EV–T100 SCR MOTOR CONTROLLER,
Description, Adjustments, Troubleshooting, Repairs, And Theory
Four SERVICE MANUAL sections are required for
the complete Description, Checks, Adjustments, Re-
pairs, and Troubleshooting of this motor controller:
• EV–T100 TRANSISTOR MOTOR CON-
TROLLER, Description, Adjustments,
Troubleshooting, Repairs, and Theory, 2200
SRM 581
• TROUBLESHOOTING AND ADJUST-
MENTS WITH A COMPUTER For
EV–100ZX And EV–T100 Motor Controllers,
2200 SRM 597
• EV–T100 TRANSISTOR MOTOR CON-
TROLLER, Parameter Tables, 2200 SRM 596
• ELECTRICAL SYSTEM, Repairs, Checks
And Adjustments, 2200 SRM 560
This section describes the operation and the functions of
the EV–T100 motor controller. The EV–T100 series of
motor controllers, used to control the operation of elec-
tric lift trucks, are made by the General Electric Com-
pany.
The “EV–T100” identify the controllers that are a tran-
sistor electronic motor controller and have diagnostic
control cards. These control cards can use an adapter for
a serial cable that will connect to a serial port on a per-
sonal computer for checks, adjustments, and trouble-
shooting.
a. A Cable Kit, Control Card to Computer, is re-
quired (Hyster Part No. 1358471).
b. The HYTECH software for a personal com-
puter is available on a 3.5 inch diskette (Hyster
Part No. 897702).
c. The Cable Kit and the 3.5 inch diskette with the
HYTECH software are available from your
dealer for Hyster lift trucks.
These control cards have logic circuits and registers that
control and keep a record of the operations of the motor
controller. The registers also keep a record of possible
malfunctions of the motor controller that can indicate
the problems during troubleshooting.
This section has the following components:
a. A “Description” of the EV–T100 Motor Con-
troller.
b. A series of “Status Code Charts” that describe
an indication of a fault and its possible causes
when the code is shown on the instrument pan-
el display.
c. Checks and replacement of the components of
the motor controller are described in “Repairs”.
d. A basic “Theory Of Operation” on how a tran-
sistor motor controller operates.
An electronic diagnostic and adjustment device can also
be used to check and adjust the control cards. This elec-
tronic diagnostic and adjustment device is called a
“Hand Set” and is described later in this section. A com-
puter with the control software installed has access to all
function registers on the control cards. The Hand Set has
access to less function registers on the control card, but
it can access all of the functions necessary for operation
on the lift truck.
A description and the replacement of the instrument
panel display is also included in the repair section.
Most of the components of the EV–T100 motor control-
ler can not be repaired, but must be replaced. This sec-
tion describes the procedures for using the electronic
diagnostic and adjustment devices for checking and ad-
justing the operation of the motor controller.
There are electrical components that are not part of the
motor controller, but give input signals to it. These com-
ponents include the following:
a. Key switch
b. START switch (earlier production units only).
c. Brake switch
d. Foot switch
e. Seat switch
f. Direction (FORWARD and REVERSE)
switches
g. Accelerator potentiometer
h. Guidance and steering systems
1
EV–T100 Motor Controller
Checks and replacement of these electrical components
are described in ELECTRICAL SYSTEM, Repairs,
Checks And Adjustments, 2200 SRM 560.
Model Number Data For EV–T100 Controller
The model numbers for the EV–T100 controller indi-
cate the following information:
Example:
IC3645EVT100 JH
(01) (02)
(01) The first series of letters and numbers indicate the
basic catalog number of the controller.
(02) These letters indicate the control card options:
JH = Traction Controller, IGBT*, 600 Amp, 24 to
80 VDC, Automatic PLUGGING/Regenerative
Braking, with Battery Discharge Indicator
(BDI).
JY = Traction Controller, IGBT*, 600 Amp, 24 to
80 VDC, Automatic PLUGGING/Regenerative
Braking, without Battery Discharge Indicator
(BDI).
LP = Pump Controller, IGBT, 450 Amp, 24 to 80
VDC
HP = Pump Controller, MOSFET*, 600 Amp, 24
to 80 VDC
The normal configuration for 36 to 48 volt lift trucks
that have a transistor controller for both the traction
and hydraulic pump motors:
JH = MOSFET Traction Controller, 24 to 48
VDC, with Battery Discharge Indicator (BDI).
JY = MOSFET Traction Controller, 24 to 48
VDC, without Battery Discharge Indicator
(BDI).
*MOSFET = Metal Oxide Silicon Field Effect Transistor
*IGBT= Insulated Gate Bipolar Transistor
(See the THEORY OF OPERATION section for a descrip-
tion of these power transistors.)
2
HP = MOSFET Pump Controller, 24 to 48 VDC,
600 Amp
The normal configuration for 72 to 80 volt lift trucks
that have a transistor controller for both the traction
and hydraulic pump motors:
JH = IGBT Traction Controller, 24 to 80 VDC,
with Battery Discharge Indicator (BDI).
JY = IGBT Traction Controller, 24 to 80 VDC,
without Battery Discharge Indicator (BDI).
LP = IGBT Pump Controller, 24 to 80 VDC, 450
Amp
This series of motor controllers have an output to oper-
ate a digital display with four digits. A digital display
unit (instrument panel display) is available for the in-
strument panel of some lift trucks. An adapter for a seri-
al cable that will connect to a RS–232–C serial port on a
personal computer (PC) can be used for checks and ad-
justments. A Hand Set with a digital display is also
available. All of the control settings are set using a PC or
the Hand Set.
The control card is a printed circuit board with elec-
tronic parts in a plastic case. The position of the control
cards in the controllers can be seen in FIGURE 3. Two
machine screws at the bottom of the plastic case fasten
the control card to the mount plate.
The control card has two 6–pin plugs (PA and PB) that
connect the signal wires between the parts of the con-
troller and the control card. A terminal strip with six
screw connections are inputs from control components
of the lift truck. A 14–pin plug (PZ) connects the control
card to the functions for SCR 1, SCR 2, and SCR 5. See
FIGURE 4. Plug PY is a 14–pin plug that connects the
instrument panel display or a PC or the Hand Set to the
control card. Some pins of plug PY are also used to con-
nect the control card to the control card for the hydraulic
pump motor. The functions of the of the signal wires are
described in TABLE 1. through TABLE 7.
 EV–T100 Motor Controller

TRANSISTOR CONTROL FOR TRACTION MOTOR AND

CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR
11 10 9 8 7 6 5

13
12

3
14

15 2
1
17

7 6 5
11 10 9 8
TRANSISTOR CONTROL FOR BOTH TRACTION
MOTOR AND HYDRAULIC PUMP MOTOR
16

12

1
17

1. TRANSISTOR MOTOR CONTROLLER 10. 1A CONTACTOR (1A)

(ALSO SEE FIGURE 3.) 11. FUSE 2, HYDRAULIC PUMP CIRCUIT
2. FIELD WEAKENING CONTACTOR 12. STEERING PUMP CONTACTOR
3. FORWARD DIRECTION CONTACTOR (F) 13. HYDRAULIC PUMP CONTACTOR
4. REVERSE DIRECTION CONTACTOR (R) 14. ELECTRONIC DRIVER, HYDRAULIC
5. REGENERATIVE BRAKING CONTACTOR (RB) PUMP CONTACTOR
6. DIODE D7 ASSEMBLY, 15. TMM1 MODULE
REGENERATIVE BRAKING 16. TRANSISTOR CONTROLLER,
7. FUSE 4, REGENERATIVE BRAKING HYDRAULIC PUMP MOTOR
8. ****** CONTACTOR (ALSO SEE FIGURE 3.)
9. FUSE 1, TRACTION CIRCUIT 17. FUSE PANEL (FU 7, FU 3, FU 5, FU 6)
FIGURE 1. TYPICAL CONFIGURATIONS OF THE EV–T100 MOTOR CONTROLLER IN
J2.00–3.20XM (J45–65XM) LIFT TRUCKS

