INTRODUCTION

GENERAL tem repair section printed for the other series of

This section describes the procedures for troubleshoot-
ing and repair of the EV–1 motor controller. The EV–1
motor controller is used, with modifications, in several
series of lift trucks. There are many components that
are not part of the motor controller, but give inputs to it.
These components include the following: (1) Key
Switch, (2) Start Switch (some units), (3) Brake
Switch, (4) Foot Switch, (5) Seat Switch (SitDrive

units only), (6) Direction (FWD/REV) Switch, (7) Ac-
celerator Potentiometer and (8) Guidance System
(some units). You will also need the information in the
following SRM sections for repair and troubleshoot-
ing:
• ELECTRICAL SYSTEM, 2200 SRM 464. De-
scribes the control switches and the adjustment of
the control card that are special for the SitDrive-

lift trucks. There is a separate Electrical Sys-
lift trucks.
• EV–1 MOTOR CONTROLLER, DESCRIP-
TION, 2200 SRM 112. Has a description of the
operation of the EV–1 controller. (This addi-
tional section is not normally necessary for
troubleshooting as described in this section.)
This section is separated into the following parts:
• SRO and PMT Circuits. A short description of
the SRO and PMT circuits and the sequence of
operation of the controller is used as an introduc-
tion to Troubleshooting. You must understand
some functions and operations so that you can se-
lect the correct fault procedure.
• Troubleshooting. General procedures and fault
analysis.

11
2

3
1 4

12

16

7
15

8
7090
14 5
6 6
1. TERMINAL STRIP 13 10 9
2. ELECTRONIC DRIVES (PMT, 1A, FW) 10. CONTROL CARD
3. CONTACTOR FOR THE HYDRAULIC MOTOR 11. CAPACITOR 1C
4. CONTACTOR 1A 12. TRANSFORMER AND INDUCTOR
5. SCR 1 ASSEMBLY ASSEMBLY
6. POWER TERMINALS 13. “REVERSE” CONTACTOR
7. SCR 5 14. “FORWARD” CONTACTOR
8. SCR 2 15. FIELD WEAKENING RESISTOR
9. CARD TERMINAL STRIPS 16. FIELD WEAKENING CONTACTOR
FIGURE 1. EV–1 MOTOR CONTROLLER

1
 • Checks and Repair. Additional information to
make the checks and repairs of the faults you find
in the troubleshooting procedures.
There are two contactors that are frequently found on
the controller base: a contactor for the hydraulic pump
motor, and a contactor for the power steering motor (if
equipped). These two contactors are not part of the op-
eration of the EV–1 controller. See the section on the
SRO CIRCUIT AND PMT CIRCUIT
STATIC RETURN TO OFF (SRO) CIRCUIT
The “Static Return to OFF” (SRO) circuit is a safety
circuit. The SRO circuit will prevent the operation of
the lift truck if the operator is not in the correct position
at the controls. The starting sequence is as follows:
a. Close the seat switch (See NOTE). The operator
must be in the correct position at the controls. The
control card must receive the voltage from the
seat switch before any of the other control signals
to move the lift truck.
NOTE: SitDrive trucks have a seat switch. “R” and
“N” trucks have a “brake switch” on the operator plat-
form. StanDrive
trucks have a platform switch. “E”
trucks equipped with a seat brake do not use the seat
switch.
b. Close the key switch. The key switch supplies the
battery voltage to the control circuits. (The
E20–120B lift trucks also have a switch con-
nected to the parking brake. The parking brake
must be released before battery voltage is sup-
plied to the control card.)
c. Move the controls to operate the lift truck. The
control card makes a comparison of the voltage
signal from the direction switch at L9 or L10 with
the voltage signal from the seat (foot) switch at
L5 and L7. If the voltage signal to L9 or L10
comes before the voltage signal from the seat
(foot) switch at L5 and L7, the lift truck will not
operate.
2
hydraulic system or the steering system for each series
of lift trucks for more information.
WHEN YOU NEED HELP. Call a Hyster lift truck
dealer if you have correctly followed a fault procedure
and have not found the fault. This section describes the
most common faults that occur in the EV–1 controller.
Hyster dealers have Service Engineers that can help
you check and repair a fault that is not common.
See the sections ELECTRICAL REPAIRS AND
ADJUSTMENTS for each series of lift trucks for
more information on the control switches.
PULSE MONITOR TRIP (PMT)
The PMT circuit opens the direction contactors if SCR
1 has two pulses without going to OFF between the
pulses. The PMT circuit is part of the control card. Af-
ter the SRO circuit is complete, the control card applies
and senses the voltage across SCR 1. If the voltage
across SCR 1 stays low, there is a fault across SCR 1. A
fault across SCR 1 can be caused by a short–circuit in
SCR 1 or the tips of contactor 1A welded closed. The
voltage must be at least 50% of battery voltage before
the control card will permit the direction contactor to
close.
The control card checks the traction circuit for faults
during operation of the lift truck. If the SCR 1 stays ON
for greater than 32 milliseconds, the PMT signal opens
the direction contactor. The control card will immedi-
ately close the direction contactor again. If the fault
continues, the control card will immediately open the
direction contactor again. The control card will not
close the contactor again until the PMT circuit is reset
by turning the key switch to OFF and then to ON gain.
This rapid double operation (double fault) of the direc-
tion contactor is an important indication when
troubleshooting. This double fault normally indicates a
fault in the OFF circuit for the SCR 1. The OFF circuit
for the SCR 1 has the SCR 2, SCR 5, capacitor C1, and
the transformer and inductor assembly.

Operator in the operator’s
position (Seat switch on “E”
and “J” trucks, “platform
switch” on “N” and “R”
trucks)
Control card energizes the
PMT electronic driver and
closes the FORWARD
contactor
Control card sends gate
signal to change SCR 1 and
SCR 5 to ON
Power pulse to traction
circuit

Key switch to the ON

position
Control card checks for 75% C1 fully charged with
Controls set for FORWARD battery voltage across SCR 1 reverse voltage. SCR 5 goes
travel OFF.

Control card checks SRO Control card sends gate Control card sends gate
circuit signal to SCR 2 signal to SCR 2

SCR 2 goes ON and SCR 2 goes ON and

connects capacitor C1 to the discharges C1 to cathode of
battery SCR 1

Control card checks for a

Control card checks for minimum of 75% of battery
approximately 50% battery voltage across C1
voltage across SCR 1 SCR 1 goes OFF
SCR 2 goes OFF when C1 is SCR 2 goes OFF
charged
Control card repeats cycle.

FIGURE 2. SEQUENCE OF OPERATION

THE SEQUENCE OF OPERATION
The sequence of operation shown in FIGURE 2. de-
scribes a sequence of the beginning condition and the
SCR operation.
The following symbols are used in the description:
R1 –– Right terminal strip numbers on the logic con-
trol cards
L1 –– Left terminal strip numbers on the logic control
cards
Wire 1 –– The wire number of the control circuits

TROUBLESHOOTING

GENERAL PROCEDURES specific gravity of 1.270 to 1.290. A discharged battery

1. Disconnect the battery and separate the connectors.
Check the specific gravity of the battery. If the specific
gravity is less than 1.260, the battery is not fully
charged or has a defect. A fully charged battery has a
has a specific gravity of approximately 1.130.
You will need a Cir/Kit meter or an ohmmeter and volt-
meter to make the following checks. The voltmeter
must have a minimum rating of 20 000 ohms per volt.

3
2. Check for 50 000 ohms or more between each termi-
nal of the battery connector for the lift truck and a clean
connection on the frame. Remove any grounds be-
tween the controller and the frame of the lift truck.
Carbon dust in a motor or other parts can cause a
ground. Check if your customer has added some addi-
tional equipment that is causing a ground.
3. Check for voltage between each terminal of the con-
nector fastened to the battery and a clean connection on
the frame. It is normal to measure some voltage be-
tween the battery and the frame even if the resistance
checks are correct. The leakage voltage is normally less
than 30% of the battery voltage. A high leakage voltage
can indicate a dirty battery or a battery with a defect.
Clean the battery and battery compartment as neces-
sary.
4. Make a visual check for parts or wires that are loose,
broken, or damaged.
The instructions for checking the parts and assemblies
are described in the section Checks And Repair. The
following WARNINGS and NOTES are given to help
during troubleshooting:
WARNING
Make sure you disconnect the battery and separate
the connector before you disassemble any part of the
4
controller. Make sure you also discharge the capaci-
tor C1.
WARNING
When the battery is connected, raise both drive
wheels from the surface before making checks.
NOTE: The correct meter polarity is necessary for the
checks. The voltage checks are made between the indi-
cated point in the troubleshooting chart and battery
negative. Connect the meter negative to battery nega-
tive. The meter polarity for the resistance checks is indi-
cated in the Repair And Adjustments section.
NOTE: Make an identification of any wires before you
disconnect them. The wires must be connected again in
the correct sequence.
Some checks and measurements must be made at the
control card plug on the back of the control card. Tilt
the control card from the controller so that you have ac-
cess to the control card plug. Apply pressure with your
fingers to loosen the locks that hold the plug in the con-
trol card. Twist a screwdriver blade in the slot where
the control plug joins the control card and disconnect
the control card plug. The pin arrangement is shown in
FIGURE 6. The function of each pin of the control card
plug is shown in FIGURE 7.
 RAISE
DRIVE WHEELS
FAULT NUMBER 1. LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. THE
DIRECTION CONTACTORS NEVER CLOSE.

