE 27 for your lift ruck. NOTE: There are function numbers higher than 18. Some function numbers are for the hour meter function and others are not used. Do not adjust these functions. “The warranty will no longer apply if these functions are adjusted. Pump Control Card (EV-100/200 LXP) NOTE: This control card is used with the motor con- troller that controls the speed of the motor for the lift pump. & warnina Ifany of the function settings are changed, the opera- tors must be told that the lift truck will operate dif- ferently. Do not adjust the function settings outside of the range shown in TABLE 12, TABLE 16 , TABLE 19 or TABLE 25. 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 result in personal injury. Connect the Hand Set to the pump control card as de- scribed in How To Connect and Check Hand Set. See FIGURE 1 and FIGURE 3. Push “CONT” on the hand set with the key OFF to get the “8888” display . Move the key to the ON position or move the power switch of the bench setup to the ON position. Follow the proce- dure described in How To Check and Adjust Func- tions to check or change function values of the pump control card FUNCTION 1 STORED STATUS CODE (Push 1) ‘This function memory contains the last status code of the possible PMT fault that caused the lift pump to stop operation. On lift truck models without a lift pump con- tactor (PMT) these faults can cause the lift pump motor to run continuously until the battery is disconnected. This status code will be written over if a new possible fault occurs and 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 ofthis function does not change operation of the hydraulic system. FUNCTION 2 INTERNAL RESISTANCE COMPENSATION START (Push 2) This function permits adjustment of the current level re- quired to start the internal resistance compensation (Function 16). FUNCTION3 CONTROLLED ACCELER- ATION AND 1A TIME (Push 3) ‘This function permits the adjustment of the maximum, rate of acceleration. The setting determines the time al- lowed to reach maximum SCR speed after the switch closes. This determines how fast the hydraulic functions ‘operate during start up. The control will stay in SCR op- eration for between 0.1 and 22 seconds afier the switch, closes. If there is a 1A contactor, it will automatically close 0.2 second after the controlled acceleration stops. FUNCTION 4 CURRENT LIMIT (Push 4) ‘This function permits the adjustment ofthe current limit of the control. ‘The rating of the control will determine the range of ad- justment for this function, See TABLE 12, TABLE 16, TABLE 19, TABLE 25 or TABLE 28. Donot adjust the setting above the factory setting. 2FUNCTION7 CONTROLLED ACCELERATION COMPENSATION (Push 7) ‘This function controls the rate at which the internal re- sistance compensation (Function 16) increases to the maximum value. The setting controls the rate of in- crease of voltage to the pump motor during the time of “controlled acceleration”. See Controlled Acceleration & 1A Time Function 3). NOTE: This function wasnot available onthe earliest ‘control cards. The values of the settings for Functions 2 and 16 also changed with the addition of Function 7. The values shown in TABLE 12, TABLE 16, TABLE 19, and TABLE 25 for these functions are acceptable set- tings for all pump control cards. FUNCTION 11 SPEED LIMIT 4 (SL1) (Push 11) This function allows the adjustment of the speed limit (maximum lift pump motor volts) when the lift pump SCR card receives a signal at control card terminal TB2. ‘Annormally open switch is connected between the TB2 terminal on the pump SCR card and battery negative ‘When the signal at TB2 is connected toattery negative, (normally open switch is closed) the lift pump motor starts and the speed limit is enabled, See TABLE 3, ‘TABLE 4, TABLE 7 and the DIAGRAMS SRM sec- tion for your lift truck model for information on which hydraulic functions activate SLI. Some series of trucks do not have this function. FUNCTION 12 SPEED LIMIT 2 (Push 12) ‘This function is the same as Function 11, but uses TB3 for an input. See TABLE 3, TABLE 4, TABLE 7 and the DIAGRAMS SRM section for your lift truck model for information on which hydraulic functions activate ‘SL2. Some series of trucks do not have this function. FUNCTION 13 SPEED LIMIT 3 (SL3) (Push 13) This function is the same as Function 11, but uses TBS for an input. See TABLE 3, TABLE 4, TABLE 7 and the DIAGRAMS SRM section for your lft truck model for information on which hydrautic functions activate SL3. Some series of trucks do not have this function. 