3
EV–T100 Motor Controller

TRANSISTOR CONTROL FOR BOTH TRACTION 1 10

MOTOR AND HYDRAULIC PUMP MOTOR 16

2
17

8
3 4 11 9 7

TRANSISTOR CONTROL FOR TRACTION MOTOR AND

CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR 1 10

14
6

5
13

2
17

8
3 4 11 9 7

10. CONTACTOR 1A
1. TRANSISTOR MOTOR CONTROLLER 11. FUSE 2, HYDRAULIC PUMP CIRCUIT
(ALSO SEE FIGURE 3.) 12. STEERING PUMP CONTACTOR
2. FIELD WEAKENING CONTACTOR (UNDER FUSE PANEL 17)
3. FORWARD DIRECTION CONTACTOR (F) 13. HYDRAULIC PUMP CONTACTOR
4. REVERSE DIRECTION CONTACTOR (R) 14. ELECTRONIC DRIVER, HYDRAULIC
5. REGENERATIVE BRAKING CONTACTOR (RB) PUMP CONTACTOR
6. DIODE D7 ASSEMBLY, 15. TMM1 MODULE
REGENERATIVE BRAKING 16. TRANSISTOR CONTROLLER,
7. FUSE 4, POWER STEERING CIRCUIT HYDRAULIC PUMP MOTOR
8. CONTACTOR L (ALSO SEE FIGURE 3.)
9. FUSE 1, TRACTION CIRCUIT 17. FUSE PANEL (FU 7, FU 3, FU 5, FU 6)
FIGURE 2. TYPICAL CONFIGURATIONS OF THE EV–T100 MOTOR CONTROLLER IN
E2.00–3.20XM (E45–65XM) LIFT TRUCKS

4
 EV–T100 Motor Controller

1. POWER
TRANSISTOR TR1
2. SUPPRESSOR
ASSEMBLY FOR TR1 1
3. CAPACITOR C1 6, 7
(C1a, C1b, C1c)
4. CONTROL CARD
5. SUPPRESSOR
ASSEMBLY FOR
DIODES D3 AND D4
6 & 7. LOCATION OF
DIODES D3 AND D4 2 5

3 3

3 CAP 1a CAP 1b CAP 1c

FIGURE 3. CONFIGURATION OF THE EV–T100 MOTOR CONTROLLER MODULE

1
7
2

3
6
3
3 3
5

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

FIGURE 4. CONTROL CARD CONNECTIONS

5
EV–T100 Motor Controller

TABLE 1. Terminal And Plug Wire Connections For Control Card JH

With: Transistor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, Premium Display or full GE
Display option, GE Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature indicators
NOTE: TABLE 1. and TABLE 2. are components of the same controller option.
Plug or Wire Color or
Terminal Wire Number Function
No.
PA1 37 To coil for Field Weakening contactor.
PA2 50 To BLU–L and then to PB3 on hydraulic pump control card.
PA3 — Not used.
PA4 — Not used.
PA5 — Not used.
PA6 — Not used.
PB1 12 Battery positive from Fuse 5.
PB2 24 To coil for Line contactor.
PB3 60 To contactor coil for Steering pump motor.
PB4 27 Forward contactor coil negative.
PB5 23 Reverse contactor coil negative.
PB6 41 1A contactor coil negative.
TB1 YEL/PNK Accelerator potentiometer input.
TB2 GRN Start switch input.
15 Voltage supply from Fuse 7.
TB3 PNK Seat switch input.
TB4 10 Battery supply voltage to TB4 on hydraulic pump control card.
10–1 Battery supply voltage.
RED/BLU–L Key switch input. Battery voltage supply from key switch.
RED/WHT Battery voltage supply to seat switch.
TB5 WHT–5 FORWARD direction switch input.
TB6 BLU–L REVERSE direction switch input.
PY1 — Not used
PY2 — Not used
PY3 — Not used
PY4 BLK–1 To instrument panel display number 9 (TGND) input (ground).
PY5 WHT–1 To instrument panel display number 1 (T5) input.
PY6 — Not used.
PY7 — Not used.
PY8 BRN/WHT Signal wire from PY12 on hydraulic pump control card.
PY9 BRN/PNK Signal wire from PY11 on hydraulic pump control card.
PY10 BRN/ORN Signal wire from PY10 on hydraulic pump control card.
PY11 YEL/GRN
PY12 — Not used.
PY13 WHT–2 To instrument panel display number 5 (PY13) input.
PY14 BLK–2 To instrument panel display number 4 (PY14) input.
PZ1 WHT/BRN Battery negative.
PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire for voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 32 to Voltage supply to accelerator potentiometer.
GRN/WHT
PZ7 17 Battery positive. (Voltage check across Regenerative Braking Diode D7.)
PZ8 31 Regenerative braking contactor negative.
PZ9 BLU Signal wire for voltage check across TR1.
PZ10 GRN to 22 Signal wire from current sensor for Regenerative Braking.
PZ11 YEL to 21 Signal wire from current sensor for Regenerative Braking.
PZ12 GRN Signal wire from motor current sensor.
PZ13 YEL Signal wire from motor current sensor.
PZ14 WHT Signal wire for battery voltage check.

6
 EV–T100 Motor Controller

TABLE 2. Terminal And Plug Wire Connections For Hydraulic Pump Control Card LP
With: Transistor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, Premium Display, GE Battery
Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature indicators
NOTE: TABLE 1. and TABLE 2. are components of the same controller option.
Plug or Wire Color or
Terminal Wire Number Function
No.
PA1 GRN/GRY Signal wire between pump control card and brush wear indicator,steering pump.
PA2 BLU–D/YEL Signal wire between pump control card and brush wear indicator,steering pump.
PA3 ORN/PNK Signal wire between pump control card and temperature switch, traction motor.
PA4 BLU–D/PNK Signal wire between pump control card and brush wear indicator, traction motor.
PA5 GRN/PUR Signal wire between pump control card and brush wear indicator, traction motor.
PA6 ORN/YEL Signal wire between pump control card and temperature switch, hydraulic pump motor.
PB1 BRN Supply voltage from Fuse 3
PB2 — Not Used.
PB3 BLU–L To 50 and then to PA2 on traction control card.
PB4 — Not Used.
PB5 — Not Used.
PB6 — Not Used.
TB1 — Not Used.
TB2 GRY To circuit board for control lever, hydraulic pump.
TB3 BLU–D/GRN To circuit board for control lever, hydraulic pump.
TB4 10 Battery supply voltage from TB4 on traction control card.
TB5 — Not Used.
TB6 BLU–D To circuit board for control lever, hydraulic pump.
PY1 — Not Used.
PY2 — Not Used.
PY3 — Not Used.
PY4 BLK–3 To instrument panel display number 10 (PGND) input (ground).
PY5 WHT–3 To instrument panel display number 2 (P5) input.
PY6 — Not Used.
PY7 — Not Used.
PY8 — Not Used.
PY9 — Not Used.
PY10 BRN/ORN Signal wire to PY10 on traction control card.
PY11 BRN/PNK Signal wire to PY9 on traction control card.
PY12 BRN/WHT Signal wire to PY8 on traction control card.
PY13 WHT–4 To instrument panel display number 7 (P13) input.
PY14 BLK–4 To instrument panel display number 6 (P14) input.
PZ1 WHT/BRN Battery negative.
PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire for voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 — Not Used.
PZ7 — Not Used.
PZ8 — Not Used.
PZ9 BLU Signal wire for voltage check across TR1.
PZ10 98 BLU–D/GRY Signal wire between pump control card and brush wear indicator, hydraulic pump motor.
PZ11 99 GRN/PNK Signal wire between pump control card and brush wear indicator, hydraulic pump motor.
PZ12 GRN Signal wire from motor current sensor.
PZ13 YEL Signal wire from motor current sensor.
PZ14 WHT Signal wire for battery voltage check.