Possible Causes: • Short–circuit across SCR 1

• Short–circuit or open circuit in the control circuit
• Accelerator circuit is damged or needs adjustment
• Control card is damaged
• Traction circuit has open circuit
• 1A contacts welded closed
• PMT electronic driver is damaged
• Open fuse in control circuit or traction circuit

1.0 Check for a minimum of 50% of battery volt-
age across SCR 1.
1.2 Connect the battery and turn the key switch
to the ON position. Close the seat switch
and parking brake switch. Do not push on
the accelerator pedal. Check for battery
voltage between battery negative and L3 of
the control card.
1.1 Short–circuit in SCR 1. Disconnect the bat-
tery. Check that the 1A contacts are not
welded together. Repair or replace a dam-
aged contactor 1A. Repair damage in the
traction circuit.
1.3 No Battery voltage at L3. There is a fault in
the control circuit. Go to Fault 1.20

1.4 Battery voltage is at L3. Check for battery 1.5 No voltage at L5 and L7. Check the seat
voltage at L5 and L7 on the control card. switch or parking brake switch and the wires
for an open circuit.

1.6 Voltage at L5 and L7 is correct. Check for

8.2 volts between R1 of the control card and
battery negative. 1.7 Voltage is outside the limits of 8.0 to 8.3
volts at R1. Replace the control card.

1.8 Voltage is correct at R1. Make sure the ac-

celerator pedal is in the up position. Check
1.9 Battery voltage at L10. There is a fault in the
for a battery voltage at L10.
accelerator circuit. Go to Fault 1.30.

1.10 No voltage at L10. Push the accelerator
pedal down. Check for battery voltage at
L10.
1.12 Voltage is correct at L10. Make sure the
controls are set so that the lift truck will oper-
ate in the REVERSE direction. Check for
greater than 0.5 volts between battery
negative and R3 of the control card. Typical
voltage is 1.0 to 2.0 volts.
1.11 No battery voltage at L10. There is a fault in
the direction switch, or start switch, or the
brake switch. Check the switches and wires
for an open circuit. Go to Fault 1.30 to check
the accelerator circuit.
1.13 A signal voltage of less than 0.5 volts nor-
mally indicates a fault in the traction circuit.
Go to Fault 1.40

To 1.14
5
 From 1.12

1.14 Voltage at R3 is correct. Check for battery

voltage between battery negative and the
positive side of the REVERSE contactor 1.15 No battery voltage. Check the wires from
coil. the direction switch to the contactor coil for
an open circuit.

1.16 Voltage is correct. Check for battery voltage

between battery negative and the negative
side of the REVERSE contactor coil. 1.17 No Battery voltage. Replace the contactor
coil.

1.18 Voltage is correct. Check for battery voltage 1.19 There is approximately battery voltage at
at terminal 3 of the PMT electronic driver. terminal 3 of the PMT electronic driver. Re-
place the PMT electronic driver.

FAULT IN THE CONTROL CIRCUIT

1.20 No battery voltage at L3. Check for battery 1.21 No voltage between cables. Check:
voltage between + cable 1P1 at the fuse • Battery plug
panel and battery negative. • Power cables

1.22 Correct battery voltage between cables. 1.23 Replace a bad fuse. Check the following
Check the fuse for the control circuit. parts for a short–circuit:
• Horn
• Battery Meter
• Hour meter
1.24 The fuse for the control circuit is good. • Power steering
Check the key switch and wires for an open • Contactor coil
circuit. Check the seat switch and parking • Key switch
brake switch. There will be battery voltage • Seat switch
at L3 at this step if the checks and repairs • Direction switch
are correctly done. • Hydraulic pump switch
• Brake switch

6
FAULT IN THE ACCELERATOR CIRCUIT WITH AN ACCELERATOR CARD
1.30 Check the accelerator potentiometer volt-
age. Measure the voltage between R5 and
battery negative. The correct voltage is 4.0
to 4.5 volts and decreases to 0.0 to 0.2 volts
at maximum speed.
1.32 The accelerator potentiometer voltage is
correct. Check the fuse to the accelerator
card.
CAUTION
A short–circuit between wire 15 and battery nega-
tive will damage the accelerator card before the fuse
can protect the circuit.
1.34 Fuse is good. Connect the battery and close
the key switch, seat switch, and parking
brake switch. Set the controls to operate in
the REVERSE direction and push the ac-
celerator pedal. Check for approximately
battery voltage between wire 15 and battery
negative.
1.36 Approximately battery voltage on wire 15
when the SRO circuit is correct. Raise the
accelerator pedal to the UP position. If the
voltage on wire 15 does not decrease to 0
volts, replace the accelerator card.
TRACTION CIRCUIT
1.40 Connect the battery and turn the key switch
to the ON position. Measure the voltage be-
tween the anode and cathode of SCR 1.
The correct battery voltage is approxi-
mately 50% of the battery voltage.
1.42 Voltage across SCR 1 is correct. Replace
the control card.
1.31 The voltage at R5 is wrong. Check the link-
age and the adjustment of the accelerator
potentiometer. If the voltage does not de-
crease smoothly between CREEP speed
and maximum speed, replace the accelera-
tor potentiometer.
1.33 Fuse is bad. Check the accelerator card for
a short–circuit. Disconnect wire 15 from the
accelerator card to the terminal strip. Con-
nect the battery and close the key switch,
seat switch, and push on the accelerator
pedal. If the fuse opens again, replace the
accelerator card.
1.35 No battery voltage on wire 15 to the direc-
tion switch. Replace the accelerator card.
1.41 No battery voltage across SCR 1. Discon-
nect the battery and discharge the capacitor
C1. Check that the contacts of contactor 1A
are not welded together. Repair or place
contactor 1A.
1.43 Check SCR 1 and D3 for a short–circuit.
Make resistance “quick check” between the
heat sink of the anode and the cathode. See
the Checks And Repairs section for more
instructions to check the SCRs.
1.45 SCR 1 is bad. Check D3. A bad D3 can
damage an SCR 1. Replace a bad SCR and
a bad diode D3.
7
 RAISE
DRIVE WHEELS
FAULT NUMBER 2.LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. A DIRECTION
CONTACTOR CLOSES AND THEN IMMEDIATELY OPENS
[PMT FAULT].
Possible Causes: • SCR 5 short–circuit or open circuit
• SCR 2 open circuit or no gate signal
• SCR 5 or SCR 2 suppressor is damaged
• Capacitor C1 is damaged
• Control card is damaged
• Transformer and inductor assembly is bad

2.0 Connect the battery and turn the key switch

to the ON position. Close the seat switch
2.1 No 8.2 volts at the control card. Replace the
and parking brake switch. Set the controls
control card.
to operate in the REVERSE direction.
Check the control card for 8.2 volts between
R1 and battery negative. You can also make
sure of a PMT fault by checking the signal
voltage between R3 and battery negative.
Typical voltage is 1.0 to 2.0 volts. Less than
0.5 volts is a PMT signal.

2.2 The control card is correct. There is a PMT

signal (less than 0.5 volts). Disconnect the
battery and separate the connector. Dis-
charge the capacitor C1. Make a resistance
“quick check” of SCR 5. See the Checks 2.3 SCR 5 is bad. Replace the SCR5. Check D3
And Repairs section for more instructions for an open circuit. An open D3 can damage
to check the SCRs. Disconnect the control SCR 5.
card plug from the control card for access to
the following pins:
Pin Number 2 gate signal
Pin Number 3 sensor wire (The sensor wire
is electrically the same point as the cath-
ode.)

2.4 SCR 5 is correct. Check SCR 2. See the

Checks And Repairs section for instructions
on checking the SCRs. The following pins of
the card connector are for SCR 2:
Pin Number 8 gate signal
Pin Number 9 sensor wire (The sensor wire 2.5 SCR 2 is bad. Replace SCR 2.
is electrically the same point as the cath-
ode.)

8
 From 2.4

2.6 SCR 2 is good. Check C1 for a short–circuit.

Disconnect C1 and measure the resistance 2.7 C1 is bad. Replace C1.
between the terminals. A good C1 will first
indicate a low resistance and then increase
to more than 100 000 ohms.