2B FUNCTION 14 SPEED LIMIT 4 (SL4) (Push 14) This function is the same as Function 11, but uses TB6 for an input. See TABLE 3, TABLE 4, TABLE 7 and the DIAGRAMS SRM section for your lift truck model for information on which hydraulic functions activate SLA. Some series of trucks do not have this function. FUNCTIONS GREATER THAN 15 NOTE: For Functions 16 or more, push and HOLD the CONT key and t ove 1S 10 total the required function number. Example: for Function 18, push CONT key and key3 (15+3=18).The display will show the selected function. After one sec~ ‘ond, the display will show the number that has been set for that function. FUNCTION 16 INTERNAL RESISTANCE COMPENSATION (Push CONT and 1) This function is used to stabilize the pump speed by in- creasing motor volts during heavy loads. This function is setusing the information from the speed torque curve of the motor used. See TABLE 12, TABLE 16, TABLE 19 or TABLE 25 for your lift truck forthe cor- rect setting. FUNCTION 17 CARD TYPE SELECTION (Push CONT and 2) A WARNING Incorrect settings of Function 17 can cause the truck: to operate differently than normal. This different operation of the truck can result in personal injury. NEVER set Function 17 toa setting thatis notshowa for your lift truck. ‘This function permits the selection of the cardtype used for your lift truck application. TABLE 12, TABLE 16, ‘TABLE 19 or TABLE 25 shows the setting toselect the type of card application depending on which control card is installed. ‘Settings of 18 to 73 have a BDI Lockout as part of the function. BDI Lockout means that the BDI signal from the traction control must be present so that the pump control can operate. This control will stop operation ‘when the battery state of charge reaches 10%. Dual Motor Traction Control Card (EV-100 LXM/LXDX/LXDT) NOTE: | This control card is used with the motor con- troller that controls the dual traction motors.& warnina Ifany of the function settings are changed, the opera- tors must be told that the lift truck will operate dif- ferently. Do not adjust the function settings outside of the range shown in TABLE20, TABLE24, or TABLE 28. Settings outside the ranges can cause damage to the components of the traction system and ‘can cause the lift truck to operate differently. This different operation of the truckean result in person- al injury. FUNCTION 1 STORED STATUS CODE (Push 1) This function memory contains the last status code of the 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 memory in the control card. This status code will be written over ifa new possible PMT fault occurs. ‘The status code can be cleared from memory by adjust- ing the setting number to-zero. The setting number must bbe stored by pushing the STORE key for one second. ‘Adjustment of this function does not change the opera- tion of the lift track. FUNCTION 2 CREEP SPEED (Push 2) This function 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 (an ohm value between 6K and 4.7K ohms). FUNCTION 3 CONTROLLED ACCELERATION AND 1A TIME (Push 3) This function permits the adjustment of the maximum rate of acceleration. The setting determines the time al- lowed to reach maximum SCR speed after the accelera- torisset formaximum speed from stop. The control will stay in SCR acceleration for between 0.77 second (8) and 22 seconds (255) before the 1A contactor will close ‘The numbers in () are the setting numbers 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 adjust the function for asetting less than the minimumsetting of 8, FUNCTION 4 CURRENT LIMIT (Push 4) ‘This function permits the adjustment ofthe current limit of the control. The rating of the control will determine the range of adjustment for this function. See TABLE 20, TABLE 24, or TABLE 27. Do not adjust the setting forany number other than the factory setting. FUNCTION 5 PLUGGING DISTANCE (CURRENT) (Push 5) This function permits the adjustment of the distance it takes to stop the lift truck when plugging by controlling the current. Settings of higher mumbers makes the lift truck stop faster. Lower numbers decreasesthe stopping rate for a longer stopping distance. A CAUTION ‘Traction motor or controller damage willoccurifthe setting is above the maximum setting of TABLE 20, ‘TABLE 24, or TABLE 28. ‘The setting for the current value of this function must be found ifthe Pedal Position Plug (Function 16) will not be used. To find the number for the current value, use the following information: Range 200 to 1000 amps (EV-100) Setting Range 00.255, Resolution 3.14 amps per se: unit (EV-100) Example: Setting of 20=263A (EV-100) 20 x 3.14A = 62.8A or 63A 63A + 200A (range min.) = 263A FUNCTION6 1A DROP OUT CURRENT (Push 6) ‘This function permits the adjustment of the current value at which the 1A contactor will deenergize (open). ‘The 1A contactor will open and the motor ‘orque will be limited to SCR current to prevent motor currents that are too high. A setting of 255 will disable the LA Drop Out. FUNCTION 7 PA4 INPUT SWITCH FUNCTION SELECTION (Push 7) This function permits the choice of two modes of opera- tion for this function. The operation of a switch con- 24nected between PA4 and battery negative makes this function operate. The two modes are shown below: 1. Setting of 128 or higher - enables a speed limit ‘when a normally closed switch opens. & warnina Settings greater than 127 will prevent the inside mo- tor from operating in reverse during a turn. This dif- ferent operation of the truck can result in personal injury. NEVER set this function toa number greater than 127, 2. Setting of Oto 127 permits the inside traction mo- tor to reverse direction when a normally open switch closes. The switch also enables a speed limit. NOTE: There are no Functions 8 through 10 for this, control card. FUNCTION 