7
EV–T100 Motor Controller

TABLE 3. Terminal And Plug Wire Connections For Control Card JH

With: Transistor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, full GE Display option, GE
Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature indicators
NOTE: TABLE 3. and TABLE 4. are components of the same controller option.
Plug or Wire Color or
Terminal Wire Number Function
No.
PA1 37 To coil for Field Weakening contactor.
PA2 50 To BLU–L and then to PB3 on hydraulic pump control card.
PA3 — Not used.
PA4 — Not used.
PA5 — Not used.
PA6 — Not used.
PB1 12 Battery positive from Fuse 5.
PB2 24 To coil for Line contactor.
PB3 60 To contactor coil for Steering pump motor.
PB4 27 Forward contactor coil negative.
PB5 23 Reverse contactor coil negative.
PB6 41 1A contactor coil negative.
TB1 YEL/PNK Accelerator potentiometer input.
TB2 GRN Start switch input.
15 Voltage supply from Fuse 7.
TB3 PNK Seat switch input.
TB4 10 Battery supply voltage to TB4 on hydraulic pump control card.
10–1 Battery supply voltage.
RED/BLU–L Key switch input. Battery voltage supply from key switch.
RED/WHT Battery voltage supply to seat switch.
TB5 WHT–5 FORWARD direction switch input.
TB6 BLU–L REVERSE direction switch input.
PY1 — Not used
PY2 — Not used
PY3 — Not used
PY4 BLK–1 To GE instrument panel display number 2 (PY4).
PY5 WHT–1 To GE instrument panel display number 5 (PY5).
PY6 — Not used.
PY7 — Not used.
PY8 BRN/WHT Signal wire from PY12 on hydraulic pump control card.
PY9 BRN/PNK Signal wire from PY11 on hydraulic pump control card.
PY10 BRN/ORN Signal wire from PY10 on hydraulic pump control card.
PY11 YEL/GRN
PY12 — Not used.
PY13 WHT–2 To GE instrument panel display number 1 (PY3).
PY14 BLK–2 To GE instrument panel display number 3 (PY2).
PZ1 WHT/BRN Battery negative.
PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire for voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 32 to Voltage supply to accelerator potentiometer.
GRN/WHT
PZ7 17 Battery positive. (Voltage check across Regenerative Braking Diode D7.)
PZ8 31 Regenerative braking contactor negative.
PZ9 BLU Signal wire for voltage check across TR1.
PZ10 GRN to 22 Signal wire from current sensor for Regenerative Braking.
PZ11 YEL to 21 Signal wire from current sensor for Regenerative Braking.
PZ12 GRN Signal wire from motor current sensor.
PZ13 YEL Signal wire from motor current sensor.
PZ14 WHT Signal wire for battery voltage check.

8
 EV–T100 Motor Controller

TABLE 4. Terminal And Plug Wire Connections For Hydraulic Pump Control Card LP
With: Transistor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, full GE Display option, GE
Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature indicators
NOTE: TABLE 3. and TABLE 4. are components of the same controller option.
Plug or Wire Color or
Terminal Wire Number Function
No.
PA1 GRN/GRY Signal wire between pump control card and brush wear indicator,steering pump.
PA2 BLU–D/YEL Signal wire between pump control card and brush wear indicator,steering pump.
PA3 ORN/PNK Signal wire between pump control card and temperature switch, traction motor.
PA4 BLU–D/PNK Signal wire between pump control card and brush wear indicator, traction motor.
PA5 GRN/PUR Signal wire between pump control card and brush wear indicator, traction motor.
PA6 ORN/YEL Signal wire between pump control card and temperature switch, hydraulic pump motor.
PB1 BRN Supply voltage from Fuse 3
PB2 — Not Used.
PB3 BLU–L To 50 and then to PA2 on traction control card.
PB4 — Not Used.
PB5 — Not Used.
PB6 — Not Used.
TB1 — Not Used.
TB2 GRY To circuit board for control lever, hydraulic pump.
TB3 BLU–D/GRN To circuit board for control lever, hydraulic pump.
TB4 10 Battery supply voltage from TB4 on traction control card.
TB5 — Not Used.
TB6 BLU–D To circuit board for control lever, hydraulic pump.
PY1 BLK–4 GE instrument panel display number 4 (PY1).
PY2 WHT–4 GE instrument panel display number 3 (PY2).
PY3 ORN GE instrument panel display number 1 (PY3).
PY4 BLK–3 GE instrument panel display number 2 (PY4) (ground).
PY5 — Not Used.
PY6 — Not Used.
PY7 — Not Used.
PY8 — Not Used.
PY9 — Not Used.
PY10 BRN/ORN Signal wire to PY10 on traction control card.
PY11 BRN/PNK Signal wire to PY9 on traction control card.
PY12 BRN/WHT Signal wire to PY8 on traction control card.
PY13 — Not Used.
PY14 — Not Used.
PZ1 WHT/BRN Battery negative.
PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire for voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 — Not Used.
PZ7 — Not Used.
PZ8 — Not Used.
PZ9 BLU Signal wire for voltage check across TR1.
PZ10 98 BLU–D/GRY Signal wire between pump control card and brush wear indicator, hydraulic pump motor.
PZ11 99 GRN/PNK Signal wire between pump control card and brush wear indicator, hydraulic pump motor.
PZ12 GRN Signal wire from motor current sensor.
PZ13 YEL Signal wire from motor current sensor.
PZ14 WHT Signal wire for battery voltage check.

9
EV–T100 Motor Controller

TABLE 5. Terminal And Plug Wire Connections For Control Card JH

With: Contactor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, Premium Display, GE Battery
Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature indicators, and TMM1 module (see TABLE 6.)
Plug or Wire Color or
Terminal Wire Number Function
No.
PA1 37 To coil for Field Weakening contactor.
PA2 50 To BLU–L and then to PB3 on hydraulic pump control card.
PA3 — Not used.
PA4 — Not used.
PA5 — Not used.
PA6 — Not used.
PB1 12 Battery positive from Fuse 5.
PB2 24 To coil for Line contactor.
PB3 60 To contactor coil for Steering pump motor.
PB4 27 Forward contactor coil negative.
PB5 23 Reverse contactor coil negative.
PB6 41 1A contactor coil negative.
TB1 YEL/PNK Accelerator potentiometer input.
TB2 GRN Start switch input.
15 Voltage supply from Fuse 7.
TB3 PNK Seat switch input.
TB4 10–1 Battery supply voltage.
RED/BLU–L Key switch input. Battery voltage supply from key switch.
RED/WHT Battery voltage supply to seat switch.
TB5 WHT–5 FORWARD direction switch input.
TB6 BLU–L REVERSE direction switch input.
PY1 — Not used
PY2 — Not used
PY3 — Not used
PY4 BLK–1 Instrument panel display number 9 (TGND) input (ground).
PY5 WHT–1 Instrument panel display number 1 (T5) input.
PY6 — Not used.
PY7 — Not used.
PY8 BRN/WHT Signal wire from TB9 on TMM1.
PY9 BRN/PNK Signal wire from TB7 on TMM1.
PY10 BRN/ORN Signal wire from TB13 on TMM1.
PY11 YEL/GRN
PY12 — Not used.
PY13 WHT–2 Instrument panel display number 5 (PY13) input.
PY14 BLK–2 Instrument panel display number 4 (PY14) input.
PZ1 WHT/BRN Battery negative.
PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire for voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 32 to Voltage supply to accelerator potentiometer.
GRN/WHT
PZ7 17 Battery positive. (Voltage check across Regenerative Braking Diode D7.)
PZ8 31 Regenerative braking contactor negative.
PZ9 BLU Signal wire for voltage check across TR1.
PZ10 GRN to 22 Signal wire from current sensor for Regenerative Braking.
PZ11 YEL to 21 Signal wire from current sensor for Regenerative Braking.
PZ12 GRN Signal wire from motor current sensor.
PZ13 YEL Signal wire from motor current sensor.
PZ14 WHT Signal wire for battery voltage check.

10
 EV–T100 Motor Controller

TABLE 6. Terminal And Plug Wire Connections For TMM1 Module

Plug or Wire No. or
Terminal Color Function
No.
TB1 ORN/PNK Signal wire for temperature switch, traction motor.
TB2 — Not Used.
TB3 ORN/YEL Signal wire for temperature switch, hydraulic pump motor.
TB4 — Not Used.
TB5 GRN/GRY Signal wire for brush wear indicator,steering pump.
TB6 BLU–D/YEL Signal wire for brush wear indicator,steering pump.
TB7 BRN/PNK
TB8 BLU–D/PNK Signal wire for brush wear indicator, traction motor.
TB9 BLU–L
TB10 GRN/PUR Signal wire for brush wear indicator, traction motor.
TB11 BLU–D/GRY Signal wire for brush wear indicator, hydraulic pump motor.
TB12 GRN/PNK Signal wire for brush wear indicator, hydraulic pump motor.
TB13 BRN/ORN

FIGURE 5. TRUCK MANAGEMENT MODULE (TMM1)

11
EV–T100 Motor Controller

TABLE 7. Terminal And Plug Wire Connections For Control Card JY

With: Contactor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand Option, Economy Display and
Curtis BDI Option, or partial GE Display Option,
Without: GE Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear or Temperature indicators

Plug or Wire Color or

Terminal Wire Number Function
No.