2.8 C1 is good. If the fault has not been found by

this step, replace the control card. Connect 2.9 The lift truck still has the fault. Disconnect
the battery and check the operation of the the battery and discharge capacitor C1.
lift truck. Check the inductor assembly. If the lift truck
still has the fault, replace the SCR 2 sup-
pressor. If replacement of the SCR 2 sup-
pressor does not correct the fault, replace
NOTE: If a lift truck has a PMT fault that is the SCR 5 suppressor. See Checks And
not regular, check SCR 2. Replace an SCR Repairs for instructions.
2 that indicates less than 50 000 ohms of re-
sistance. An SCR 2 that indicates less than
50 000 ohms will sometimes cause a PMT
fault in an operating circuit, but test good
when checked by the tests described in
Checks And Repairs.

NOTE: A suppressor for SCR 5 and SCR 2

often will not indicate a fault except during
operation. If the other parts of the circuit are
good at this step, replace a suppressor and
check the operation of the lift truck.

NOTE: When the battery is connected and

the key switch is ON, the capacitor will
slowly charge to battery voltage in 4–5 min-
utes. If SCR 2 or SCR 5 has a short–circuit,
C1 will charge immediately to battery volt-
age. If C1 has a short–circuit, it will not
charge.

9
 RAISE
DRIVE WHEELS
FAULT NUMBER 3. LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. THE
DIRECTION CONTACTORS CLOSE NORMALLY (NO PMT FAULT)

Possible Causes: • Open power fuse (short–circuit in traction circuit)

• Accelerator potentiometer is damaged or linkage needs
adjustment
• Open circuit power connections
• Traction motor is damaged
• SCR 2 has a short–circuit
• Control card is damaged (no gate signal to SCR 1)
• SCR 1 is damaged
• Wires (YEL/GRN) to motor current sensor have an open circuit

3.0 Check the 500 ampere fuse to the traction 3.1
circuit. Connect the battery and check for
battery voltage between battery negative
and the fuse.
3.2 Fuse for the traction circuit is good. Check
the accelerator potentiometer voltage be-
tween R5 and battery negative. The correct
voltage is 3.5 to 3.7 volts at CREEP speed
and decreases to 0.0 to 0.2 volts at maxi- 3.3
mum speed.
Fuse for the traction circuit is open. Discon-
nect the battery. Check the following parts
for a short–circuit:
• Diode D3
• Power cables and connections to the trac-
tion motor.
Repair a damaged part.
The voltage at R5 is wrong. Check the link-
age and the adjustment of the accelerator
potentiometer. Repair as needed.

3.4 The accelerator potentiometer voltage is

correct. Disconnect the battery and dis-
charge C1. Check SCR 2 for a short–circuit.
3.5 SCR 2 is damaged. Replace SCR 2.
NOTE: A short–circuit across SCR 2 or
SCR 5 will also cause capacitor C1 to
charge immediately to battery voltage when
the key switch is turned to ON. If SCR 2 and
SCR 5 are good, capacitor C1 will slowly
charge to battery voltage in approximately 3.7 No battery voltage between the anode and
4–5 minutes. cathode of SCR 1. Disconnect the battery.
Check the following parts for an open cir-
cuit:

3.6 SCR 2 is correct. Connect the battery and
turn the key switch to the ON position. Set
the controls to operate in the FORWARD di-
rection. The FORWARD contactor must
close to do the following test. Check for bat-
tery voltage between the anode and cath-
ode of SCR 1.
To 3.8
• Power cables and connections
• Traction motor brushes
Check the condition of the contacts in the di-
rection contactors and the regenerative
braking contactor to make sure they close
correctly. Check the condition of the
brushes and the commutator in the traction
motor. Do necessary repairs.

10
 From 3.6

3.8 There is battery voltage between the anode

and the cathode of SCR 1. Disconnect the
battery and use a tester to check SCR 1.
Make sure SCR 1 will go ON when a gate
signal is applied. 3.9 Replace a damaged SCR 1.

3.10 SCR 1 is good. Check the wires to the motor

current sensor for an open circuit. Make
sure the black sensor wire between SCR 1 3.11 Repair a broken wire or a bad connection.
cathode and PC5 is connected correctly.
The traction circuit will not operate if the
YEL/GRN wires between the current sen-
sor and the control card are not connected
to PC 13 and PC 14.

3.12 If the lift truck still has a fault at this step, re-
place the control card. Check that you are
using the correct fault description. Check
that you have correctly made the tests de-
scribed in the troubleshooting steps. Call
your Hyster Dealer for other recommenda-
tions.

FAULT NUMBER 4.LIFT TRUCK WILL MOVE IN ONLY ONE DIRECTION. DIRECTION
CONTACTORS CLOSE NORMALLY (NO PMT FAULT).

Possible Causes: • Bad direction contactor

4.0 Disconnect the battery. Check the condition 4.1 Repair a contactor that does not close cor-
of the contacts on the direction contactor. rectly. Replace bad contacts.
Make sure that the contacts close correctly.

11
 RAISE
DRIVE WHEELS
FAULT NUMBER 5.ONE DIRECTION CONTACTOR WILL NOT CLOSE. THE TRACTION
CIRCUIT OPERATES NORMALLY IN ONE DIRECTION.

Possible Causes: • Direction switch is damaged

• Control card is damaged
• Contactor coil is damaged
• Broken or disconnected wires
• PMT electronic driver is damaged on one output

5.0 Connect the battery and turn the key switch

to the ON position. Close the seat switch,
and push on the accelerator pedal. Set the
controls to operate in the direction that the
contactor will not close. 5.1 No voltage between L9 or L10 and battery
negative. Repair or replace the directional
If the FORWARD contactor does not close,
switch or the wires. Make sure that you
check for battery voltage between L9 and
check for a broken wire that still has the
battery negative. If the REVERSE contactor
outer insulation in good condition.
does not close, check for battery voltage
between L10 and battery negative.

5.2 Voltage at L9 or L10 is correct. Check the

PMT signal. Check for approximately 5.3 The PMT signal is less than 0.5 volts. The
1.0–2.0 volts between terminal 1 of the PMT control card has a fault. Replace the control
electronic driver and battery negative. card.

5.4 The PMT signal from the control card is cor-
rect. Check for battery voltage on the termi-
nal (3 or 4) of the PMT electronic driver for
the contactor coil that will not close.
5.6 The voltage at terminal 3 or 4 of the PMT
electronic driver is approximately battery
voltage. Measure the voltage between ter-
minal 3 (REVERSE) or terminal 4 (FOR-
WARD) and terminal 2. Approximately 0.0
volts is correct between the terminal 3 or 4
and terminal 2.
5.5 No battery voltage on terminal (3 or 4) of the
PMT electronic driver. Check for battery
voltage at the negative terminal of the con-
tactor coil. If there is 0.0 volts at the negative
terminal, check the voltage on the positive
terminal of the contactor coil. If there is volt-
age on the positive terminal, replace the
contactor coil. If there is no voltage on the
positive terminal, check and repair the di-
rection switch or the wires.
5.7 Battery voltage across the PMT electronic
driver indicates that the PMT electronic
driver is not sending a signal to the contac-
tor coil. Make sure that wire 13A is good be-
tween terminal 2 and battery negative. Dis-
connect the battery and replace the PMT
electronic driver.

12
 RAISE
DRIVE WHEELS
FAULT NUMBER 6.DIRECTION CONTACTOR WILL NOT OPEN WHEN PEDAL IS
RETURNED TO THE UP POSITION

Possible Causes: • Accelerator potentiometer is damaged or has a wrong

adjustment
• Accelerator card is bad

6.0 Connect the battery and turn the key switch

to the ON position. Close the seat switch 6.1 The accelerator voltage is not correct. Re-
and parking brake switch. Set the controls pair or adjust the accelerator potentiometer.
to operate in the REVERSE direction and
push on the accelerator pedal. Measure the
voltage between R5 and battery negative.
The correct voltage is 4.0–4.5 and de-
creases to 0.0–0.2 volts when the accelera-
tor is moved to maximum speed.

6.2 The accelerator voltage decreases cor-

rectly. Check for a short–circuit in the accel-
erator card. A short–circuit in the accelera-
tor will cause the following problems: The
control card will sense a voltage from the di- 6.3 The accelerator card has a short–circuit.
rection switch at L9 or L10 and the contactor Replace the accelerator card.
coil before the voltage is applied at L5 and
L7. The SRO circuit will prevent the PMT
electronic driver from closing the direction CAUTION
contactor. If the direction switch is moved If an accelerator card has a short–circuit,
when the SRO circuit is completed, the check the coil of the contactor for a short–
movement will momentarily interrupt the circuit. A short–circuit in the contactor coil will
SRO circuit. The logic in the control card will cause a fault in a replacement accelerator
sense the SRO circuit as being correct and card. Make sure any fault has been corrected in
the direction contactor will close. When the the circuit for the direction contactor before
accelerator is returned to the up position, you install a new accelerator card.
and the lift truck will stay at CREEP speed.
The direction contactor will not open.

