Hyster EV-100 Motor Controller Maintenance And Repair

Description

• Model List:
  • EV-100 Motor Controller

• 1. RM0287-(01-1994)-US-EN
• 2. RM0288-(01-1994)-US-EN
• 3. RM0294-(03-2008)-US-EN
• 3.1. General
• 3.2. Brush and Commutator Inspection
• 3.3. Brush Replacement
• 3.4. Stoning the Commutator
• 3.5. Motors Repair
• 3.6. Brush Alignment, Traction and Hydraulic Motors
• 3.7. Tests for Damaged Field and Armature
• 3.8. Troubleshooting
• 4. RM0312-(03-1997)-US-EN
• 5. RM0326-(03-2007)-US-EN
• 5.1. General
• 5.2. Description
• 5.3. Steering Axle Assembly Repair
• 5.4. Wheels and Hubs Repair (All Units)
• 5.5. Spindles and Bearings Repair (All Units)
• 5.6. Tie Rods Repair (All Units)
• 5.7. Steering Cylinder Repair
• 5.8. Troubleshooting
• 6. RM0338-(05-2009)-US-EN
• 6.1. Brake System
• 6.2. Safety Precautions Maintenance and Repair
• 6.3. General
• 6.4. Description and Operation
• 6.5. Brake Booster and Master Cylinder
• 6.6. Master Cylinder
• 6.7. Service Brake Assembly
• 6.8. Parking Brake
• 6.9. Seat Brake
• 6.10. Brake Shoe Assemblies Repair
• 6.11. Remove and Disassemble
• 6.12. Clean and Inspect
• 6.13. Assemble and Install
• 6.14. Master Cylinder Repair
• 6.15. Master Cylinder For Lift Truck Models S3.50-5.50XL (S70-120XL) (
• 6.16. Disassemble
• 6.17. Assemble
• 6.18. Install
• 6.19. Master Cylinder For Lift Truck Models E3.50-5.50XL (E70-120XL, E
• 6.20. Remove and Disassemble
• 6.21. Clean and Inspect
• 6.22. Assemble and Install
• 6.23. Brake Booster Repair
• 6.24. Disassemble
• 6.25. Clean and Inspect
• 6.26. Assemble
• 6.27. Install
• 6.28. Brake System Air Removal
• 6.29. Brake Pedal Adjustment
• 6.30. Brake Pedal for Lift Truck Models H3.50-5.00XL (H70-110XL) (F005
• 6.31. Brake Shoes Adjustment
• 6.32. Parking Brake Adjustment
• 6.33. Parking Brake Adjustment, Lift Truck Models S3.50-5.50XL (S70-12
• 6.34. Parking Brake Lever and Switch Adjustment E3.50-5.50XL (E70-120X
• 6.35. Seat Brake Assembly
• 6.36. Clean and Inspect
• 6.37. Install
• 6.38. Adjustments
• 6.39. Solenoid Adjustment
• 6.40. Traction cutoff Switch Adjustment
• 6.41. Cable Adjustment
• 6.42. Brake Booster Relief Valve Check
• 6.43. Troubleshooting
• 7. RM0413-(11-2006)-US-EN
• 7.1. Drive Axle, Speed Reducer, and Differential
• 7.2. Safety Precautions Maintenance and Repair
• 7.3. General
• 7.4. Description
• 7.5. Drive Axle, Speed Reducer, and Differential Repair
• 7.6. General
• 7.7. Traction Motor, Speed Reducer, and Differential
• 7.8. Disassemble
• 7.9. Speed Reducer
• 7.10. Differential
• 7.11. Inspect
• 7.12. Assemble
• 7.13. Speed Reducer
• 7.14. Differential
• 7.15. Drive Axle Housing
• 7.16. Inspect
• 7.17. Assemble
• 7.18. Troubleshooting
• 7.19. Table 1. Pinion Assembly Shims Adjustment
• 7.20. Table 2. Ring and Pinion Tooth Contact Adjustment
• 8. RM0414-(01-1992)-US-EN
• 9. RM0460-(07-1999)-US-EN
• 10. RM0464-(01-1994)-US-EN
• 11. RM0485-(08-2003)-US-EN
• 11.1. Steering System for Electric Lift Trucks
• 11.2. Safety Precautions Maintenance and Repair
• 11.3. General
• 11.4. Description
• 11.5. Steering Wheel and Column Assembly Repair
• 11.6. Assembly Components, Remove
• 11.7. Assembly Components, Install
• 11.8. Power Steering Motor and Pump
• 11.9. Description
• 11.10. Remove and Disassemble, Models E1.25-3.00XL (E25-60XL), J2.00-3.