PA1 37 To coil for Field Weakening contactor.

PA2 — Not used.
PA3 — Not Used.
PA4 — Not used.
PA5 — Not used.
PA6 — Not used.

PB1 12 Battery positive from Fuse 5.

PB2 24 To coil for Line contactor.
PB3 60 To contactor coil for Steering pump motor.
(Not used when equipped with “On Demand” power steering.)
PB4 27 Forward contactor coil negative.
PB5 23 Reverse contactor coil negative.
PB6 41 1A contactor coil negative.

TB1 YEL/PNK Accelerator potentiometer input.

TB2 GRN Start switch input.
15 Voltage supply from Fuse 7.
TB3 PNK Seat switch input.
10–1 Battery supply voltage.
TB4 RED/BLU–L Key switch input. Battery voltage supply from key switch.
RED/WHT Battery voltage supply to seat switch.
PNK Input to instrument panel display (Seat Switch SSW 16)
TB5 WHT–5 FORWARD direction switch input.
TB6 BLU–L REVERSE direction switch input.

PY1 WHT–3 Not Used.

PY2 BLK–2 Not Used.
PY3 WHT–2 Not Used.
PY4 BLK–1 Instrument panel display number 2 (PY4) input (GE display option only).
PY5 WHT–1 Instrument panel display number 5 (PY5) input (GE display option only).
PY6 — Input to Hand Set.
PY7 — Not used.
PY8 — Not used.
PY9 — Not used.
PY10 — Not used.
PY11 — Not used.
PY12 — Not used.
PY13 WHT–2 Instrument panel display number 1 (PY3) input (GE display option only).
PY14 BLK–2 Instrument panel display number 3 (PY2) input (GE display option only).

PZ1 WHT/BRN Battery negative.

PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire for voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 32 to Voltage supply to accelerator potentiometer.
GRN/WHT
PZ7 17 Battery positive. (Voltage check across Regenerative Braking Diode D7.)
PZ8 31 Regenerative braking contactor negative.
PZ9 BLU Signal wire for voltage check across TR1.
PZ10 GRN to 22 Signal wire from current sensor for Regenerative Braking.
PZ11 YEL to 21 Signal wire from current sensor for Regenerative Braking.
PZ12 GRN Signal wire from motor current sensor.
PZ13 YEL Signal wire from motor current sensor.
PZ14 WHT Signal wire for battery voltage check.

12

REGISTER PARAMETERS
General
The control cards have an electronic device called an
EEPROM (Electrically–Erasable–Programmable–
Read–Only–Memory). The EEPROM has a number of
memory elements called registers. These registers can
have electronic data stored in them to control an opera-
tion. The range of data that can be stored in the registers
is called a parameter. A parameter is a measurement
number that works with other measurement numbers
(parameters) to define a system. The EEPROM in the
control card is a control system for the operation of the
lift truck.
WARNING
Each register in each control card has a range of
numbers so that the control card can be used on dif-
ferent models of lift trucks. This variation is needed
for lift trucks of different sizes and operating volt-
ages. Adjustment of the register to the wrong num-
ber for your lift truck model can cause the truck to
operate differently than normal. This different op-
eration of the truck can cause an injury.
Do NOT adjust any of the registers without using
the parameters shown in EV–T100 TRANSISTOR
MOTOR CONTROLLER, Parameter Tables.
NOTE: EV–T100 TRANSISTOR MOTOR CON-
TROLLER, Parameter Tables, 2200 SRM 596 show
the permitted ranges and the default setting for each
control function. The Factory Set Parameters are the
recommended settings for new units. These settings will
give satisfactory performance for most applications.
Some functions can be adjusted within the permitted
range to change the lift truck operation for a specific
application. Adjustment of a register to a number that is
different than the factory setting is allowed, but follow
the instructions carefully and stay within the minimum
and maximum limits. Adjustments other than the facto-
ry settings will cause the lift truck to operate differently
and can cause increased wear of parts.
Function Numbers
The Function Numbers are code numbers for the differ-
ent parameters that can be set for the control cards. The
Personal Computer or the Hand Set must be used to ad-
EV–T100 Motor Controller
just the parameters for the control card. There is a de-
scription of the code numbers for the different control
cards in the “Parameter Tables”. These tables have the
correct setting numbers for the parameters on each con-
trol card.
CONTROL CARD, CHECKS AND
ADJUSTMENTS
A Personal Computer (PC) or a Hand Set is used to per-
mit Authorized Personnel to make the following
checks and adjustments:
• Check the system status codes for both traction
and hydraulic pump SCR systems
• Check for status codes that are not regular nor
constant
• Check the state of charge of the battery on mo-
tor controllers with type ZH and ZY control
cards
• Check the hourmeter readings on the traction
circuit and hydraulic pump SCR controllers
• Monitor or adjust the following control func-
tions:
♦ Creep Speed
♦ Controlled Acceleration and 1A Time
♦ Current Limit
♦ Steering pump time delay and define signal
input (seat switch or directional switch) (This
setting also controls the time delay for the
seat switch.)
♦ Plugging distance (Current)
♦ Accelerator pedal position, plug range or
disable
♦ 1A drop out current or disable
♦ Field Weakening drop–out
♦ Field Weakening pick–up
♦ Regenerative Braking current limit
♦ Regenerative Braking drop–out
♦ Speed limit points (SL1, SL2 and SL3)
♦ Internal resistance compensation for battery
state of charge indication
♦ Battery voltage (36/48V is auto ranging)
• Selection of type of card operation:
♦ Traction circuit with Field Weakening
♦ Traction circuit with Regenerative Braking
and Field Weakening
♦ High or low current limit for all of the above
functions
13
EV–T100 Motor Controller

HAND SET
1
How To Check And Adjust The Registers
The Hand Set can be used with the EV–100 series motor
controllers. The Hand Set is used to access the registers 2
for the traction or pump motor functions, indicate status
codes (possible faults) and make adjustments to the op-
erating limits set in the control cards. Some of the regis-
ters in the “ZX” series of control cards can not be ac-
cessed with the Hand Set. The Hand Set can access the
registers that control the operation of the lift truck. The 3
values for the limits on the control card functions must
PLUG WIRING
be set with either a PC or the Hand Set. The Hand Set has
MOD. PLUG
a Light Emitting Diode (LED) display, a keypad for data PLUG PY
entry and an adjustment knob for changing function val- 1 9
2 6
ues. See FIGURE 6. 3 3
4 4
NOTE: The vehicle will operate with the Hand Set con- 5 5
nected, however, the adjustment knob MUST be set 6 8
fully clockwise to make sure the control can operate at 7 1
8 2
maximum speed. 4
This section has the control card checks and adjustments 5 6
that can be made using the Hand Set. The control card
checks and adjustments are usually made with the con-
trol card installed in the lift truck. Bench checks and ad- 12657
justments can also be made with the control card con- 1. ADJUSTMENT 4. COIL CORD
nected as shown in FIGURE 8. The checks show the KNOB 5. PLUG PY (14 PIN)
stored setting numbers that have been stored for the dif- 2. LED DISPLAY 6. MODULAR PLUG
ferent control card functions. This section also includes 3. KEYPAD (8–PIN Hand Set)
a description of each of the different functions. Use the FIGURE 6. HAND SET
adjustment knob on the Hand Set to adjust the function
How To Scroll Through The Fault Codes And
settings. See FIGURE 6. Clear Them (See FIGURE 7.)
The EV100ZX controller has function registers (31
through 47) that store the last 16 status codes that caused
the operation of the lift truck to stop and the battery
charge at the time the fault occurred. (A PMT fault is re-
set by turning the key switch to OFF and then to ON.)
The first of the 16 status codes will be overwritten each
time a new status code occurs. The stored status can be
cleared from the register by using the Hand Set. (The PC
software programs clears the fault register automatical-
ly.) Use the procedure in FIGURE 7. to access and clear
the fault code registers with the Hand Set:

14
 EV–T100 Motor Controller

NOTE: The bench supply voltage does not need to be

Check and Adjustment
mode. See the numbers the same as the voltage of the lift truck.
8888.
The Hand Set can also be used to check and adjust the
functions of the control card when it is connected to a
Key Switch OFF bench power supply for bench checks and adjustments.
The following parts are required:
Push ESC and CONT
at the same time
a. A power source to supply a minimum of 24 DC
volts at 0.5 Amps. (A 12–volt battery that can
supply 50 milliamperes can be used if a PC is
Release ESC and CONT used for checks and adjustments. A Hand Set
requires more power for its operation and a
power supply or two 12 volt automotive batter-
Status Code Displayed ies in series must be used. A DC power supply
to a maximum of 84 volts can be used)

Push CONT Button b. An electrical adaptor to connect to the Plug Z

connector of the control card must be made.