11 SPEEDLIMIT 4 (PAS or PAS) (Push 11) This function permits the adjustment of the speed limit (maximum battery volts to the motor) when the limit ‘switch inputsignal isreceived by the control card at PAS or PAG. The limit switch used is a normally open switch connected to battery negative, closing the switch en- ables speed limit. See Function 7 for switch operation. Some series of trucks do not use this function, FUNCTION 12 SPEED LIMIT 2 (PAA) (Push 12) This functionis the same as Function 11, butis activated ‘when the limitswitch input signal is received by the con- ‘tol card at PA4. The limit switch used is a normally open switch connected to battery negative, closing the switch enables speed limit. See Function 7 for switch operation. Someseries of trucks donotusetthis function. FUNCTION 13 SPEED LIMIT 3 (Push 13) ‘This speed limit is activated by fault codes 90 and 93. Some series of trucks do not use this function. A setting of 0 will disable this speed limit function. FUNCTION 14 INTERNAL RESISTANCE COMPENSATION (Push 14) Adjusting this function setting to the wrong number can cause battery damage. 25 ‘This function is used when the control card has the Bat- tery Discharge Indicator (BDI) function. Control cards that have BDI are “LX” type “T” control cards. ‘TABLE 20, TABLE 24, and TABLE 27 show the set- tings for a battery in average condition. ‘You can do a quick check to see if the functionsetting is accurate for your battery. Operate the lift truck until the battery indicator function has a display of approxi- ‘mately 60 (1/2 discharge). Stop the lift truck for 5 mi utes. Disconnect the battery connector then connect the battery connector again and check the display for the battery indicator. If the change of display numbers is Jess than 10, the setting number for this Function (14) is correct. For the best use of your battery energy, the setting canbe adjusted using the following procedure. However, you ‘must use the procedure to change the setting as the bat- tery ages or battery damage can occur. Setting the num- ber too low for your battery can allow the battery to dis- charge below the minimum specific gravity value. This minimum specific gravity is specified by the battery ‘manufacturer to prevent battery damage. A caution Iftwo.or more batteries are normally used in this lit truck, use the oldest battery to make this adjust- ment. Making this adjustment using a new battery can result in a setting too low for an older battery that is not in as good a condition. Adjust the setting using the following procedure: 1. Operate the lift truck on a normal work cycle. Travel at medium speeds. 2. When lift interrupt occurs, park the lift truck and wait for approximately 10 minutes. 3. Check the specific gravity of several battery cells. If the specific gravity is between 1.140 and 1.150, the set- ting is correct for that battery. If the specific gravity reading is high, adjust the function setting for a lower number. If it is low, adjust the setting for a higher num- ber NOTE: It canbe necessary to charge the battery and do Steps 1 through 3 again to get an accurate setting for your battery. FUNCTION 15 BATTERY VOLTS (Push 15) This function permits adjustment for the operating volt- age of the lifttruck, For the lifttruckto operate correctly,the setting number shown in TABLE 20, TABLE 24, and TABLE 27 must be entered. Battery Volts Setting 24 volts Between Oand 31 36 volts Between 32 and 44 48 volts, Between 45 and 69 Tvolts Between 70 and 80 80 volts Between 81 and 183 36/48 volts Between 184 and 250 No BDI Between 251 and 255 NOTE: Adjusting the function setting to a number other than the number shown for your lift truck in TABLE 20, TABLE 24, or TABLE 28 will cause a status code of -15 or -16. Make sure the battery is fully charged and battery connector has good connections be- fore making this adjustment. FUNCTIONS GREATER THAN 15 NOTE: ForFunctions 16 ormore, thinkof the CONT key equaling 15, Push and hold the CONT key plus the i above 15 to total the required function_number. Example: for Function 18, push CONT key and key3 (15+3=18). The display will show the selected function. After one second, the display will show the setting number that has been set for that func- tion, FUNCTION 16 PEDAL POSITION PLUG (Push CONT and 1) This function permits adjustment of the pedal position plug range. Pedal position will reduce the plugging cur- rent to the current value set by this function as the accel- erator is returned to the creep speed position. There is ‘maximum plug current when the accelerators inthe top speed position. To disable the pedal position plug func- tion, adjust the current value tothe same current value as the plug distance current. See the description of Func~ tion 5, Example: If Plug Distance Current (Function 5) is set at 500 amps, then set pedal plug current at 500 amps. With this setting, pedal position will have no effect on the plugging distance. Use the following information to adjust the current value: Range 100 to 930 amps (EV-100) Setting Range Oto 255 Resolution 3.2A per setting unit (EV-100) Example: Setting of 20 = 164 amps 20 x 3.2A = 64A 644+ 100(range mini