• 11.11. Remove and Disassemble, Models E3.50-5.50XL (E70-120XL, E70-120X
• 11.12. Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM
• 11.13. Remove and Disassemble, Models A1.00-1.50XL (A20-30XL)
• 11.14. Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40X
• 11.15. Assemble and Install – All models with a vertical mount except J
• 11.16. Assemble and Install, Models J2.00-3.20XM (J40-60XM, J40-60XM 2
• 11.17. Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM
• 11.18. Power Steering Pump, Repair
• 11.19. Seal, Replace
• 11.20. Hydraulic Steering Motor
• 11.21. Description
• 11.22. Hydraulic Steering Motor Repairs
• 11.23. Disassemble
• 11.24. Clean and Inspect
• 11.25. Assemble
• 11.26. Install
• 11.27. Steering System Air Removal
• 11.28. Steering Pressure Check
• 11.29. Steering Chain Tension Check (Unit With MDU Only)
• 11.30. Optical Encoder and Activator Circuits Check
• 11.31. Troubleshooting
• 12. RM0557-(08-2003)-US-EN
• 12.1. EV-100ZX SCR Motor Controller
• 12.2. Safety Precautions Maintenance and Repair
• 12.3. General
• 12.4. Model Number Data For EV-100ZX Controller
• 12.5. Register Parameters
• 12.6. General
• 12.7. Function Numbers
• 12.8. Control Card, Checks and Adjustments
• 12.9. Handset
• 12.10. How to Check and Adjust Registers
• 12.11. How to Scroll through Fault Codes and Clear Them
• 12.12. Checks and Adjustments on Workbench
• 12.13. When Handset Is Connected to Control Card Installed In Lift Truc
• 12.14. Function Numbers 1 through 15
• 12.15. Function Numbers 16 through 30
• 12.16. Function Numbers 48 through 62
• 12.17. Control Cards
• 12.18. Function Number Descriptions
• 12.19. Traction Control Cards (Label Letters – ZH and ZY)
• 12.20. Function Number 1 STORED STATUS CODE
• 12.21. Function Number 2 CREEP SPEED
• 12.22. Function Number 3 CONTROLLED ACCELERATION AND 1A TIME
• 12.23. Function Number 4 CURRENT LIMIT
• 12.24. Function Number 5 PLUGGING DISTANCE (CURRENT)
• 12.25. Function Number 6 1A DROP OUT CURRENT
• 12.26. Function Number 7 FIELD WEAKENING PICK UP
• 12.27. Function Number 8 FIELD WEAKENING DROP OUT
• 12.28. Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT
• 12.29. Function Number 10 REGENERATIVE BRAKING START
• 12.30. Function Number 13 SPEED LIMIT 3 (SL3)
• 12.31. Function Number 14 INTERNAL RESISTANCE COMPENSATION
• 12.32. Function Number 15 BATTERY VOLTS
• 12.33. Function Numbers GREATER THAN 15
• 12.34. Function Number 16 PEDAL POSITION PLUG
• 12.35. Function Number 17 CARD TYPE SELECTION
• 12.36. Function Number 18 STEERING PUMP TIME DELAY
• 12.37. Function Number 19 MAINTENANCE ALERT (Tens/Units)
• 12.38. Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)
• 12.39. Function Number 21 MAINTENANCE SPEED LIMIT
• 12.40. Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS
• 12.41. Function Number 29 HOURMETER (Tens/Units)
• 12.42. Function Number 30 HOURMETER (Thousands/Hundreds)
• 12.43. Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE
• 12.44. Function Number 48 CONTROLLED ACCELERATION AND 1A TIME
• 12.45. Function Number 49 FIELD WEAKENING PICK UP
• 12.46. Function Number 50 SPEED LIMIT 1
• 12.47. Function Number 52 CONTROLLED ACCELERATION AND 1A TIME