Battery charge shown c. A switch for the circuit

when fault occurred [only
if equipped with BDI– d. Approximately 45 cm (18 inches) of 18 gage
otherwise zero (0)].
wire

Push CONT Button e. A PC or a Hand Set.

If batteries are not used, the power supply must have a

Display hour reading Push ESC to full bridge rectifier with a filter to give a good quality
when fault occurred. erase stored data DC voltage. Make the following connections for the
bench checks and adjustments:
Push CONT Button a. Connect the switch and a Plug Z to the power
source using the wire as shown in FIGURE 8.
FIGURE 7. HOW TO SCROLL THROUGH THE
FAULT CODES AND CLEAR THEM b. Make sure the switch is in the OFF position
and connect the wire to TB4

c. Connect Plug Z to the Plug PZ connector on

the control card and the PC or the Hand Set to
the Plug PY connector.

NOTE: There are no connections to the Plug A or Plug

Checks And Adjustments On The Work
Bench (See FIGURE 8.)
CAUTION
Prevent damage to the control card. The control
card can be damaged if power is not correctly con-
nected or disconnected. Always disconnect the bat-
tery connector before connecting or disconnecting
the control card plugs.
B connectors of the control card.
NOTE: The bench checks and adjustments are done us-
ing the same procedures described in the following
pages.
WARNING
NEVER adjust any of the parameters without using
the procedures and settings given in this section.

15
EV–T100 Motor Controller

MALE TO FEMALE PLUG B (CABLE END) PLUG Y (CABLE END) PLUG Z (CABLE END)
DB9 SOCKET TO PC
1 2 3 4 5 1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7

6 7 8 9
4 5 6 8 9 10 11 12 13 14 8 9 10 11 12 13 14

TO TB3 AND TB4

NOTE: If the Hand Set is

used with this power supply, NEG (–) POS (+)
connections to TB3 and TB4
must be available so that all POWER SUPPLY
function keys can be used. 24VDC
O.5 Amps

NOTE: If a PC is used,
a 12–volt battery that
can supply 50 milliamps
can be used instead of
1 the power supply.

1. SHIELDED SERIAL CABLE ASSEMBLY (HYSTER PART NO. 1358470) D–9 SERIAL CABLE,
MALE TO FEMALE (STANDARD COMPUTER EXTENSION CABLE)
2. ADAPTER CABLE (HYSTER PART NO. 1358469)

FIGURE 8. COMPUTER SYSTEM CONNECTIONS FOR CONTROL CARD ADJUSTMENTS AND

TROUBLESHOOTING (EV–T00)

When The Hand Set Is Connected To A connected or disconnected to a control card that is
Control Card Installed In A Lift Truck installed in a lift truck, raise the drive wheels. Then
turn the key switch to OFF, disconnect the battery
WARNING
and discharge capacitor C1.
Prevent movement of the lift truck when making
checks and adjustments. Before the Hand Set is

16

CAUTION
Do Not use the “plugging” mode when the drive
wheels are raised. The higher motor speed can gen-
erate high current and voltage that can damage the
controller.
NOTE: After the battery is disconnected, the capacitor
C1 can be discharged by pressing the horn button. The
horn will sound and decrease to silence. The horn but-
ton must be pressed for approximately 15 seconds af-
ter the sound has stopped in order to completely dis-
charge the capacitor C1.
Make sure the power is off as described in the WARN-
ING. If the lift truck has an instrument panel display
connected, disconnect Plug Y at the SCR control card
(traction or hydraulic pump). Connect the Hand Set plug
at the connector for Plug Y on the control card. Connect
the battery and turn the key to ON. The following dis-
play sequence will occur:
• Display of 8888 for one second to check the
display segments.
• Status Code display of –01 if seat is in the UP
position.
• Another Status Code will be displayed if a pos-
sible fault has occurred.
• Blank display if the operator is on the seat and
there is no Battery Indicator function installed.
• Battery state of charge if the operator is on the
seat and there is a Battery Indicator function
installed.
Turn the key switch to OFF. The following display se-
quence will occur:
• Display shows the hourmeter reading for the
traction motor for four seconds.
• Display shows the hourmeter reading for the
hydraulic pump motor for four seconds. If there
is no SCR control for the hydraulic pump , the
display will be blank.
The registers can be set when the operator is on the seat
or when off the lift truck. Disconnect Plug Y at the SCR
control card (traction motor or hydraulic pump motor) if
the instrument panel display is connected. See
FIGURE 4. Connect the Hand Set plug at connection
EV–T100 Motor Controller
PY on the control card. Connect the battery. Push and
hold the CONT button of the Hand Set so that it is de-
pressed when power is applied. Turn the key to the ON
position or move the power switch of the bench setup to
the ON position. The display will show “8888” to check
that all segments of the display are working. The register
parameters can now be checked or changed.
Function Numbers 1 through 15.
1. Push the keypad numbers for the desired register. The
register and Hand Set numbers are shown in EV–T100
TRANSISTOR MOTOR CONTROLLER, Parame-
ter Tables, 2200 SRM 596.
Function Numbers 16 through 30.
(The seat switch must be open.)
Think of the CONT key equaling 15. Push and hold
the CONT key plus the additional key number above
15 to total the required Hand Set number. Example:
for Function Number 18, push the CONT and key 3
(15+3=18). The display will show the selected register.
After one second, the display will show the parameter
that has been set in that register.
2. Push and hold the CONT key for one second. The dis-
play number will blink.
3. To change the parameter, check for the correct pa-
rameter for that register in the “Parameter Tables”.
Change the parameter by turning the Adjustment Knob
on the Hand Set. The display will continue to blink as the
number changes.
4. Push and hold the STORE key for one second. When
the new parameter is set (stored), the display will stop
blinking.
5. Push and hold the ESC key for one second. The dis-
play will show “8888”. To check or set another register,
do Steps 1 through 3. To return to normal operation (run
mode), push and hold ESC again for one second or
longer. The display will return to the status code mode or
display the state of battery charge if the operator is in the
seat. The display can also be blank (if there are no status
codes and the battery indicator is not installed).
NOTE: Make sure the motor controller control is in the
run mode before disconnecting the Hand Set. If the mo-
tor controller control is not in the run mode, the battery
must be disconnected and connected again to reset the
system.
The vehicle can now be operated with the Hand Set con-
nected or the Hand Set can be disconnected.
17
EV–T100 Motor Controller
NOTE: If the vehicle is operated with the Hand Set con-
nected, make sure to set the Adjustment Knob fully
clockwise to make sure the control can operate at top
speed.
Disconnect the plug at connection Y on the control card
to disconnect the Hand Set. Connect the plug for the in-
strument panel display at connection Y.
Function Numbers 48 through 62.
(The seat switch must be closed.)
1. Turn the key switch to ON after the Hand Set is
connected to the traction card. (Turn the key switch
to OFF after the Hand Set is connected to the hy-
draulic pump card.)
Think of the CONT key equaling 47. Push and hold the
CONT key plus the additional key number above 47 to
total the required Hand Set number. Close the seat
switch and the key switch. Example: for Function Num-
ber 48, push the CONT and key 1 (47+1=48, 47+2=49,
47+3=50, 47+5=52, etc.). The display will show the se-
lected register. After one second, the display will show
the parameter that has been set in that register.
NOTE: HS Numbers 47, 51, 55 and 59 are the registers
for the MODE numbers and are not used. Do not try to
set these numbers with the Hand Set.
2. Push and hold the CONT key for one second. The dis-
play number will blink.
3. To change the parameter, check for the correct pa-
rameter for that register in the “Parameter Tables”.
Change the parameter by turning the Adjustment Knob
on the Hand Set. The display will continue to blink as the
setting changes.
4. Push and hold the STORE key for one second. When
the new parameter is set (stored), the display will stop
blinking.
5. Push and hold the ESC key for one second. The dis-
play will show “8888”. To check or set another register,
do Steps 1 through 3. To return to normal operation (run
mode), push and hold ESC again for one second or
longer.
FUNCTION NUMBER DESCRIPTIONS
The following pages have descriptions for the different
Function Numbers. The setting for each function is spe-
cific for each control card. To identify the control card,
18
check the label at the top edge of each card case. There
are some painted letters and numbers followed by letters
on the lower part of the label. The last two letters identi-
fy the type of card installed. The following types of con-
trol cards are used:
JH = Traction Controller with three–wire
potentiometer and with Battery Discharge
Indicator (BDI).
JY = Traction Controller with three–wire
potentiometer and without Battery
Discharge Indicator (BDI)
LP or HP = Pump Motor Controller
These same letters are also shown in the “Parameter
Tables” and in the section headings for the control cards
for the traction motor and hydraulic pump motor.
TRACTION CONTROL CARDS
(LABEL LETTERS – JH AND JY)
NOTE: These control cards are used with the motor
controllers that control the speed of the traction motor.
WARNING
If any of the parameters are changed, the operators
must be told that the lift truck will operate differ-
ently.
Do not adjust the parameters outside of the range
of numbers shown in the “Parameter Tables”. Pa-
rameters set outside of the ranges can cause dam-
age to the components of the traction system and
can cause the lift truck to operate differently than
normal. This different operation of the lift truck
can result in personal injury.
Function Number 1
STORED STATUS CODE
(Push 1)
This register contains the last status code of a possible
PMT fault that caused the lift truck to stop operation.
These codes can be removed from the display by turning
the key switch to OFF. The code will be stored in regis-
ters in the control card. This status code will be replaced
with the same status code if another possible PMT fault
occurs. The status code can be cleared from memory by
adjusting the setting number to zero. The number must
be stored by pushing the STORE key for one second.
Adjustment of the values this register does not change
the operation of the lift truck.