FUNCTION 17 CARD TYPE SELECTION (Push CONT and 2) A WARNING Incorrect settings of Function 17 can make the truck operate ina way thatis not normal. This differ- ent operation of the truck can result in personal inju- ry. NEVER set Function 17 to a setting that is not shown for your lift truck. This function permits the selection ofthe card type used for your lift truck application. TABLE 20 and TABLE 24 shows the correct setting for this control card FUNCTION 18 STEER PUMP TIME DELAY (Push CONT and 3) & warning ‘A setting lower than the number shown in ‘TABLE 20 or TABLE 24 can let the steer pump stop ifthe seat switch opens momentarily during normal operation. There is no power steering if this happens. ‘The sudden and difficult steering effort that is not ‘expected can result in personal injury or property damage. This function permits the selection of the input for the steering pump contactor. Either the seat switch or FWD/ REV switch closing can be the input. The setting also sets the time delay for the contactorto drop out after the switch opens. NOTE: There is no delay time for contactor closing after getting the input signal from the closing of the seat or FWD/REV switches. Settings in the 0-128 range ad- just the delay after the seat switch opens. Settings in the 129-255 range adjust the delay after the FWD/REV switch opens. Adjust the setting to the number shown in ‘TABLE 20, TABLE 24, or TABLE 28 for your lift struck. NOTE: There are function numbers higher than 18. ‘Some function numbers are for the hour meter function and others are not used. Do not adjust these functions. ‘The warranty will no longer apply if these functions are adjusted, 26FUNCTION TABLES (See TABLE 10 through TABLE 28) Settings for these functions must be between the mini- ‘mum and maximum numbers shown. Do NOT adjust a function to asettingthat isnot shown inthe correctable. ‘There are 11 tables for the EV-100 control cards and two tables for the EV-200 control card. Only four of the ta~ bles (TABLE 12, TABLE 16, TABLE 19, TABLE 25, and TABLE 27) are fora pump motor control card. Nine of the tables are for the different types of control cards for traction motor control with only one traction motor. ‘There arc three tables (TABLE 20, TABLE 24, and ‘TABLE 28) for the dual traction motor control. Make 27TABLE 26TABLE 25 sure you use the cor recltable when youmake adjustments. tis always good to check the function setting and compare the setting ‘numberto the number in the table before making the ad~ justment. The correct factory setting, and the value (cur- rent, time, etc.) for that setting, are in the columns ‘out the gray background. The minimum and maximum factory setting and value are shown with the gray back- ground. NOTE: Toidentify the control cardon your lifttruck, check the label at the top edge of each card case. 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-100 and EV-200 Motor Controllers. Make sure to read the WARNINGS and CAUTIONS under each function description and in the section CHECKING AND ADJUSTING FUNCTION SET- TINGS. These WARNINGS and CAUTIONS must be read before setting a function toa setting other than the factory setting, Following is a list of the tables for the Function Settings for the different lift track models: ‘TABLE 10 - EV-100 LXT FUNCTION VALUE SET. ‘TINGS ~ E/J1.25-1.75XL (E25-35XL) 36/48 (Trac- tion Card with Regen.) ‘TABLE 11 ~ EV-100 LX FUNCTION VALUE SET- TINGS - E/J1.25-1.75XL (E25-35XL) 36/48V (Trac- tion Card without Regen.) ‘TABLE 12 - EV-100 LXP FUNCTION VALUE SET- ‘TINGS - E/J1.25-1.75XL (E25-35XL) 36/48 (Pump Card) 27 ‘TABLE 13 - EV-100 LXT FUNCTION VALUE SET- TINGS - E2.00-3.00XL (F/J40-60XL) 36/48V (Trac- tion Card with Regen.) ‘TABLE 14 - EV-100 LXT FUNCTION VALUE SET- ‘TINGS - E2.00-3.00XL (E/J40-60XL) 72/80V (Trac- tion Card with Regen.) TABLE 15 - EV-100 LX FUNCTION VALUE SET- TINGS - E2.00-3,00XL (E/J40-60XL) All (Traction Card without Regen.) TABLE 16 - EV-100 LXP FUNCTION VALUE SET- ‘TINGS - E2.00-3.00XL (E/J40-60XL) (Pump Card) ‘TABLE 17 - EV-100 LX FUNCTION VALUE SET- TINGS - E3.50-5.50XL (E70-120XL) 36/48V (Trac- tion Card with Regen.)(1I in, Motor) TABLE 18 - EV-200 LX FUNCTION VALUE SET- TINGS - £3.50-5.50XL (E70-120XL) 36/48V (Trac- tion Card with Regen.)(13 in. Motor) ‘TABLE 19 - EV-200 LXP FUNCTION VALUE SET- TINGS - £3.50-5.50XL (E70-120XL) (Pump Card) ‘TABLE 20 - EV-100 LXM FUNCTION VALUESET- TINGS ~ J25-35B (Dual Traction Card Type) ‘TABLE 21 - EV-100 LX FUNCTION VALUE SET- TINGS ~ N40-45FR (Traction Card) ‘TABLE 22 - EV-100 LX FUNCTION VALUE SET- TINGS - R30E/EAJEF (Traction Card) ‘TABLE 23 - EV-100 LX FUNCTION VALUE SET-. TINGS - R30XM/XMA/XMF (Traction Card) ‘TABLE 24 - EV-100 LXD FUNCTION VALUE SET- TINGS -J30XMT, J35XMT and J40XMT (Dual ‘Traction Card Type LXDX, LXDT) ‘TABLE 25 - EV-100 LXP FUNCTION VALUE SET- TINGS -J30XMT, J3SXMT and J40XMT (LiftPump Card Type LXPX) TABLE 26 - EV-100 LX FUNCTION VALUE SET- TINGS - E30ER, E40ER and ESOER (Traction Card) ‘TABLE 27 - EV-100 LXD FUNCTION VALUE SET- TINGS - J1.60XMT, J1.80XMT and J2.00XMT. (Dual Traction Card Type LXDX, LXDT) TABLE 28 - EV-100 LXP FUNCTION VALUE SEI TINGS - J1.60XMT, J1.80XMT