• 12.48. Function Number 53 FIELD WEAKENING PICK UP
• 12.49. Function Number 54 SPEED LIMIT 1
• 12.50. Function Number 56 CONTROLLED ACCELERATION AND 1A TIME
• 12.51. Function Number 57 FIELD WEAKENING PICK UP
• 12.52. Function Number 58 SPEED LIMIT 1
• 12.53. Function Number 60 CONTROLLED ACCELERATION AND 1A TIME
• 12.54. Function Number 61 FIELD WEAKENING PICK UP
• 12.55. Pump Control Card (Label Letter ZP)
• 12.56. Function Number 1 STORED STATUS CODE
• 12.57. Function Number 2 INTERNAL RESISTANCE COMPENSATION START
• 12.58. Function Number 3 CONTROLLED ACCELERATION
• 12.59. Function Number 4 CURRENT LIMIT
• 12.60. Function Number 7 CONTROLLED ACCELERATION COMPENSATION
• 12.61. Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) – Tilt and S
• 12.62. Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) – Slow Lif
• 12.63. Function Number 13 SPEED LIMIT 3 (SL3)
• 12.64. Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift
• 12.65. Function Numbers Greater Than 15
• 12.66. Function Number 16 INTERNAL RESISTANCE COMPENSATION
• 12.67. Function Number 17 CARD TYPE SELECTION
• 12.68. Function Numbers 18 through 28 TEMPORARY DATA REGISTERS
• 12.69. Function Number 29 HOURMETER (Tens/Units)
• 12.70. Function Number 30 HOURMETER (Thousands/Hundreds)
• 12.71. Function Number 48 CONTROLLED ACCELERATION
• 12.72. Function Number 49 SPEED LIMIT 2
• 12.73. Function Number 50 SPEED LIMIT 3
• 12.74. Function Number 52 CONTROLLED ACCELERATION
• 12.75. Function Number 53 SPEED LIMIT 2
• 12.76. Function Number 54 SPEED LIMIT 3
• 12.77. Function Number 56 CONTROLLED ACCELERATION
• 12.78. Function Number 57 SPEED LIMIT 2
• 12.79. Function Number 58 SPEED LIMIT 3
• 12.80. Function Number 60 CONTROLLED ACCELERATION
• 12.81. Function Number 61 SPEED LIMIT 2
• 12.82. Function Number 62 SPEED LIMIT 3
• 12.83. Register Parameters
• 12.84. Troubleshooting
• 12.85. General
• 12.86. Status Codes
• 12.87. Register Maps
• 12.88. Status Code Charts
• 12.89. EV-100ZX SCR Motor Controller Repair
• 12.90. SCR, Check
• 12.91. SCR Assembly
• 12.92. Thermal Protector
• 12.93. SCR 1 Assembly, Replace
• 12.94. OFF Circuit for SCR 1
• 12.95. Reactor Assembly, Check
• 12.96. Suppressors for SCR 2 and SCR 5, Check
• 12.97. SCR 2 and SCR 5, Check
• 12.98. SCR 2 and SCR 5, Replace
• 12.99. Capacitor C1, Check
• 12.100. Diodes D3 and D4
• 12.101. Diodes D3 and D4, Check
• 12.102. Diodes D3 and D4, Replace
• 12.103. Motor Current Sensor
• 12.104. Contactors
• 12.105. Contactor, Repair
• 12.106. Control Card
• 12.107. Control Card Plugs
• 12.108. Brush Wear Indicators
• 12.109. Theory of Operation
• 12.110. Electronic Speed Controls
• 12.111. Silicon Controlled Rectifier (SCR)
• 12.112. Motor Circuit That Operates With Pulses
• 12.113. Traction Circuit
• 12.114. Hydraulic Pump Motor
• 12.115. SCR 1 OFF Circuit
• 12.116. Induction Current from Motor
• 12.117. Control Cards
• 12.118. Pulse Monitor Trip (PMT) (Traction Circuit Only)
• 12.119. SRO Circuit (Traction Circuit Only)
• 12.120. Sequence of Operation
• 12.121. Control Card Adjustments (Traction Circuit)
• 12.122. Accelerator Control
• 12.123. SCR Control (Hydraulic Pump Motor)
• 12.124. Contactors
• 12.125. Circuit Protection