Function Number 2
CREEP SPEED
(Push 2)
This register permits the adjustment of the creep speed
of the lift truck. The range of adjustment is from 0 (5%)
to 255 (15%). The percent values are the SCR 1 “ON
Time”. A constant creep speed frequency will be main-
tained when the accelerator input voltage is between 3.7
and 3.5 volts (a potentiometer resistance value between
6K and 4.7K ohms).
Function Number 3
CONTROLLED ACCELERATION AND 1A
TIME
(Push 3)
This register permits the adjustment of the maximum
rate of acceleration. The setting determines the time al-
lowed to reach maximum SCR speed after the accelera-
tor is set for maximum speed from stop. The control will
stay in SCR acceleration for between 0.77 second (set-
ting 8) and 21.5 seconds (setting 255) before the 1A con-
tactor will close. The numbers in () are the parameters
for the times shown. The 1A contactor will automati-
cally close 0.2 second after the controlled acceleration
stops. The speed control input is less than 0.5 volt (ac-
celerator potentiometer set at less than 50 ohms). Do not
adjust the number in the register to less than the mini-
mum setting of 8.
Function Number 4
CURRENT LIMIT
(Push 4)
This register permits the adjustment of the current limit
of the motor controller. The current rating of the motor
controller will determine the range of adjustment for
this register. See the “Parameter Tables”. Do not ad-
just the register to any number other than the factory set-
ting.
Function Number 5
PLUGGING DISTANCE (CURRENT)
(Push 5)
This register permits the adjustment of the distance it
takes to stop the lift truck when plugging. A parameter
set to higher numbers makes the lift truck stop faster.
Lower numbers decrease the plugging for a longer stop-
ping distance.
EV–T100 Motor Controller
WARNING
A parameter set greater than the number shown in
the “Parameter Tables” will make the lift truck
slow at a rate faster than normal. A parameter set
at less than the number shown will make the lift
truck have a slower plugging effect. This different
operation of the truck can result in injury. A faster
plugging rate can also damage the control system or
the traction motor.
The number for this parameter for the current value of
this register must be found if the Pedal Position Plug
(Function Number 16) will not be used. To find the num-
ber for the current value, use the following information:
Range 200 to 1000 amps
Setting Range 0 to 255
Resolution 3.14 amps per set unit
Example: Setting of 20=263A (EV–100)
20 x 3.14A = 62.8A or 63A
63A + 200A (range min) =
263A
Function Number 6
1A DROP OUT CURRENT
(Push 6)
This register permits the adjustment of the parameter for
the current value at which the 1A contactor will dee-
nergize (open). The 1A contactor will open and the mo-
tor torque will be limited to SCR current to prevent mo-
tor currents that are too high. A value of 255 will disable
the 1A Drop Out function.
Function Number 7
FIELD WEAKENING PICK UP
(Push 7)
CAUTION
A setting HIGHER than the setting shown in the
“Parameter Tables” will make the Field Weakening
Contactor energize too soon. This operation can
damage the traction motor.
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface.
Do NOT set this register to a number greater than
the number set by Function Number 8. If this regis-
19
EV–T100 Motor Controller
ter is set to a number less than 5, the Field Weaken-
ing function will be deenergized.
Function Number 8
FIELD WEAKENING DROP OUT
(Push 8)
CAUTION
A parameter set HIGHER than the number shown
in the “Parameter Tables” will make the Field
Weakening Contactor remain energized at high
currents. This operation can cause motor heating
and damage the traction motor.
This register permits adjustment of the current value at
which the FW contactor will deenergize (open). This pa-
rameter permits the FW contactor to open when the lift
truck requires more than 300% of the running current
with a full load on a level surface.
Function Number 9
REGENERATIVE BRAKING CURRENT LIMIT
(Push 9)
WARNING
A parameter set greater than the number shown in
the “Parameter Tables” will make the lift truck
slow at a rate faster than normal. A parameter set
at less than the number shown will make the lift
truck have a slower regenerative braking effect.
This different operation of the truck can result in
personal injury. A faster regenerative braking rate
can also damage the control system or the traction
motor.
This register permits adjustment of the Regenerative
Braking current limit. The higher the current limit set-
ting, the shorter the stopping distance. The shorter stop-
ping distance causes faster wear on the drive train and
brushes of the traction motor.
Function Number 10
REGENERATIVE BRAKING START
(Push 10)
CAUTION
A parameter set greater than the number shown in
the “Parameter Tables” can prevent regenerative
braking. The lift truck will remain in the plugging
mode longer and increase brush wear in the trac-
tion motor.
20
This parameter permits adjustment of the percent ON
time at which the control will start to energize the regen-
erative braking circuit. The percent ON time can be be-
tween 0% and 95%. This adjustment sets the speed
where regenerative braking will start. This parameter
prevents the controller from energizing the regenerative
braking circuit when motor current is too low.
Function Number 11 and 12
SPEED LIMIT 1 and 2 (SL1 and SL2)
(Not Used)
Function Number 13
SPEED LIMIT 3 (SL3)
(Push 13)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. The adjustment sets the speed limit for the time
when the input signal from the SL3 limit switch is re-
ceived by the control card. This signal can be a signal
from the sensor in the traction motor or the hydraulic
pump motor. If the sensor shows that a motor is too hot,
the control will decrease the maximum motor speed to
this speed setting. The SL3 limit switch is a normally
closed switch connected to battery negative. When the
switch opens, it enables the speed limit function. A set-
ting of 0 will disable the speed limit function. This zero
setting will permit top speed when no limit switch is
connected. A zero setting will not slow the motor with
an input from the sensor and can damage the motor.
Some models of lift trucks do not use this function. This
function is activated by Status Codes –90 and –93.
Function Number 14
INTERNAL RESISTANCE COMPENSATION
(Push 14)
CAUTION
Adjusting this function setting to the wrong num-
ber can cause battery damage.
This register is used when the control card has the Bat-
tery Discharge Indicator (BDI) function. Control cards
that have BDI are type ZH control cards. The “Parame-
ter Tables” show the parameters for a battery in average
condition.
For the best use of your battery energy, the register can
be adjusted using the following procedure. However,
you must use the procedure to change the parameter in
the register as the battery changes during months the