13
 RAISE
DRIVE WHEELS
FAULT NUMBER 7. DIRECTION CONTACTORS CLOSE NORMALLY. THE LIFT TRUCK
HAS ONLY LOW POWER OR MOVES SLOWLY.
Possible Causes: • Diode D3 has an open circuit
• Thermal sensor has an open circuit
• Accelerator potentiometer is damaged or needs adjustment
• Control card has a fault
• SCR 2 has a short–circuit
• SCR 2 or SCR 5 suppressor is damaged
• Field weakening contactor (if equipped) has the contacts
welded closed
• Auxiliary plugging contactor is open (E60–120B and
N30–50C lift trucks only)

7.0 Disconnect the battery and discharge the 7.1 Replace a damaged D3.
capacitor C1. Check D3 for an open circuit.

7.2 D3 is good. Check SCR 2 for a short–circuit.

7.3 SCR 2 is damaged. Replace SCR 2.

7.4 SCR 2 is good. Check the thermal sensor.

Disconnect the card plug and measure the
resistance between the terminals. The cor- 7.5 The thermal sensor is damaged. Replace
rect resistance is approximately 120 to 150 the thermal sensor.
ohms at 21°C (70°F).

7.6 Check the acceleration potentiometer.

Measure the voltage between R5 on the
control card and battery negative. The cor-
rect voltage is 3.5 to 3.7 volts and de- 7.7 The accelerator voltage is not correct. Re-
creases to 0.0 to 0.2 volts when the accel- pair or adjust the accelerator potentiometer.
erator is moved to maximum speed.

7.8 If the lift truck is equipped with a field weak-

ening contactor. check that the contacts are
not welded closed. Check that the adjust-
ments F.W.P.U. and F.W.D.O. on the control 7.9 Repair a bad field weakening contactor.
card are set to the correct specifications.

To 7 10

14
 From 7.9

7.10 Connect the battery and turn the key switch

to the ON position. Close the seat switch
and parking brake switch. If the lift truck is
equipped with an auxiliary plugging contac-
tor, check that the (AP) contactor closed af-
ter one of the direction contactors closed.
7.11 The auxiliary plugging contactor did not
close. See Fault Number 12 for the proce-
dure to check the auxiliary plugging system.

7.12 If the lift truck is equipped with a field weak-

ening contactor, check if the contactor
7.13 If the field weakening contactor is closed,
closed when you connected the battery and
replace the field weakening electronic
closed the SRO circuit.
driver

7.14 If the fault is not found before this step, re-

place the control card.

NOTE: Make sure the correct replacement
for the control card is used. If a 1H3 control
card is used as a replacement for a 1E3
control card, the field weakening function
can be continuously energized.
7.15 If a replacement control card did not correct
the fault, replace the suppressor for SCR 2
and then SCR 5.

7.16 If the lift truck still has a fault at this step,

check that you are using the correct fault
description. Check that you have made the
tests described in the troubleshooting
steps. Call your Hyster lift truck dealer for
other recommendations.

15
 RAISE
DRIVE WHEELS
FAULT NUMBER 8.CONTACTOR 1A WILL NOT ENERGIZE. THE OTHER OPERATIONS
OF THE LIFT TRUCK ARE NORMAL.
Possible Causes: • Control card is damaged or needs adjustment
• Contactor 1A is damaged
• 1A electronic driver is damaged
• Accelerator potentiometer is damaged or needs adjustment
• Accelerator card is bad
• Violet sensor wire from T2 to pin 10 on the control card is
open

8.0 Disconnect the battery and separate the 8.1 Set the adjustments according the specifi-
connector. Check the adjustments on the cations for the lift truck for which you are
control card. making repairs. The operation of the lift
truck will not be correct if any of the sensor
wires are disconnected or open.

8.2 Connect the battery and turn the key switch

to the ON position. Set the controls so that
the lift truck will normally operate. Check the
adjustment of the accelerator potentiome-
ter. Measure the voltage between R5 and
battery negative. The correct voltage is 3.5
to 3.7 volts at CREEP and decreases
smoothly to 0.0 to 0.2 volts when the accel-
erator is moved to maximum speed. The 1A
contactor is normally energized at less than
0.5 volts.
8.3 The voltage at R5 is wrong. Check the link-
age and the adjustment of the accelerator
potentiometer. If the voltage does not de-
crease smoothly between CREEP and
maximum speed, replace the accelerator
potentiometer.

8.4 The voltage at R5 decreases correctly.

Check the voltage at terminal 1 of the 1A
electronic driver when the voltage at R5 has 8.5 The signal voltage from the accelerator
decreased to less than 0.5 volts. card does not decrease to less than 0.5
volts. Disconnect the battery and replace
NOTE: Check if the contactor 1A will close the accelerator card.
when the lift truck with a load is started on a
ramp. If the contactor 1A will not close on a
ramp, the accelerator potentiometer or the
accelerator card is bad.

Check the output of the accelerator card.

Measure the voltage between R6 and bat-
tery negative. The correct voltage is ap-
proximately 8 volts at CREEP and de-
creases to 0.0 to 0.2 volts at maximum
speed. This signal voltage must decrease
to less than 0.5 volts before the control card
will permit the contactor 1A to close on
TIME.
To 8.6

16
 From 8.4

8.6 The voltage at R6 decreases correctly.

Check the voltage at R8 when the voltage at
R6 has decreased to 0.0 to 0.2 volts. 8.7 The voltage at R8 is less than 0.5 volts. The
control card has a defect. Replace the con-
trol card.

8.8 1.0 to 2.0 volts at R8. Check for battery volt- 8.9 There is battery voltage across the elec-
age between terminal 3 of the 1A electronic tronic driver. Disconnect the battery and re-
driver and battery negative. place the electronic driver.

8.10 No battery voltage across the electronic 8.11 Battery voltage at the positive side of the
driver. Check for battery voltage at the posi- coil for the contactor 1A. Replace the coil.
tive side of the coil for the 1A contactor.

17
 RAISE
DRIVE WHEELS
FAULT NUMBER 9. THE FIELD WEAKENING CONTACTOR WILL NOT ENERGIZE (36–48
VOLT LIFT TRUCKS ONLY). THE OTHER OPERATIONS OF THE LIFT
TRUCK ARE NORMAL.
Possible Causes: • Control card is damaged or needs adjustment
• Accelerator potentiometer is bad or needs adjustment
• Accelerator card is bad or needs adjustment
• Field weakening contactor is damaged
• Electronic driver for field weakening is damaged

9.0 Check adjustments C/L, F.W.P.U. and

F.W.D.O. on the control card. Check the
wires between the current sensor and the
control card.
9.2 Turn the key switch to ON and set the con-
trols so that the lift truck can operate nor-
mally. Check the adjustment of the accel-
erator potentiometer. Measure the voltage
between R5 and battery negative. The cor-
rect voltage is 4.0 to 4.5 volts and de-
creases smoothly to 0.0 to 0.2 volts when
the accelerator is moved for maximum
speed.
9.1 Set the adjustments according to the speci-
fications for the lift truck for which you are
making repairs. The operation of the lift
truck will not be correct if any of the sensor
wires are disconnected or open.
9.3 The voltage at R5 is wrong. Check the link-
age and the adjustment of the accelerator
potentiometer. If the voltage does not de-
crease smoothly between CREEP and
maximum speeds, replace the accelerator
potentiometer.

9.4 The accelerator potentiometer is correct.

Check the output of the accelerator card. 9.5 The signal voltage from the accelerator
Measure the voltage between R6 and bat- card does not decrease to 0.5 volts. Discon-
tery negative. The correct voltage is ap- nect the battery and replace the accelerator
proximately 8 volts at CREEP and de- card.
creases to 0.0–0.2 volts at maximum
speed. This signal voltage must decrease
to 0.5 volts before the control card will per-
mit the field weakening contactor to close.

9.6 The signal voltage decreases correctly at

R6. Measure the voltage between R9 and
9.7 The voltage at R9 is less than 0.5 volts. Re-
battery negative when the voltage at R6 is
place the control card.
less than 1.0 volts.

9.8 The voltage is correct (typical voltage is 1.0

to 2.0 volts when R6 is 0.5 volts).
9.9
Check for battery voltage between terminal
3 of the electronic driver for field weakening
and battery negative.
There is battery voltage across the elec-
tronic driver, disconnect the battery and re-
place the electronic driver.

9.10 No battery voltage across the electronic 9.11 Battery voltage at the positive side of the
driver. Check for battery voltage at the posi- coil for the field weakening contactor. Re-
tive side of the coil for the field weakening place the coil.
contactor.