and J2.00XMT (Lift Pump Card Type LXPX)TABLE 10 - -100 LXT FUNCTION VALUE SETTINGS - E/J1.25-1.75XL (E25-35XL) 36/48V (Traction Card with Regen.) FUNCTION [RECOMMENDATION] "ALLOWED RANGE. No] Description Sentng | ‘Vatue’_| wna wine 1_|Stored Status Code ‘0008 = }000'/255 = 2 |Creep Speed 000 5% 000/255 5%/15% 3_| Controlled Acceleration & 1A Time_ 010, 0.94 Sec_| 008/255 0.77 Sec/215 Sec 4 |Current Limit C/L a 200, 180 Amp_| 000/210_ = 5. | Plugging Distance (Current) 750_| 670 Amp | 000/160 200 Amp/700 Amp 6 [1A Drop Out Current (077__| 700 Amp Jooo/2s02 | 450 Amp/1260 Amp 7 [Field Weakening Pick Up (Current) re a 7 8 [Field Weakening Drop Out (Current) (000 2 (000/255 = 9 [Regen Braking Or. 125 | s50Amp | ooors | __75 Amp/a00 Amp 10 | Regen. Start (% ON Time) og0_| 30% _| oonrass |_ox/as% SOR 1 ON Time 11 [Speed Limit 1 (Max mtr. VwiNG sw open)| 000 ee = 12 [Speed Limit 2 (Max mtr, V WING sw open)| _ 000. 7 ‘000/255, a 19 [Speed Limit 3 (Max mir, VNC sw open)| 120 aoseBatv| 000/180 | —96%(Min Limit-Max Spo)/ (0% (Max Limt-Min Spa). 1 [Internal Resistance Compensation oie | - __[oasroas z 15 [Battery Votts 200 | seaav_| 184/250 | 36 or 48 Volt Operation 16_| Pedal Position Plug 040. 228 Amp_| 000/187_ 100 Amp/700 Amp _ (Card Type Selection ov [J oaoioae = ‘Steer Pump Time Delay (Seat Sw) 025, 14 Sec a“ +: 1 Any number other than “zero” can be read as a possible fault. 2 Settings greater than 250 will disable the 1 Drop Out function ® average value for most batteries. See procedure for a more accurate value. 4 Setting of 000-128 (1.5-65.0 Sec) with seat brake, Setting of 021-128 (12-65 Sec) without seat brake.‘TABLE 11 - EV-100 LX FUNCTION VALUE SETTINGS - E/J1.25-1.75XL (E25-35XL) 36/48V (Traction Card without Regen.) FUNCTION [RECOMMENDATION "ALLOWED RANGE Value Description Min/Max. [Stored Status Code = [Creep Speed BENS% Controlled Acceleration & 1A Time 0.77 Seciaa Sec Current Limit G/L 235 Amp Plugging Distance (Gurrent) 200 Ampiai6 Amp ‘1A Drop Out Current "450 Amp/1260 Amp Field Weakening Pick Up (Current) Field Weakening Drop Out (Current) Regen. Braking Ci Regen. Start (% ON Time) 7 ‘Speed Limit 4 (Max mir, V wiNC sw open) = = ‘Speed Limit 2 (Max mtr, V wiNC sw open) = [Speed Limit 3 (Max mtr, V wINC sw open) lea%Batt V '96%(Min Limit-Max Spa)/ (096(Max Limit-Min Spd) Internal Resistance Compensation Battery Volts ‘86 or 48 Volt Operation Pedal Position Plug 400 Ampi416 Amp (Card Type Selection z [Steer Pump Time Delay (Seat Sw) 3 "Any number other than “zero” can be read as a pos: 2 Settings greater than 250 will disable the 1 Drop Out function. 3 Average value for most batteries. See procedure for a more accurate value. 4 Setting of 000-128 (1.5-65.0 Sec) with seat brake. Setting of 021-128 (12-65 Sec) without seat brake. 29‘TABLE 12 - EV-100 LXP FUNCTION VALUE SETTINGS - E/J1.25-1.75XL (E25-35XL) 36/48V (Pump Card) FUNCTION Stored Status Code RECOMMENDATION. ‘ALLOWED RANGE Factory Setting Factory Value Internal Resistance Comp. Start —_ (000/255 84.5 Amp/1320 Amp. Controlled Acceleration & 1A Time 0.31 Sec 0.1 Secit.1 See Current Limit C/L (Lift Relief) Current Limit G/L (Titt Relief) 375 Amp. 190 Amp 255 255 375. Amo 190 Amp Controlied Acceleration Compensation 39 Amp77249 Amp? Speed Limit 1 (Max mtr, V wiNO ow ol 13%Batt V (035/064 1996/24% Bat Volts ‘Speed Limit 2 (Max mtr, V wINO sw cl) ‘21%6Batt V 19% /24% Batt Volts ‘Speed Limit 3 (Max mtr, V wINO sw cl) 100% Batt V| 18%/100% Batt Volts ‘Speed Limit 4 (Max mtr, V wiNO ew cl) 100% Batt V} 13%/100% Batt Volts Internal Resistance Compensation 2.28V Card Type Selection + Any number other than “zero” can be read as a possible fault. 2 Average value for most batteries. See procedure for a more accurate value. 7 Open center current (newer card only). Older card value is 44 Amp. ® Current at relief (newer card only). Older card value is 226 Amp, Hl with BOI NOTE: There are no functions 5, 6, 8 through 10, 15 or 18 for the Pump Card, Settings for these functions, have no effect on operation.‘TABLE 13 - EV-100 LXT FUNCTION VALUE SETTINGS - £2.00-3.00XL (E/J40-60XL) 36/43 (Fraction Card with Regen.) FUNCTION "ALLOWED RANGE Setting Value Description Min/Max Min/Max [Stored Status Code =_[ooot255 = Greep Speed 3% | 0007255 Bem Controlled Acceleration & 1A Time 0:94 See | 008/255 | 0.7 Seci2i.5 Sec Current Limit C/L 250Amp | 255 250Amp Plugging Distance (Current) 514 Amp | 000/105 | __200Amp/530 Amp TA Drop Out Current ‘900 Amp | 000/252 | 450 Amp/1260 Amp Field Weakening Pick Up (Current) le 185 Amp | 000/10 52 Ampi228 Amp Field Weakening Drop Out (Current) 487 Amp | 000/140 65 Amp/s20 Amp Regen. Braking CL 328 Amp | 000/143 75 Ampia90 Amp Regen. Start (% ON Time) 30% | 0007255 | O%/95% SCR ONTime ‘Speed Limit 1 (Max mir, V wINC sw open) = | 0007255 = ‘Speed Limit 2 (Max mtr, V wINC sw open) =| 000285 = ‘Speed Limit 8 (Max mir, V WING sw open) leareBatt V | 000/180 | 96%6{Min Limit-Max Spay/ 0% (Max Limit-Min Spa) Internal Resistance Compensation = Battory Volts 36/48V 36 oF 48 Volt Operation Pedal Position Plug 228 Amp 100 Ammp/S30 Amp Card Type Selection = = ‘Steer Pump Time Delay (Seat Sw) 14 Sec s + Any number other than “zero” can be read as a possible fault. 