battery is used or battery damage can occur. Setting the
parameter too low for your battery can allow the battery
to discharge below the minimum specific gravity value.
This minimum specific gravity is the specification given
by the battery manufacturer to prevent battery damage.
Using the following procedure to adjust the parameter:
a. Operate the lift truck on a normal work cycle.
Travel at medium speeds.
b. When lift interrupt occurs, stop the lift truck
and wait for approximately 10 minutes.
c. Check the specific gravity of several battery
cells. If the specific gravity is between 1.140
and 1.150, the setting is correct for that battery.
If the specific gravity reading is high, adjust the
parameter in the register to a lower number. If
the specific gravity reading is low, adjust the
parameter to a higher number.
NOTE: It can be necessary to charge the battery and do
Steps 1 through 3 again to get an accurate number for
your battery.
Function Number 15
BATTERY VOLTS
(Push 15)
This register permits adjustment for the operating volt-
age of the lift truck. The adjustment also permits correct
operation of the Battery Discharge Indicator function
for lift trucks equipped with BDI. For the controller and
BDI to operate correctly, the parameter shown in the
Tables for the Register Parameters must be entered.
Battery Volts Parameter
36 volts Between 32 and 44
48 volts Between 45 and 69
72 volts Between 70 and 80
80 volts Between 81 and 183
36/48 volts Between 184 and 250
No BDI Between 251 and 255
NOTE: If the parameter is set to a number other than the
number shown for your lift truck in Tables for the Regis-
ter Parameters, a status code of –15 or –16 will occur.
Make sure the battery is fully charged and battery con-
nector has good connections before making this adjust-
ment. This check is especially important when adjusting
for 36/48 volt operation (numbers 184 to 250).
EV–T100 Motor Controller
Function Numbers GREATER THAN 15
NOTE: For registers greater than 15, think of the
CONT key as equal to 15. Push and hold the CONT key
plus the additional key number above 15 to total the re-
quired register number. Example: for Function 18, push
the CONT key and key 3 (15+3=18). The display will
show the selected function. After one second, the dis-
play will show the setting number that has been set for
that register.
NOTE: The Seat Switch must be OPEN for Function
Numbers 16 through 30.
Function Number 16
PEDAL POSITION PLUG
(Push CONT and 1)
This register permits adjustment of the range for pedal
position plugging. The parameter in this register permits
the pedal position to control the plugging current and the
plugging distance. The current value set by this register
is enabled as the accelerator is returned to the creep
speed position. There is maximum plugging current
when the accelerator is in the maximum speed position.
To disable the pedal position plugging function, adjust
the current value to the same current value as the plug-
ging distance current. See the description in Function
Number 5.
Example: If Plugging Distance Current (Function Num-
ber 5) is set at 500 amps, then set pedal plugging current
to 500 amps. The pedal position will have no effect on
the plugging distance with this setting.
Use the following information to adjust the current
value:
Range 100 to 930 amps
Parameter Range 0 to 255
Resolution 3.2A per set unit
Example: Parameter of 20 = 164 amps
20 x 3.2A = 64A
64A+100(range min)=164A
Function Number 17
CARD TYPE SELECTION
(Push CONT and 2)
WARNING
Wrong parameters entered into the register in
Function Number 17 can cause the truck to operate
differently than normal. This different operation of
21
EV–T100 Motor Controller
the truck can cause an injury. NEVER set Function
Number to a parameter that is not shown for your
lift truck.
This register permits the selection of the card type used
for your lift truck application.
Function Number 18
STEERING PUMP TIME DELAY
(Push CONT and 3)
WARNING
A parameter set lower than the number shown in
the “Parameter Tables” can permit the steering
pump to stop if the seat switch opens momentarily
during normal operation. There is no power steer-
ing if the steering pump stops. The sudden and dif-
ficult steering effort that is not expected can cause
injury or property damage.
This register permits the selection of the input for the
steering pump contactor. Closing the seat switch or the
FWD/REV switch can be the input. The parameter also
sets the time delay for the contactor to open after the
switch opens.
NOTE: There is no delay time for the contactor to close
after receiving the input signal from the seat switch or
the FWD/REV switch. Parameters in the 0–128 range
adjust the delay after the seat switch opens. Parameters
in the 129–255 range adjust the delay after the FWD/
REV switch opens. Adjust the setting to the number
shown in “Parameter Tables”.
Function Number 19
MAINTENANCE ALERT (Tens/Units)
(Push CONT and 4)
This register can be set by the service person to give a
Status Code –99 when scheduled maintenance is re-
quired. The range for this register is 0 to 99 hours.
Function Number 20
MAINTENANCE ALERT (Thousands/Hundreds)
(Push CONT and 5)
This register can be set by the service person to give a
Status Code –99 when scheduled maintenance is re-
quired. The range for this register is 100 to 9900 hours.
22
Function Number 21
MAINTENANCE SPEED LIMIT
(Push CONT and 6)
This register can be set by the service person to control
the speed limit (maximum battery volts to the motor)
when the Maintenance Alert (Status Code –99) is acti-
vated by the control card. The range for this register is 0
to 180.
Function Numbers 22 through 26
TEMPORARY DATA REGISTERS
These registers can be read with the Hand Set, but the
data in them changes during lift truck operation. Do not
change the parameters in registers for Function numbers
22 through 26.
CAUTION
Function 25 (temporary storage register for fault
data) and Function 26 (temporary storage register
for battery charge data) must not be changed by the
user to any number above zero. Any number above
zero can cause the instrument panel display to not
operate correctly and the lift truck can become dis-
abled.
Function Number 27
STOP PLUGGING SET POINT
(Push CONT and 12)
The PLUGGING function normally stops when the ON
time of TR1 decreases to 15%. This function permits a
decrease of the STOP PLUGGING set point to a percent
of ON time between 13.4% and 6.8%.
Function Number 28
FAULT INDICATOR POINTER REGISTER
Th1s register can be read with the Hand Set. Function
number 28 is the fault indicator pointer and must be
set to zero when all faults or malfunctions have been
fixed or removed from the controller.
Function Number 29
HOURMETER (Tens/Units)
(Push CONT and 14)
This register has the data for the accumulated operating
hours of the lift truck. This register is not normally
changed unless a new control card is installed. If a new
control card is installed, the total hours from the old con-
trol card must be entered so that the total operating hours
of the lift truck is correctly recorded.

Function Number 30
HOURMETER (Thousands/Hundreds)
(Push CONT and 15)
This register has the data for the accumulated operating
hours of the lift truck. This register is not normally
changed unless a new control card is installed. If a new
control card is installed, the total hours from the old con-
trol card must be entered so that the total operating hours
of the lift truck is correctly recorded.
Function Number 48 Through Function Number 62
SET LIFT TRUCK PERFORMANCE.
If the lift truck is equipped with a Premium instrument
panel, the lift truck can be set to four performance levels
by the operator. (If the customer does not want this func-
tion available to the operator, a service person can set all
four levels to the same setting.) Each time the operator
pushes the button on the instrument panel, the perfor-
mance level will increase by one step. At the maximum
(rabbit) level, the performance levels will begin at the
lowest (turtle) level again. The four performance levels
set by the manufacturer are:
a. Low performance for handling fragile loads.
b. Medium speed for less consumption of battery
charge during a work shift.
c. Higher performance with higher consumption
of battery charge during a work shift.
d. Maximum lift truck performance with higher
consumption of battery charge.
The four performance levels can be set to any level up to
the maximum limits. Two or more adjacent perfor-
mance levels can be set to the same limits. The perfor-
mance levels must be set at the same or in ascending or-
der (from turtle to rabbit). The register interlocks will
not permit a higher performance level setting toward the
turtle than the adjacent registers toward the rabbit.
NOTE: The Seat Switch must be CLOSED for Func-
tion Numbers 48 through 62.
EV–T100 Motor Controller
Function Number 48
CONTROLLED ACCELERATION AND 1A
TIME
(Push CONT and 1 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 1 (Turtle). The parameter
determines the time allowed to reach maximum SCR
speed after the accelerator is set for maximum speed
from stop. The control will stay in SCR acceleration for
3.5 seconds (setting 40) before the 1A contactor will
close. The numbers in () are the parameters for the times
shown. The 1A contactor will automatically close 0.2
second after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator po-
tentiometer set at less than 50 ohms). Do not set the
number in the register to less than the parameter in the
register for Function Number 52.
Function Number 49
FIELD WEAKENING PICK UP
(Push CONT and 2 while the key switch and seat
switch are closed)
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface. The mini-
mum parameter is zero. Do not set the number in the reg-
ister greater than the number in the register for Function
Number 53.
Function Number 50
SPEED LIMIT 1
(Push CONT and 3 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register to
less than the parameter for Function Number 54. Do not
set the number in the register greater than 180.
23
EV–T100 Motor Controller
Function Number 52
CONTROLLED ACCELERATION AND 1A
TIME
(Push CONT and 5 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 2. The parameter deter-
mines the time allowed to reach maximum SCR speed
after the accelerator is set for maximum speed from
stop. The control will stay in SCR acceleration for 2.6
seconds (setting 30) before the 1A contactor will close.
The numbers in () are the parameters for the times
shown. The 1A contactor will automatically close 0.2
second after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator po-
tentiometer set at less than 50 ohms). Do not set the
number in the register to less than the parameter for
Function Number 56. Do not set the number in the regis-
ter greater than the number in the register for Function
Number 48.
Function Number 53
FIELD WEAKENING PICK UP
(Push CONT and 6 while the key switch and seat
switch are closed)
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface. Do not set
the number in the register to less than the parameter for
Function Number 49. Do not set the number in the regis-
ter greater than the number in the register for Function
Number 57.
Function Number 54
SPEED LIMIT 1
(Push CONT and 7 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register to
less than the parameter for Function Number 58. Do not
set the number in the register greater than the number in
the register for Function Number 50.
24
Function Number 56
CONTROLLED ACCELERATION AND 1A
TIME
(Push CONT and 9 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 3. The parameter deter-
mines the time allowed to reach maximum SCR speed
after the accelerator is set for maximum speed from
stop. The control will stay in SCR acceleration for 1.8
seconds (setting 20) before the 1A contactor will close.
The numbers in () are the parameters for the times
shown. The 1A contactor will automatically close 0.2
second after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator po-
tentiometer set at less than 50 ohms). Do not set the
number in the register to less than the parameter for
Function Number 60. Do not set the number in the regis-
ter greater than the number in the register for Function
Number 52.
Function Number 57
FIELD WEAKENING PICK UP
(Push CONT and 10 while the key switch and seat
switch are closed)
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface. Do not set
the number in the register to less than the parameter for
Function Number 53. Do not set the number in the regis-
ter greater than the number in the register for Function
Number 61.
Function Number 58
SPEED LIMIT 1
(Push CONT and 11 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register
greater than the number in the register for Function
Number 58.