18
FAULT NUMBER 10. PLUGGING PROBLEMS

10.0 Plugging is too quick. 10.1 Plugging is too slow.

Check the PLUG adjustment on the control Check the PLUG adjustment on the control
card. card.

Check D4 for an open circuit. Replace the control card if there is no ad-
justment.
Check if the current sensor wires are bro-
ken or disconnected.

Replace the control card if there is no ad-

justment.

FAULT NUMBER 11. WHEN KEY SWITCH IS CLOSED, CONTACTOR 1A AND FIELD
WEAKENING CONTACTOR (IF EQUIPPED) WILL CLOSE.
DIRECTION CONTACTORS WILL NOT CLOSE.
Possible Causes: • Bad connection between control card and battery negative
• Bad control card

11.0 Disconnect the battery and discharge ca- 11.1 Make a good connection or replace a bro-
pacitor C1. Check the wire that goes be- ken wire. If the wire and connections are
tween pin 6 of the control card plug and the good, replace the control card.
terminal for 13B. If the connections are
good, make a resistance check to make
sure that the wire is not broken.

19
FAULT NUMBER 12. PLUGGING PROBLEMS (E60–120B and N30–50C LIFT TRUCKS
ONLY)

NOTE: The weight of the E60–120 and N30–50C lift trucks can cause the brushes of the traction motor to
wear quickly and also cause too much heat to be generated in the traction motor during plugging. These se-
ries of lift trucks have an auxiliary resistor for the current flow generated during plugging. When plugging, a
plugging contactor opens so that the current flows through the plugging resistor. During lift truck operation,
the auxiliary plugging contactor is closed except during plugging. This fault procedure checks the parts of the
auxiliary plugging system.

12.0 Do the checks in 10.0 or 10.1 except do not 12.1 Plugging is too slow. Disconnect the bat-
replace the control card. Replace the con- tery. Check that the auxiliary plugging resis-
trol card if there is no plugging signal as de- tor is connected correctly. Lift truck will not
scribed in the checks in this procedure. operate if the plugging resistor is open.

12.2 Plugging is too quick. Measure the voltage

between the terminal 2 of the auxiliary plug-
ging card and battery negative during plug- 12.3 Replace the control card if there is no ad-
ging. The correct voltage is approximately 8 justment.
volts. If there is no voltage from R10 to ter-
minal 2 during plugging, replace the control
card.

12.4 If the voltage is correct between R10 and

terminal 2, check for battery voltage be-
tween terminal 5 of the auxiliary plugging 12.5 The coil for the auxiliary plugging contactor
card and battery negative during plugging. has a short–circuit. Repair the contactor
If there is more than 0.5 volts at terminal 5, coil.
the auxiliary plugging card will not permit
the auxiliary plugging contactor to open.
Replace the auxiliary plugging card. Check
the auxiliary plugging contactor for a coil
with a short–circuit.

12.6 Adjust the potentiometer adjustment on the

auxiliary plugging card so that the auxiliary
plugging contactor closes just after the lift
truck comes to a stop.

20
 1

6240

AUXILIARY PLUGGING CARD

1. ELECTRICAL TERMINALS 1 THROUGH 7
2. ADJUSTMENT POTENTIOMETER
TERMINAL
NUMBER FUNCTION
1 . . . . . . . . Battery negative.
2 . . . . . . . . Senses the plugging signal from R10 of the control card (0.0 volts when not plugging
and increases to approximately 8.0 volts when plugging).
3 . . . . . . . . Battery negative. Connected to R4 on the control card.
4 . . . . . . . . Sends signal to R7 on the control card that plugging is completed.
5 . . . . . . . . Output voltage to energize the auxiliary plugging contactor. (Approximately battery
voltage when contactor is closed. Less than 0.5 volts when the contactor is open during
plugging.)

6 . . . . . . . . Battery positive supply.

7 . . . . . . . . Senses voltage at the armature terminal A1 to indicate when plugging is complete.

FIGURE 3. TERMINAL FUNCTIONS FOR THE AUXILIARY PLUGGING CARD

CHECKS AND REPAIRS

GENERAL
This section gives you additional information for mak-
ing checks and repairs for faults found in the
Troubleshooting section. Each series of lift trucks has
its own arrangement of control switches and accelera-
tor. To repair and adjust the control switches for lift
trucks using the EV–1 motor controller, see the section
ELECTRICAL SYSTEM, 2200 SRM 464 for the
SitDriver units or the ELECTRICAL REPAIRS
AND ADJUSTMENTS SRM section for the other se-
ries of electric lift trucks.
WARNING
Some adjustments in this section must be done with
the battery connected and power applied to the con-
troller. When making these adjustments, make sure
the drive wheels are raised from the floor. Do not dis-
able the SRO circuit.
WARNING
Make sure you disconnect the battery and separate
the connector before you disassemble any part of the
controller. Make sure you also discharge the capaci-
tors C1.
CHECKING FOR THE CORRECT
OPERATION
A service person must understand the operation of the
lift truck with an EV–1 controller. If you understand
and have operated a lift truck with normal operation,
you will better understand a bad operation. Listen and

21
feel for a normal or bad operation as you operate the lift
truck on a level surface.
1. Check the specific gravity of the battery. If the spe-
cific gravity is less than 1.260, the battery is not fully
charged or has a defect.
2. Connect the battery connector. The horn can now be
operated.
3. You must be on the operator’s seat to close the seat
switch (or the operator’s platform to close the foot
switch). Move the MONOTROL or accelerator to the
operating range before you turn the key switch to the
ON position. Turn the key switch to the ON position.
The SRO circuit will keep the logic from energizing the
traction circuit. (A SitDrivesr with a FORWARD and
REVERSE lever on a column mount can be checked
the same as a lift truck with MONOTROL control.
Move the lever to a FORWARD or REVERSE posi-
tion before moving the accelerator to the operating
range). Release the accelerator to reset the SRO circuit.
Changing the controls from REVERSE to FOR-
WARD or FORWARD to REVERSE will also reset
the SRO circuit. The lift system can be operated when
the key switch is ON. The lift truck is ready to move.
CONTROL AND POWER FUSES
The power fuse panel is found under the floor plate or
behind an access panel on the left side of SitDrive
trucks. The power fuse panel is found in the motor
compartment of other electric lift trucks. The control
fuse is separate from the power fuse panel on all the lift
trucks. The control fuse is under the floor plates of the
SitDriver trucks. The fuses can be checked electrically
with an ohmmeter.
CONTROL CARD
The control card has an “Static Return to OFF” (SRO)
circuit. The key switch and seat (or “brake switch” on
the “N” and “R” trucks) switch must be closed before
the accelerator is moved to operate the lift truck. A
service person must understand the SRO sequence
when troubleshooting. The SRO is a safety circuit. The
switches for the SRO circuit are described in the sec-
tion ELECTRICAL REPAIRS AND ADJUST-
MENTS. A section is printed for each series of electric
lift trucks.
2

4. Slowly move the accelerator a small amount for the

REVERSE direction. Listen for the reverse contactor
to close. Listen for a very low volume hum from the 1
controller. The lowest power that can be applied to the
traction circuit when the direction contactor is closed is
the CREEP speed. The CREEP speed can be adjusted
so that the lift truck will or will not begin to move at the
low power setting where the controller just begins to
operate.
9500

5. Move the accelerator a small amount so that the lift

truck will begin to move very slowly.

6. Increased movement of the accelerator causes the lift

truck to move faster. The SCR hum becomes louder OSCILLATOR ASM.
IC36450SC IH3
with a higher frequency sound. DS
24 48 VOLTS DC 259A8100P1

7. Check the plugging. During full speed in the reverse

1. LEFT TERMINAL STRIP
direction, move the control to the FORWARD full 2. RIGHT TERMINAL STRIP
speed position. A correctly adjusted lift truck will stop
smoothly and will then move in a forward direction. It FIGURE 4. THE CONTROL CARD
will accelerate smoothly to full speed.

22
STEP 1. Disconnect the Battery.

9530

STEP 2. Remove the (L) and (R) terminal strips.

Loosen the two mounting screws for each STEP 3. Use a screwdriver to remove each terminal
terminal strip only enough to release the ter- strip from the control card. Leave the wires
minal strip. If the screws are removed, the connected to the terminal strip.
O–ring retainers can be lost.

STEP 4. Open the two latches. Push on the edge of the

control card with your fingers. Rotate the
STEP 5. Disconnect the control card plug from the
control card towards you while lifting the
control card.
control card from its pivots.