2 Settings greater than 250 will disable the 1A Drop Out function. 3 Average value for most batteries. See procedure for a more accurate value. 4 Setting of 000-128 (1.5-65.0 Sec) with seat brake. Setting of 021-128 (12-65 Sec) without seat brake. 31‘TABLE 14 - EV-100 LXT FUNCTION VALUE SETTINGS - E2.00-3.00XL (E/J40-60XL) 72/80V (Traction Card with Regen.) FUNCTION Factory | Factory | Setting Value Description Setting | Value Min/Max 1 |Stored Status Code ‘0008 = 001/255. = 2 |Creep Speed 000 5% 000/255 5%/15% 3 |Controlied Acceleration & 1A Time 010 0.94 Sec | 008/255 0.77 Seci22 Sec 4 |Current Limit C/L 125 480 Amp | 000/130 480 Amp 5 |Plugging Distance (Current) 050 357 Amp | 000/055 200 Amp/373 Amp 6 |1A Drop Out Current 012 489 Amp | 000/250? 450 Amp/1260 Amp 7 [Field Weakening Pick Up (Current) 000 = (000/255 = € [Fie Weakening Drop Gut Cuver | —000| ~~ oonss : Regen, Braking C/L 102 _| 299 Amp | 000/125 75 Amp/349 Amp. Regen. Start (% ON Time) 010 3.70% 000/255. 0%/95% SCR ON Time [Speed Limit 1 (Max mtr, V wiNC sw open) | _ 000 = (000/255 = 1a [Speed Lint? (Max mi VwiNC aw pen) | 000 | = Foooss = 13 [Speed Limit 3 (Max mtr, VwINC swopen)| 120 [64%BattV | 000/180 | _96%(Min Limit-Max Spa)/ i ‘0% (Max Limit-Min Spd) 14 |Internal Resistance Compensation 0123 - 005/025 eS |Battery Volts 72V 075 72 070/080 ‘72 Volt Operation [Battery Volts B0V 085 80V 081/183 80 Volt Operation Pedal Position Plug 040 | 228Amp | ooo/08s 100 Amp/373 Amp 17 _|Card Type Selection 042 — 040/044 = [Steer Pump Time Delay (Seat Sw) 025 | 14Sec * * Any number other than “zero” can be read as a possible fault. 2 Settings greater than 250 will disable the 1 Drop Out function. 3 Average value for most batteries. See procedure for a more accurate value. 4 Setting of 000-128 (1.5-65.0 Sec) with seat brake. Setting of 021-128 (12-65 Sec) without seat brake. 32.TABLE 15 - EV-100 LX FUNCTION VALUE SETTINGS - E2.00-3.00XL (E/J40-60XL) All (Traction Card without Regen.) FUNCTION ALLOWED RANGE Description [Stored Status Code Value Min/Max [Creep Speed B%I15%. [Controlled Acceleration & 1A Time 0.77 Seci22 Sec [Current Limit G/L 36/48V [Current Limit G/L, 72180V 250 Amp 480 Amp Plugging Distance (Current) 96/48V. Plugging Distance (Current) 72/80. 200 Amp/a16 Amp 200 Amp/373 Amp. ‘1A Drop Out Current 96/48V 1A Drop Out Current 72/80V 450 Amp/1260 Amp 450 Amp/1260,Amp Field Weakening Pick Up (Current) Field Weakening Drop Out (Current) Regen. Braking Ch. [Regen. Start (% ON Time) [Speed Limit 1 (Max mic, V wiNC sw open) [Speed Limit 2 (Max mtr, V wINC sw open) [Speed Limit 3 (Max mtr, V wiNC sw open) ea2%Batty ‘96%6(Min Limit-Max Spd)/ (0% (Max Limit-Min Spa) Internal Resistance Compensation36/48V internal Resistance Compensation72/80V_ Battery Volts. 36/48V) Battery Volts, Te Battery Volts Bov 36/48V 7y gov. 36/48 Volt Operation ‘72\Volt Operation 80 Volt Operation Pedal Position Plug 36/48 Pedal Position Plug 72180V 100 Amp/530 Amp, 100 Amp/373 Amp [Card Type Selection [Steer Pump Time Delay (Seat Sw) + Any number other than "zero" can be read as a possible fault. 2 Settings greater than 250 will disable the 1A Drop Out function. 3 Average value for most batteries. See procedure for a more accurate value. 4 Setting of 000-128 (1.5-65.0 Sec) with seat brake. Setting of 021-128 (12-65 Sec) without seat brake. 33‘TABLE 16 - EV-100 LXP FUNCTION VALUE SETTINGS - E2.00-3.00XL (E/J40-60XL) All (Pump Card ) FUNCTION Description [RECOMMENDATION| ALLOWED RANGE. Siored Status Code = [o00'7255 = 2 | Internal Resistance Comp. Star® 10 | 65 Amp | cones | 84.5 Amp/iaz0 Amp Internal Resistance Comp. Start® 020 | 65.amp | 000/255 | 84.5 Amp/1320 Amp 3 | Controlied Acceleration & 1A Time 010 | 0.31 Sec | 000/050 0.4 Secii.45 Sec 4 | Current Limit O/L (Lift Retief) 255__| 250Amp | 255 250 Amp? 7 | Controlied Acceleration Compensation® | 018 = 015 ‘88 Amp7/270 Amp® Controlled Acceleration Compensation® | 050 : 050 - 11 | Speed Limit 1 (Max mir, VwNOswel® | 035 | 19%BarV| 036/064 | 13%/24% Batt Volts ‘Speed Limit 1 (Max mtr, V wiNO sw ci)® | 050 | 26%Battv | 070/096 | 26% /36% Batt Volts 12 [Speed Limit 2 (Max mtr, VwiNO swcl® | 055 |2t%Batv| 095/064 | 19% /24% Batt Volts ‘Speed Limit 2 (Max mtr, VwiNO sw) | 080 | 30%Batt V | 070/096 | __ 26%/46% Batt Voits 13 | Speed Limit (Max mtr, VwiNO swt) | 255 [roo%Batt | o7o/255 | 26% /100% Batt Vons 14 | Speed Limit 4 (Max mtr, VwiNO sw c)® | 180 |100%BattV| 095/255 | _ 13%/100% Batt Vos Speed Limit 4 (Max mtr, V wiNO sw ol | 10 _|100%Batt V| 070/180 | 26% /100% Batt Volts 16 | Internal Resistance Compensation® oie | 228v | o10I025 Internal Resistance Compensation® 2.28v_| 095025 Card Type Selection + Any number other than "zero" can be read as a possible fault. ® Average value for most batteries. See procedure for a more accurate value. 5 36/48 volts ONLY 8 72180 volts ONLY 7 Open center current 8 Current at relief ® MUST be set to 030 if optional PMT kitis installed or system will not operate. NOTE: There are no fun have no effect on operation. 