• 12.126. Traction Circuit Fuse
• 12.127. Current Limit
• 12.128. Thermal Protection
• 12.129. Suppressors
• 12.130. Truck Management Module (TMM1)
• 12.131. Display Panels
• 12.132. Display Panel
• 12.133. Basic Display
• 12.134. Performance Display
• 12.135. Brush Wear Indicators
• 12.136. Table 1. Terminal and Plug Wire Connections for Control Card ZY,
• 12.137. Table 2. Terminal and Plug Wire Connections for Control Card ZH,
• 12.138. Table 3. Terminal and Plug Wire Connections for Control Card ZH,
• 12.139. Table 4. Terminal and Plug Wire Connections for Controller with
• 12.140. Table 5. Status Codes List
• 12.141. Table 6. Register Map for Control Cards ZH and ZY (Traction)
• 12.142. Table 7. Register Map for Control Card ZP (Hydraulic Pump)
• 12.143. Table 8. Terminal and Plug Wire Connections for TMM1 Module
• 13. RM0560-(07-2005)-US-EN
• 13.1. Electrical System
• 13.2. Safety Precautions Maintenance and Repair
• 13.3. General
• 13.4. Description
• 13.5. ZX Series Display Panels
• 13.6. Display Panel
• 13.7. Basic Display Panels
• 13.8. Performance Display
• 13.9. Brush Wear Indicators
• 13.10. SEM Display Panels – Features
• 13.11. Descriptions of Common Features
• 13.12. Additional Features of Premium Display Panel
• 13.13. Descriptions of Additional Features
• 13.14. SEM Display Panel Indicators
• 13.15. All Indicator Symbols
• 13.16. Hourmeter Indicator Symbol
• 13.17. Wrench Symbol
• 13.18. Battery Symbol
• 13.19. Battery Discharge Indicator (BDI)
• 13.20. Brake Fluid Too Low Symbol
• 13.21. Parking Brake Symbol
• 13.22. Fasten Seat Belt Symbol
• 13.23. LCD Screen (Standard Display Panel)
• 13.24. Additional Components of Premium Display Panel
• 13.25. Alpha Numerical Screen
• 13.26. STAR Push Button
• 13.27. Push Buttons 1 Through 5 – SEM
• 13.28. Other Control Components
• 13.29. Display Panel Components Replacement
• 13.30. ZX Panel Replacement
• 13.31. Display Panel Assembly
• 13.32. Key Switch, Replace
• 13.33. Indicator LEDs
• 13.34. Battery Indicators
• 13.35. Digital Display (Performance Display Panel Only)
• 13.36. Status Code or Performance Level Switches and Indicator LEDs (Pe
• 13.37. Basic Display Panel, Replace Parts
• 13.38. Performance Display Panel, Replace Parts
• 13.39. SEM Display Panel Replacement
• 13.40. Motor Controller (SR or SP) Replacement
• 13.41. Install
• 13.42. Control Components Replacement
• 13.43. Start Switch, Replace
• 13.44. Brake Light Switch, Replace
• 13.45. Seat Switch, Replace
• 13.46. External Seat Switch, Adjust
• 13.47. Switch for Optional Seat Brake, Replace
• 13.48. Parking Brake Switch, Replace
• 13.49. Direction Switches (MONOTROL Pedal), Replace
• 13.50. Direction Control Switches (Steering Column), Replace
• 13.51. Direction Control Switches, E70-120XL 3 (Steering Column)
• 13.52. Brake Fluid Switch, Replace
• 13.53. Brush Wear and Overtemperature Sensors
• 13.54. Rocker Switches for Lights
• 13.55. Accelerator Position Sensor, Replace
• 13.56. On-Demand Steering Components
• 13.57. Lights, Converter, Relay, and Reverse Alarm
• 13.58. Incandescent Brake, Tail, and Reverse Light Assembly, Replace
• 13.59. LED Brake, Tail, and Reverse Light Assembly, Replace