23
The control card has a pulse monitor trip (PMT) circuit
that checks for a short–circuit of SCR 1. If short–circuit
occurs in a circuit connected to SCR 1, the logic in the
control card will stop the lift truck.
CAUTION
Some voltage measurements must be made with the
SRO circuit complete. If you are working alone, put
a weight in the seat to close the seat (or foot) switch.
You can operate the controls with your hand and also
make the voltage measurement. Make sure the drive
wheels are raised from the surface before doing
troubleshooting.
CAUTION
Do not try to put jumpers on the terminals in the con-
troller. The terminals are close together and it is easy
to make a very high cost error.
Removal
The control card is a plastic case holding a printed cir-
cuit board with electronic parts. A 14 pin connector
connects the logic control card to the traction circuit.
The control card has a left (L) and right (R) terminal
strip. A reference number such as R5 in this section in-
dicates terminal number 5 on the right (R) terminal
strip.
There are two different control cards used in the elec-
tric lift trucks made by Hyster Company. Both control
cards look the same. A label on the edge of the cases
shows if the control card is a 1H3 or a 1E3. The 1E3
card has the Field Weakening function. In an emer-
gency, a 1E3 card will work as a replacement for the
1H3 card. The Field Weakening function will not be
energized. DO NOT use a 1H3 card as a replacement
for a 1E3 card.
A bad control card cannot be repaired by service per-
sonnel and must be replaced. See FIGURE 4.
Installation
To install a control card as follows:
1. Carefully install the control card plug.
2. Install the control card in the mounts and close the
latches.
24
3. Install the terminal strips.
SCRs
In this section on Checks And Repairs, there are in-
structions to check the SCRs. This part of the section
describes the methods to check the SCRs.
An SCR “QUICK CHECK”
Turn the key switch to the OFF position and discon-
nect the battery. Discharge the capacitor C1. Set the se-
lector switch on your ohmmeter to the R x 100 scale.
Do not disconnect any wires. Make a resistance check
between the anode and the cathode of the SCR. Re-
place any SCR that indicates a short–circuit.
The normal failure of an SCR is a short–circuit. This
“quick check” will indicate a short–circuit in an SCR.
This “quick check” can help you quickly find if the
fault is in the traction circuit or one of the control cir-
cuits of an electric lift truck. This same check can be
used to find a short–circuit in D3 or D4. This check will
not always indicate a fault in D3 or D4. A diode failure
in the traction circuit will first have a short–circuit. The
increased current flow can cause the diode to open. To
check an SCR or diode for an open circuit, complete
the following procedures.
Checking An SCR
NOTE: The following checks will indicate most SCRs
with defects. The checks will not always indicate a fault
that does not occur regularly during operation. Nor-
mally, an SCR with this type of fault will indicate a resis-
tance between the anode and cathode of less than 50 000
ohms.
WARNING
Make sure you disconnect the battery and separate
the connector before you disassemble any part of the
controller. Make sure you also discharge capacitor
C1.
You will need a Cir/Kitr or an ohmmeter to check the
SCRs. Disconnect the control card plug for access to
the ends of the wires. See FIGURE 6. The SCRs can
stay attached to the heat sink to make checks.
 SEE FIGURE 7. FOR
PIN FUNCTIONS
5496
1. CATHODE
2. THERMAL SENSOR
3. ANODE
4. GATE
5. CATHODE SENSOR WIRE

FIGURE 6. CHECKING THE SCR

2. Measure the resistance between the gate wire and the

PIN FUNCTION
NO. cathode. Change the probe connections to the reverse
direction and measure the resistance again. Replace
1 Not connected. Used for EV–1 Analyzer the SCR if the resistance indicates zero or infinity on
2 Signal to SCR 5 gate
3 Senses SCR 5 cathode voltage the R x 1 scale in either direction.
4 Sends gate signal to SCR 1
5 Senses SCR 1 cathode voltage NOTE: Six volts is needed as a gate signal to check the
6 Battery negative to control card SCRs. Use an ohmmeter and a six volt supply for a gate
7 Senses capactitor C1 voltage as output signal or use a Cir/Kitr meter to check the SCRs. The
to control card
8 Sends gate signal to SCR 2 Cir/Kitr has a six volt supply.
9 Senses SCR 2 cathode voltage
10 Senses traction motor voltage

11 Thermal sensor wire 3. Measure the resistance between the cathode (1) and
12 Thermal sensor wire the cathode sensing lead (5). The resistance must be
13 Motor current sensor wire (current limit) less than 5 ohms (R x 1 scale) or the SCR is bad.
14 Motor current sensor wire (current limit)

FIGURE 7. PIN ARRANGEMENT AND
FUNCTION FOR THE CONTROL CARD PLUG
1. Touch the probes of the Cir/Kitr or ohmmeter to the
heat sink and the cathode wire. Measure the resistance.
Change the probe connections to the reverse direction
and measure the resistance. Replace the SCR if the re-
sistance indicates less than 50 000 ohms in either direc-
tion.
4. Momentarily connect six volts from the Cir/Kitr [or
a battery between the gate (+) and the cathode (–)]. The
resistance indication on the Cir/Kitr or the ohmmeter
will decrease to less than 10 ohms on the R x 1 Scale.
Replace the SCR if the resistance does not decrease
when a six volt gate signal is applied momentarily.
Make sure you touch the gate wire momentarily with
the six volt connection or you will damage the SCR.
Make sure the polarity of your test circuit is correct.

25
5. When the checks are complete, connect the wires un-
less the SCR must be replaced.
The SCR 1 Assembly
The SCR 1 assembly cannot be disassembled. The SCR
1 assembly includes an SCR 1 fastened between two
metal blocks used as heat sinks. An epoxy case holds
the complete assembly. There is a thin sheet of electri-
cal insulation between the SCR 1 assembly and the
base plate. The insulator permits heat to transfer from
the heat sinks to the base plate.
6
1 D Part No. 304408 is a silicon bearing grease and is
2 used between the SCRs, diodes, and their heat
5
To remove the SCR 1 from the circuit for making the
checks, do the following: Disconnect the control card
plug from the control card. Disconnect the power strap
from the anode. Disconnect the wire for the gate signal.
Be careful that you do not let the wire connection screw
fall into the controller.
NOTE: Silicon compound is used between the heat
sinks and the parts of the controller. The purpose of this
compound is to fill in the micrometer size spaces be-
tween the parts to give better heat flow. Always use a
very thin layer of compound between the parts. Too
much compound will be an insulator and cause both
electrical and heat faults. It is better to use no compound
instead of too much. There are two types of compounds:
sinks.

D Part No. 1198757 is a silicon compound and is

only used between heat sinks and the base plate.
This silicon compound must be used only as a
3 very thin layer. DO NOT USE this silicon com-
pound on SCRs and diodes.

5907 Replacing The SCR 1 Assembly

4 1. Disconnect the electrical connections to the SCR 1
assembly.
1. CATHODE SENSOR 4. GATE TERMINAL
CONNECTION 5. ANODE HEAT
2. Remove the two mounting screws.
2. MOUNT HOLE FOR SINK
THERMAL SENSOR 6. THERMAL
3. CATHODE HEAT SENSOR
3. Check the insulator between the SCR 1 assembly
SINK and the base plate. Replace the insulator if it has dam-
age. The insulator is also a heat conductor. Use a very
FIGURE 8. SCR 1 ASSEMBLY
thin coat of silicon grease (Part No. 1198757 or ap-
proved equivalent) between the surfaces of the parts.
Thermal Sensor Keep dirt from the surfaces.

The thermal sensor is a resistor that changes resistance CAUTION

as the temperature increases. The thermal sensor is in a
stud mount on the cathode heat sink for SCR 1. When
the temperature increases above 85°C (185°F), the
thermal sensor changes the input to the logic card. The
card decreases the percent of SCR 1 ON time to de-
crease the SCR 1 temperature.
Checking SCR 1
The insulator is very thin. Dirt between the surfaces
of the SCR 1 and the base plate will damage the insu-
lator and cause a short–circuit.
4. Install the new SCR 1 assembly. Make sure the heat
sinks make full contact with the insulator and base
plate. Check the resistance between both heat sinks and
the base plate with an ohmmeter. A correct installation
will indicate infinity.

See the section SCRs for doing the checks on SCR 1. 5. Install the electrical connections.

26
THE INDUCTOR AND CAPACITOR • Suppressors for SCR 2 and SCR 5
ASSEMBLY
(THE “OFF” CIRCUIT FOR SCR 1) • Capacitor C1

The transformer and inductor assembly is a plastic case

WARNING
Make sure you disconnect the battery and separate
the connector before you disassemble any part of the
controller. Make sure you also discharge capacitor
C1.
that fastens to the base plate. This assembly is also the
mount for the other parts.
The normal repair of the transformer and inductor as-
sembly is to replace it. There are four screws that hold
the inductor assembly to the base plate.

Checking The Transformer and Inductor

Assembly
A fault in the transformer assembly does not often oc-
cur. Most faults that do occur at the transformer assem-
bly are caused by loose internal connections. A trans-
former assembly will not normally indicate a fault ex-
cept during the stress in an operating circuit. A check
with an ohmmeter between T1 and T2 or between T3
6026
and T4 will indicate an open circuit. A good trans-
former winding will indicate approximately zero ohms.