08/0719 Hi with BDI 8 5, 6, 8 through 10, 15 or 18 for the Pump Card. Settings for these functions.TABLE 17 - EV-100 LX FUNCTION VALUE SETTINGS - £3.50-5.50XL (E70-120XL) 36/48V_ (Traction Card with Regen.) (II in, Motor) RECOMMENDATION. "ALLOWED RANGE Setting Value Description Min/Max Min/Max [Stored Status Code (00087255, = [Creep Speed (000/255 576/15% [Controlled Acceleration & 1A Time o0gi255 | __ 0.77 Seci2t.5 Sec [Current Limit G/L 255 380 Amp, Plugging Distance (Gurrent) aoo/10s | 200 Ampi530 Amp [1A Drop Out Gurrent jeoores0? [450 Amp/1260 Amp Field Weakening Pick Up (Current) 000/110 ‘52,Amp/228 Amp Field Weakening Drop Out (Current) 000/140 65 Amp/520 Amp Regen. Braking Cit. 000/143 75 Amp/a90Amp Regen. Start (At X% SCR ON Time) 30% | 00/255 '| _0%6/95% SCR ON Time [Speed Limit 1 (Max mir, V WING sw open) = [roooass = [Speed Limit 2 (Max mtr, V wINC sw open) ae - [Speed Limit 3 (Max mtr, V wINC sw open) Jea%Ban V | 000/180 | 96% (Min Limit-Max Spa)/ (0% (Max Limit-Min Spd) Internal Resistance Compensation 005/025 = Battery Volts 36/48. 184/250 | 36/48 Volt Operation Pedal Position Plug 000/184 | 100 Amp/s23 (Card Type Selection 040/044 Lee [Steer Pump Time Delay (Seat Sw) = # Any number other than “zero” can be read as a possible fault 2 Settings greater than 250 will disable the 1 Drop Out function. ® Average value for most batteries. See procedure for a more accurate value. 4 Setting of 000-128 (1.5-65.0 Sec) with seat brake. Setting of 021-128 (12-65 Sec) without seat brake, 35TABLE 18 - EV-200 LXT FUNCTION VALUE SETTINGS ~ E3.50-8.50XL (£70-120XL) 36/48V (Fraction Card with Regen) (13 in. Motor) FUNCTION RECOMMENDATION. "ALLOWED RANGE Factory | Setting Value Description Min/Max [Stored Status Code. = [Creep Speed 5% SI /15% [Controlled Acceleration & 1A Time 1.78 Sec 1,36 Seo/22 See [Current Limit G/L 380 Amp 380 Amp [Plugging Distance (Current) 1240 Amp 800 Amp/1288 Amp 1A Drop Out Gurrent 1200 Amp’ 675 Amp/iscoAmp Field Weakening Pick Up (Current) 210 Amp, 78 Amp/258 Amp Field Weakening Drop Out (Current) “488 Amp 98 Ampist3 Amp Regen. Braking CL 515 Amp 7S.AmpIseS Amp Regen. Start (% ON Time) 37% (0%6/95% SCR ON Time [Speed Limit 1 (Max mir, V WING sw open) = [Speed Limit 2 (Max mtr, V wING sw open) = [Speed Limit § (Max mtr, V WNC sw open) ‘96% (Min Limit-Max Spa/ (O%6(Max Limit-Min Spd) internal Resistance Compensation = [008/025 = Battery Volts 36/48V_ 36/48V_[ 184/250 | 36/48 Volt Operation Pedal Position Plug 450 Amp | 000/227. 150 Amp/1288 Amp [Card Type Selection = __| rosie = [Steer Pump Time Delay (Seat Sw) 14 Sec f 2 + Any number other than “zero” can be read as a possible fault. 2 Settings greater than 250 will disable the 1A Drop Out function ® Average value for most batteries. See procedure for a more accurate value. 4 Setting of 000-128 (1.5-65.0 Sec) with seat brake. Setting of 021-128 (12-65 Sec) without seat brake. 36‘TABLE 19 - EV-200 LXP FUNCTION VALUE SETTINGS - £3.50-5.50XL (E70-120XL) FUNCTION (Pump Card) "ALLOWED RANGE Description Value Min/Max Stored Status Code (0007/2585) Internal Resistance Comp. Start 65 Amp (000/255 ‘84.5 Amp/i320 Amp Controlled Acceleration & 1A Time 0.31 Sec (000/050 0.4 Sec/t.15 Sec Current Limit G/L 375 Amp. 255 375 Amp. Controlled Acceleration Compensation 01S 54 Amp7/202 Amp® ‘Speed Limit 1 (Max mtr, V wiNO sw cl) f13%6Batt V (035/064 1396/24% Batt Volts ‘Speed Limit 2 (Max mir, V wiNO sw cl) aiseBattV ‘0350/64 19%/24% Batt Volts ‘Speed Limit 3 (Max mir, V wiNO sw ci) [roozBatt 305/255 19%/100% Batt Volts ‘Speed Limit 4 (Max mir, V wiNO ew el) froo%Batt 19%/100% Batt Volts Internal Resistance Compensation 2.28V Card Type Selection Any number other than “zero” can be read as a possible fault, 3 Average value for most batteries. See procedure for a more accurate value. 7 Open center current. ® Current at relief Hil with BDI NOTE: There are no functions 5, 6, 8 through 10, 15 or 18 for the Pump Card. Settings for these functions have no effect on operation. 37‘TABLE 20 - EV-100 LXM FUNCTION VALUE SETTINGS - J25-35B (Dual Traction Card) FUNCTION RECOMMENDATION. "ALLOWED RANGE Value Deseription Min/Max Stored Status Code = [Creep Speed 5%/15% Creep Speed 5%/15% 3 [Controlled Acceleration & 1A Time: 0.7 Seci21.5 Sec 4 [Curent Limit CL [ 330 Amo Plugging Distance (Current) 200 AmpI671 Amp Plugging Distance (Current) 200 Amp/671 Amp TA Drop Out Current “450 Amp/t260 Amp 1A Drop Out Current 450 Amp/1260 Amp PAS Input Sw Function (See WARNING below) ‘Speed Limit = [Speed Limit 2 = Speed Limits 3 Internal Resistance Compensation = Battery Vols 2A Volt Operation Battery Volts 36 Volt Operation Pedal Position Plug 100. Amp/916 Amp Card Type Selection ‘Steer Pump Time Delay (w/o Seat Brake) 1 Any number other than “zero” can be read as a possible fault 2 Settings greater than 250 will disable the 1A Drop Out function. ® Not used, set to 000 (zero). 