NOTE: The 72–80 volt lift trucks do not use a trans-

former winding between T1 and T2 because the induc-
tance from the power cables is great enough to charge
capacitor C1. There is a cable connection at T1, but T2
1. T1 (TO SCR 1 CATHODE)
is removed on the 72–80 volt lift trucks.
2. T2
3. T4 Checking the Suppressors for the SCR 2
4. INDUCTOR RESISTOR and SCR 5
5. SCR 5 FILTER
6. SCR 5 The suppressors are a resistor and capacitor in series in-
7. CATHODE WIRES side a plastic case. The suppressors prevent damage to
8. SCR 2
9. 1X the SCRs from electrical noise. To check the SCR sup-
10. SCR 2 FILTER pressors, remove the suppressors from the transformer
11. T3 and inductor assembly. Touch the probes of an ohmme-
12. TRANSFORMER AND INDUCTOR ASSEMBLY
ter to the terminals. The indicator will begin to move
FIGURE 9. PULSE TRANSFORMER AND toward the low resistance direction and then return to
INDUCTOR ASSEMBLY infinity. A bad suppressor can cause a fault that does
not occur regularly during lift truck operation. A bad
suppressor can also cause a fault similar to a bad SCR 2
There is an inductor and a capacitor assembly for the
or bad SCR 5.
traction circuit. This assembly generates the reverse
polarity voltage to change the SCR 1 to OFF for each NOTE: Checking these suppressors for a short–circuit
pulse. This assembly has the following parts: can be difficult. Sometimes these suppressors will not
indicate a defect except during the stress in an operating
• Transformer and inductor assembly circuit.
• SCR 2 and heat sink
The inductor resistor has a resistance of 4.75 to 5.25
• SCR 5 and heat sink ohms when checked with an ohmmeter.

27
Checking the SCR 2 and SCR 5 charge C1 and disconnect the terminals. Measure the
resistance between the terminals. The ohmmeter will
The heat sink and mount for the SCR 2 and SCR 5 are
indicate a low resistance and increase to more than 100
part of the pulse transformer and inductor assembly.
000 ohms. A capacitor with a short–circuit must be re-
The heat sink is also the anode connection for the SCR.
placed.
There are three wires connected to the SCR. A large
black wire is the cathode wire. The white wire is the
supply for the gate signal. The red wire is a sensor con-
nection for the control card. The red wire is connected
to the cathode wire at the junction of the SCR. 4

Replacing the SCR 2 and SCR 5

3
CAUTION
Do not use a hammer and punch to loosen or tighten
the SCRs.
NOTE: Make an identification of the wires before you 2
disconnect them. The wires must be connected again in
the correct positions.
NOTE: Silicon compound is used between the heat 1
sinks and the parts of the controller. The purpose of this 1. CAPACITOR
compound is to fill in the micrometer size spaces be- 2. NUTS
9532
tween the parts to give better heat flow. Always use a 3. MOUNTING BRACKET
4. CAPSCREWS
very thin layer of compound between the parts. Too
much compound will be an insulator and cause both FIGURE 10. CAPACITOR C1
electrical and heat faults. It is better to use no compound
instead of too much. There are two types of compounds:
D3 And D4 Heat Sink Assembly
• Part No. 304408 is a silicon bearing grease and is
used between the SCRs, diodes, and their heat The heat sink assembly for the diodes D3 and D4 is
sinks. also the connection for the power cables. A suppressor
for D3 and the motor current sensor is connected to this
• Part No. 1198757 is a silicon compound and is
assembly. The heat sink assembly is connected to the
only used between heat sinks and the base plate.
base plate. A thin insulator with a silicone surface sepa-
This silicon compound must be used only as a
rates the heat sink assembly from the base plate.
very thin layer. DO NOT USE this silicon com-
pound on SCRs and diodes.
Checking The Diodes D3 and D4
Disconnect the wires to the SCR. Use a deep socket to
remove the SCRs. Put the wires through the top of the You will need a Cir/Kitr or an ohmmeter to check the
socket and use a handle or wrench to turn the socket. rectifiers. Disconnect the cathode wires from the con-
Use a thin layer of silicon grease (Part No. 304408 or nectors. The diodes can stay attached to the heat sinks
approved equivalent) between the surfaces of the heat to make checks.
sink and the replacement SCR. Tighten the SCR to a
Touch the probes of the Cir/Kitr or ohmmeter to the
torque of 3.4 N.m (30 lbf ft).
heat sink and the cathode wire. Measure the resistance.
Checking The Capacitor C1 Change the probe connections to the reverse direction
and measure the resistance. A good diode will indicate
The capacitor C1 is connected to the transformer and 7 to 14 ohms on the R x 1 Scale in one direction and
inductor assembly. To check C1 for a short–circuit, dis- greater than 50 000 ohms in the other direction.

28
 tance. This small resistance between the two sensor
wires sends a voltage signal to the control card. The
voltage signal increases as the motor current increases.
The control card compares the voltage with the “C/L”
5
current limit adjustment. The control card controls the
current flow so that the traction circuit is not damaged.
4

2
9533
3
7081
1
1. D3
2. D4 2
3. HEAT SINK
1
4. MOTOR CURRENT SENSOR
5. D3 SUPPRESSOR

FIGURE 11. THE D3 AND D4 HEAT SINK 1. SENSOR WIRES

ASSEMBLY 2. POWER STRAP

FIGURE 12. MOTOR CURRENT SENSOR

Replacing The Diodes D3 and D4

CAUTION
Do not use a hammer and punch to loosen or tighten
the diodes.
Disconnect the wire to the rectifier. Use a deep socket
to remove the diodes. Put the wire through the top of
the socket and use a handle or wrench to turn the
socket. Use a thin layer of silicone grease (Part No.
304408) between the surfaces of the heat sink and re-
placement diode. Tighten the diode to a torque of 3.4
N.m (30 inch pounds).
NOTE: The D3 has a suppressor connected in parallel
to the diode. The suppressor is a capacitor and resistor in
series. This suppressor can be checked like the suppres-
sors described on page 27.
MOTOR CURRENT SENSOR
The motor current sensor is a shunt with two sensor
wires connected. All of the traction motor current
flows through this power strap. The metal between the
connection points of the sensor wires has a small resis-
THE ELECTRONIC DRIVER MODULE
The electronic drivers are solid–state switches. The
small voltage from the control card controls the opera-
tion of the electronic drivers. The electronic driver con-
trols the operation of the contactors.
The electronic drivers are in a stack and connected to
the base plate of the controller. The following list is the
normal arrangement for the stack:
• the PMT electronic driver is on the bottom next to
the base plate.
• the electronic driver for field weakening (if used)
will be in the middle.
• the electronic driver for 1A (if used) will be on
top of the stack.
NOTE: The access to the electronic drivers on the bot-
tom of the stack is difficult. Remove the two mounting
screws and separate the drivers as necessary for access
to the terminals. Make sure you disconnect the battery
when you separate or connect the electronic drivers. Do
not cause a short–circuit.

29

5913
9496
FIGURE 13. ELECTRONIC DRIVER MODULE
The electronic driver modules are most easily checked
in the lift truck. Raise the drive wheels from the floor.
Connect the battery. Set the controls of the lift truck so
that the electronic driver you are checking will operate.
Check that there is an input signal on terminal 1 of 1.0
to 2.0 volts.
If there is 1.0 to 2.0 volts at terminal 1 of the electronic
driver, check for approximately battery voltage be-
tween battery negative and terminal 3 or terminal 4. If
there is approximately battery voltage, the electronic
driver has a defect. A good electronic driver will indi-
cate a small voltage across the transistors during opera-
tion.
30
CONTACTORS
Contactors are electromagnetic switches that close and
open a power circuit. The largest contactor is normally
used to control the hydraulic pump motor. Electric
switches control the current to the coils for the contac-
tors for the hydraulic pump motor and the power steer-
ing motor. A small electric current from the electronic
drivers energizes the coils for the contactors that con-
trol travel and direction. The electromagnetic field in
the coil moves the armature against spring pressure to
close the contact. When the coil is deenergized, the
spring pressure moves the armature and opens the con-
tacts. When a spring holds the contacts of a switch
open, the switch is said to be normally open (NO). If a
spring holds the contacts of a switch closed, the switch
is said to be normally closed (NC).
The direction contactors (FORWARD and RE-
VERSE) each have two sets of NC and NO contacts.
When a coil for a direction contactor is energized, the
NO contacts close and the NC contacts open. This de-
sign prevents the contacts from being closed in the
wrong sequence.
Lift trucks equipped with 1A and field weakening
(FW) circuits have contactors with NO contacts. Lift
trucks that have an auxiliary plugging resistor have an
auxiliary plugging contactor with NO contacts. The hy-
draulic pump contactor also has NO contacts. Lift
trucks equipped with power steering have a contactor
in a closed case. A power steering contactor is replaced
if it is bad.
“FORWARD” And “REVERSE”
Contactors
The FORWARD and REVERSE contactor assem-
blies control the direction of current flow through each
traction motor. The traction circuit has a FORWARD
and REVERSE contactor assembly. Each contactor as-
sembly has the following parts: two sets of normally
open (NO) contacts, two sets of normally closed (NC)
contacts, and a coil. The coil is an electromagnet that
moves the NO contacts to the closed position against
spring pressure. The coil is in the control circuit. The
contactor tips are in the traction circuit. A suppressor is
part of each coil.
When a contactor coil is energized, the normally open
(NO) contacts close and the normally closed (NC) con-
tacts open. This action gives a direction control to the
traction motor. The contacts normally have a long serv-
ice life because the current flow through the contacts is
stopped before the contacts open. The SCR 1 is OFF flow is PMT.
before the contactor coil is deenergized. The only con-
dition where the contacts open during a large current

1. BASE PLATE 12 CORE ASSEMBLY 17. SPRING CUP(2)

2. COIL 13. LOWER CONTACT SUPPORT 18. MOVING CONTACT SPRING
3. SUPPORT FRAME 14. MOVING CONTACT CARRIER (2) 19. MOVING CONTACT (NC)
4. ARMATURE ASSEMBLY 15. CONTACT SHIM
5. FIXED CONTACTS (NO) 16. MOVING CONTACT (NO)
6. CENTER CONTACT CLAMP (2)
7. FIXED CONTACTS (NC)
8. UPPER CONTACT CLAMP
9. WASHER (4)
10. THROUGH BOLT (4)
11. SPRING

5497

NOTE: THE POWER CONNECTIONS

FOR THE FIXED CONTACTS CAN BE
DIFFERENT THAN SHOWN

FIGURE 14. FORWARD AND REVERSE CONTACTOR ASSEMBLY

CONTACTOR REPAIR
(See FIGURE 14. and FIGURE 15.)
The normal repair to the contactor assembly is the re-
placement of the contacts, coil and the complete assem-
bly.
Remove A Contactor Assembly
Make an identification and disconnect the wires and
cables from the contactor assembly. Remove the
mounting screws and remove the contactor assembly.
Contactor Contacts
CAUTION
ALWAYS replace all of the contacts of a contactor at
the same time. Replace the Pump contactor contacts
after 1000 hours of operation. Replace other contac-
tor contacts when any area of a contact has worn
70% or more or there is any transfer of contact mate-
rial.
The contactor contacts are made of special silver alloy.
The contacts will look black and rough from normal
operation. This condition does not cause problems with
the operation of the lift truck. Cleaning is not neces-
sary. DO NOT USE A FILE ON THE CONTACTS.
DO NOT LUBRICATE THE CONTACTS. When con-
tact(s) need to be replaced, replace all of the contacts in
a contactor at the same time. Replace the contacts
every 1000 hours of operation or when the thickness of
a contact is 30% less than that of a new contact. Re-
place contacts as described even if there is no transfer
of metal.
Coil
Check the coil with an ohmmeter. The typical resis-
tance for a coil is as follows:
All 24V 5 to 9 ohms
36–48V Coil for Direction
Contactor 23 to 29 ohms

31
 1. BASE PLATE 10 CORE ASSEMBLY
2. COIL 11. LOWER CONTACT CLAMP
3. SUPPORT FRAME 12. MOVING CONTACT CARRIER
4. ARMATURE ASSEMBLY 13. CONTACT SHIM
5. FIXED CONTACTS 14. MOVING CONTACT
6. UPPER CONTACT CLAMP 15. MOVING CONTACT SPRING
7. WASHER (4) 16. SPRING CUP
8. THROUGH BOLT (4)
9. SPRING

5498

NOTE: THE POWER CONNECTIONS

FOR THE FIXED CONTACTS CAN BE
DIFFERENT THAN SHOWN
FIGURE 15. PUMP, 1A OR FW CONTACTOR

36–48V Coils for 1A, FW and sor if the measurements are not as described. Make
Auxiliary Plugging 60 to 70 ohms sure the coil wires are connected again to the correct
terminals and install the suppressor on the coil.
36–48V Coil for Power Steering 150 ohms

72–80V Coils for Direction and 1A 72 to 88 ohms CHECK THE PMT CIRCUIT

72–80V Coils for Auxiliary
Plugging 125 to 150 ohms
A suppressor diode (and sometimes a resistor in series)
is part of the coil. The diode will cause the ohmmeter to
indicate a difference in resistance in one direction. Re-
verse the probes of the ohmmeter to the opposite termi-
nals and measure the resistance. Use the highest resis-
tance indication. Replace the coil if it has damage.
Make sure the coil wires are connected again to the cor-
rect terminals.
If the coil in the contactor has an external suppressor,
remove the suppressor and check the coil and the sup-
pressor separately with an ohmmeter. The suppressor
will have a high resistance in one direction and a low
resistance in the other direction. Replace the suppres-
The pulse monitor trip (PMT) circuit can be checked
for correct operation. Use the following procedure to
check the PMT circuit in the lift truck.
WARNING
Incorrect operation of the PMT circuit will allow the
SCR 1 to go fully “ON” without opening any
contactors. The traction motor will run at high speed
until the battery plug is disconnected.
1. Raise the drive wheels off the ground so that the lift
truck will not move. Release the park brake.
2. Disconnect the battery.
3. Disconnect the gate lead from SCR 5 (white/purple
wire). The gate lead has a push–on connector. Make
sure end of lead does not touch any other surface.

32
4. Connect the battery.
5. Sit in the seat and turn the key to ON. Actuate the
directional control (Monotrol pedal or column
mounted lever) to forward or reverse.
6. Listen for a the direction contactor to open. The trac-
tion system will not operate. The traction motor con-
troller will allow two power pulses before opening the
contactor.
7. As soon as the PMT circuit disables the traction con-
trol turn the key switch to OFF.
8. Disconnect the battery.
9. Connect the SCR 5 gate lead.
10. Connect the battery and check for normal operation
of the traction circuit.

TERMINAL
NUMBER FUNCTION

L1 . . . . . . . Not used.
L2 . . . . . . . Not used.
L3 . . . . . . . Battery positive to the control card. This voltage also resets the SRO check and the PMT
circuit.
L4 . . . . . . . Not used when lift truck has MONOTROL pedal. On lift trucks with a direction control
lever, this terminal is connected to L7. This connection is so that the SRO check does
not deenergize the controller when the direction switch is in the NEUTRAL position.
L5 . . . . . . . Input for the SRO check. A four volts or greater signal must be received at this terminal
before a voltage signal is applied at L9 or L10.
L6 . . . . . . . Not used.
L7 . . . . . . . Input for the SRO check. The controller is deenergized if battery voltage is removed from
this terminal for more than 0.75 seconds after voltage is applied at L9 or L10.
L8 . . . . . . . Not used.
L9 . . . . . . . Battery voltage from the direction switch for the FORWARD direction.
L10 . . . . . . Battery voltage from the direction switch for the REVERSE direction.

R1 . . . . . . Test point for 8.2 volt power supply.

R2 . . . . . . Not used.
R3 . . . . . . Supplies 1.0 to 2.0 volt control signal to PMT electronic driver. Less than 0.5 volts is a PMT
signal.
R4 . . . . . . Not used. Electrically the same as battery negative.
R5 . . . . . . The control card supplies 4.8 to 5.0 volts at R5. The accelerator potentiometer decreases
this voltage by decreasing the resistance between R5 and battery negative. This voltage
controls the ON time of the SCR 1 and controls the travel speed of the lift truck. When
the voltage has decreased to less than 0.5 volts, the control card permits the
contactor 1A to close.
R6 . . . . . . For lift trucks with a contactor 1A: Input signal to the control card from the accelerator
card to begin 1A TIME. The time begins when the voltage signal decreases from 8.0
volts to 0.5 volts.
R7 . . . . . . Not used.
R8 . . . . . . 1.0 to 2.0 volt signal from the control card to the 1A electronic driver. The voltage signal
causes the contactor 1A to close.
R9 . . . . . . 1.0 to 2.0 volt signal from the control card to the Field Weakening electronic driver for
SitDrive trucks. The voltage signal causes the Field Weakening contactor to close. “R”
trucksr and “N” trucks use this signal for a “soft” start.
R10 . . . . . E60–120B and N30–50C lift trucks only: supplies approximately 8.0 volts to the Auxiliary
Plugging Card during plugging.

FIGURE 16. DESCRIPTION OF CONTROL CARD TERMINALS

33