4 Setting of 000-128 (1.5-65.0 Sec) with seat brake. Setting of 021-128 (12-65 Sec) without seat brake. NOTE: There are no Functions 8 through 10, forthe Dual Traction Card, Settings for these functions have no effec on operation A WarNiNG Settings greater than 127, for Function 7, will prevent the inside motor from operating in reverse during a turn. This different operation ofthe truck ean result in personal injury. NEVER set Function 7 toa number greater than 127, 38‘TABLE 21 ~ EV-100 LX FUNCTION VALUE SETTINGS - N40-45FR 24 or 36 V (Traction Card) FUNCTION RECOMMENDATION’ ALLOWED RANGE Factory | Factory Value Value Min/Max Description Stored Status Code = (Creep Speed 536/15% (Controlled Acceleration & 1A Time 24V 0.5 Seci22 Sec [Current Limit CAL T 375/650 Amp Plugging Distance (Current) 200 Amp/g50 Amp 1A Drop Out Current ‘450 Amp/1260 Amp Field Weakening Pick Up (Current) Ficld Weakening Drop Out (Current) Regen. Braking G/L Regen. Start (% ON Time) Speed Limit 1 (Max mtr, V wiNC sw open) ‘Speed Limit 2 (Max mtr, V w/NC sw open) (0009 ‘Speed Limit 3 (Max mtr, V w/NC sw open) 000% Internal Resistance Compensation 0008 = Battery Volts 251/255 No BOL Pedal Position Plug 100 Amp/930 Amp Card Type Selection ele)~fo]o/=]>]s]— 3! zB a 3 e ‘Steer Pump Time Delay 1.5 Sec/65 Sec 1 Any number other than “zero” can be read as a possible fault. 2 Settings greater than 250 will disable the 1 Drop Out function ® Not used, set to 000 (zero). 39‘TABLE 22 - EV-100 LX FUNCTION VALUE SETTINGS - R30E/EA/EF (Traction Card) FUNCTION ALLOWED RANGE Value Min/Max Stored Status Code - [Creep Speed SH6/15% [Controlled Acceleration & 1A Time 24V (0.94 Seci2t 5 Sec Current Limit Cf 330 Amp Plugging Distance (Current) 200 Ampi592 Amp. 1A Drop Out Current = Field Weakening Pick Up (Current) 2 Field Weakening Drop Out (Current) = Regen. Braking C/L Rogen. Start (4 ON Time) a ‘Speed Limit 1 (Max mtr, V wiNC sw open) ‘Speed Limit 2 (Max mtr, V wiNC sw open) [Speed Limit 3 (Max mir. V wING sw open) = Internal Resistance Compensation = Battery Volts av 124 Volt Operation Battery Volts 36 ‘36 Volt Operation Pedal Position Plug 100 Ammpi523 Amp [Card Type Selection - [Steer Pump Time Delay = + Any number other than "zero" can be read as a possible faut. 2 Settings greater than 250 will disable the 1 Drop Out function ® Not used, set to 000 (zero)TABLE 23 - EV-100 LX FUNCTION VALUE SETTINGS - R30XM/XMA/XMF (Fraction Card) FUNCTION FACTORY SETTING ‘ALLOWED RANGE No. DESCRIPTION | NUMBER | VALUE | MIN/MAX | MIN/MAX NUMBER | VALUE 1 | Stored Status Code 000 - ‘000/000 - 2 | creep Speed (24 Vorts) 200 13% Ce Creep Speed (36 Volts) 100 9% (000/255 Sm/5% 3. | Controller Acceleration 18 16sec | o1ess | 122Se0c 4 | Current Limit 255 eee 5 | Plugging (Current) 24 Votts 75 435 Amps 7518s | 435/487 Amps Plugging (Current) 36 Votts 50 357 Amps: 0160 | 357/888 Amps 6 | 1A Drop Out Current 255 pisasueo | 255/265 | DISABLED 7 | Field Weakening Pick Up 000 NA 000 NA 8 | Field Weakening Drop Out 000 NA 000 NA 9 | Regen, Braking Current Limit ‘000 NA 000 NA 10 | Regen, Start (% ON Time) (000 NA (000 NA 11 | Speed Limit 1, 24V, 4.0 MPH 118 40MPH | MiNTEO | 0-40MPH ‘Speed Limit 1, 96V, 4.0 MPH 118 aompH | minieo | 0-40MPH 12 | Speed Limit 2, 24v, 1.2MPH, 150°t0 212272" | 150 tamPH | MINtgo | 0-12MPH Speed Limit 2, 96, 1.2MPH, 150"to 212072 | 163 12meH | inigo | 0-1.2MPH 13 | Spoed Limit 9, 24, 22 MPH, 60° to 150" 142 2amPH | inneo | 0-22MPH ‘Speed Limit 3, 96V, 2.2 MPH, 60° to 150" 142 2emPH | miNigo | 0-22MPH 14 [internal Resistance Compensation 000 DISABLED ‘000 DISABLED 15. | Battery Vons 255 NO BD! 255/255 NO BDI 16 | Pedal Position Plugging (24 Votts) 40 228 Amps 40150 228/260 Pedal Position Plugging (36 Volts) 25 180 Amps 25/95, teot2 17 _ | Card Type Selection 22 STOOL, 20704 STD ONL " Any number other than “zero” can be read as a possibie fault. NOTE: A value of 000 indicates the absence of any fault. NOTE: Reference setting, may vary. NOTE: To set 4.0 MPH speed on non-traction performance trucks, pull wire #45 from 10° relay coil (or from connector to tram on tran-equipped truck) and test speeds with platform between 24" and 60°. If unplugging prox switches to simulate platform height, all lower prox switches must also be unplugged. 4‘TABLE 24 - EV-100 LXD FUNCTION VALUE SETTINGS - J30XMT, J3SXMT and J40XMT (Dual Traction Card Type LXDX, LXDT) FUNCTION Description ‘*Factory Setting RECOMMENDATION Factory Value ‘Stored Fault Code 000" Creep Speed Controlled Acceleration & 1A (STD) 100 No Move at Start (86 and 48 votts) lz 3 1.2.Secto 1A Controlled Acceleration & 1A (EE) . (36 volts only) Current Limit 220 10% Grade w/ load Plugging Distance Firm and Smooth, 4A Drop Out Current 45 10% Grave Start Field Weakening 0 Optional ‘Speed Limit 1 (@6 volt) 110 60 Degree Turn| "| speed timit 1 (48 volty 120 60 Degree Turn ‘Speed Limit 2 (@6 volt) 115 90 Degree Tum’ 12 | speed timit 2 (48 volt) 125 90 Degree Turn 13__ [Speed Limit 3 0 A 14__ [Internal Resistance Gompensation 17 1.94 Volts Drop 15 _ [Battery Volts 200 200 16 | Pedal Position Plug 32. 200 Amps 17 _ | Card Type Selection 2 36/48 Volts 18 __ | Steer Pump Time Delay 7 10 Seconds: ‘Any number other than “zero” can be read as a possible fault. NOTE: The factory settings listed in this chart are + 2 unless otherwise specified. All card functions not listed in the chart are to be set to zero (0) NOTE: There are no functions 8 throught0 for this Dual Traction card. Settings for these functions have no effect on operation. *Contact your authorized HYSTER Dealer for Lift Trucks for approval of settings other than the FACTORY SETTINGS. a