Function Number 60
CONTROLLED ACCELERATION AND 1A
TIME
(Push CONT and 13 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 4 (Rabbit). The parameter
determines the time allowed to reach maximum SCR
speed after the accelerator is set for maximum speed
from stop. The control will stay in SCR acceleration for
0.94 seconds (setting 10) before the 1A contactor will
close. The numbers in () are the parameters for the times
shown. The 1A contactor will automatically close 0.2
second after the controlled acceleration stops. The
speed control input is less than 0.5 volt (accelerator po-
tentiometer set at less than 50 ohms). Do not set the
number in the register to less than 8. Do not set the num-
ber in the register greater than the number in the register
for Function Number 56.
Function Number 61
FIELD WEAKENING PICK UP
(Push CONT and 14 while the key switch and seat
switch are closed)
This register permits the adjustment of the current value
at which the FW contactor will energize (close). This
parameter permits the FW contactor to close when the
lift truck has returned to approximately 150% of its run-
ning current with a full load on a level surface. Do not set
the number in the register to less than the parameter for
Function Number 57. Do not set the number in the regis-
ter greater than 110.
PUMP CONTROL CARD
(LABEL LETTER LP)
NOTE: This control card is used with the motor con-
troller that controls the speed of the motor for the hy-
draulic pump.
WARNING
If any of the register parameters are changed, the
operators must be told that the lift truck will oper-
ate differently.
Do not adjust the register parameters outside of the
range shown in the Tables for the Register Parame-
ters. Settings outside the ranges can cause damage
to the components of the hydraulic system and dif-
EV–T100 Motor Controller
ferent truck operation. This different operation of
the truck can cause personal injury.
Function Number 1
STORED STATUS CODE
(Push 1)
This register contains the last status code of a possible
fault that caused the pump motor to run continuously.
The battery must be disconnected to stop the motor if it
runs continuously. This status code will be replaced with
the same status code if another possible fault occurs.
The status code can be cleared from memory by adjust-
ing the setting number to zero. Any new number (in-
cluding zero) must be stored by pushing the STORE
key for one second. Adjustment of this register does not
change operation of the hydraulic system.
Function Number 2
INTERNAL RESISTANCE COMPENSATION
START
(Push 2)
This register permits adjustment of the current level re-
quired to start the internal resistance compensation
(Function Number 16).
Function Number 3
CONTROLLED ACCELERATION
(Push 3)
This register permits the adjustment of the maximum
rate of acceleration. The parameter determines the time
allowed to reach maximum SCR speed after the switch
closes. This parameter determines how fast the hydrau-
lic functions will begin to operate. The control will stay
in SCR operation for 0.1 to 22 seconds after the switch
closes.
Function Number 4
CURRENT LIMIT
(Push 4)
This register permits the adjustment of the current limit
of the control. The current limit is normally set at the
maximum (255).
Function Number 7
CONTROLLED ACCELERATION
COMPENSATION
(Push 7)
This register permits the adjustment of the rate (in se-
conds) that it takes for the controller to add the internal
25
EV–T100 Motor Controller

resistance compensation voltage that is applied to to to 0%. A parameter set over the maximum parameter
motor. This function will add 0.375 volts to the motor at can cause the motor or controller to become too hot.
the rate of time set in the register until the total (current x
Function Numbers Greater Than 15
resistance) compensation voltage has been added.
NOTE: For registers greater than15, push and HOLD
Range 0.0015 to 0.383 seconds the CONT key and the additional key number above 15
Set 0 to 255 to total the required register number. Example: for Func-
Resolution 0.375 volts per set unit tion Number 18, push CONT key and key 3 (15+3=18).
Example: A parameter of 20 = 0.032 seconds The display will show the selected register. After one
second, the display will show the parameter that has
Example: If 2.08 volts is set in Function Number 16 and
been set in that register.
added to the motor, this example would require 0.18 se-
conds to add a total of 2.08 volts. NOTE: The Seat Switch must be OPEN for Function
(2.08 volts/0.375 volts per unit)0.032 seconds = 0.1775 Numbers 16 through 30.
or 0.18 seconds
Function Number 16
Function Number 11 INTERNAL RESISTANCE COMPENSATION
SPEED LIMIT 1 (SL1) (Push CONT and 1)
(Slow Speed) – Tilt and Slow Auxiliary This register is used to give the pump speed better stabil-
(Push 11) ity by increasing the motor voltage during heavy loads.
This register permits the adjustment of the speed limit This parameter is set using the information from the
speed torque curve of the motor used. See the correct
(maximum battery volts applied to the motor). When
switch SL–1 is closed, the signal to TB2 on the control- setting in the “Parameter Tables”.
ler card causes the controller to apply the limit on battery The voltage selected will be added to the motor for each
volts to the motor. 100 ampere increment starting with the parameter set in
Function Number 2. The voltage selected will be added
Function Number 12
in steps of 0.375 volts until the entire voltage is added.
SPEED LIMIT 2 (SL2)
For example, a parameter of 10 will add 2.28 volts in six
(Medium Speed) – Slow Lift and Medium
steps of 0.375 volts each.
Auxiliary
(Push 12) Function Number 17
CARD TYPE SELECTION
This register permits the adjustment of the speed limit (Push CONT and 2)
(maximum battery volts applied to the motor). When
switch SL–2 is closed, the signal to TB3 on the control- WARNING
ler card causes the controller to apply the limit on battery Wrong parameters entered into the register in
volts to the motor. Function Number 17 can cause the truck to operate
differently than normal or cause damage to the con-
Function Number 13
troller. This different operation of the truck can re-
SPEED LIMIT 3 (SL3)
sult in personal injury. NEVER set Function Num-
(Push 13)
ber 17 to a parameter that is not shown for your lift
Not Connected. truck.

Function Number 14 This register permits the selection of the card type used
SPEED LIMIT 4 (SL4) for your lift truck application. See the correct setting in
Fast Lift the “Parameter Tables”.
(Push 14) Function Numbers 18 through 28
TEMPORARY DATA REGISTERS
This register uses SL4 limit switch for an input to TB6.
This function permits adjustment of the speed limit These registers can be read with the Hand Set, but the
(maximum battery volts to the motor). The range is 96% data in them changes during lift truck operation. Do not

26

change the parameters in registers for Hand Set numbers
21 through 27. Hand Set number 28 is the fault indi-
cator pointer and must be set to zero when all faults
or malfunctions have been fixed or removed from
the controller.
CAUTION
Function 25 (temporary storage register for fault
data) and Function 26 (temporary storage register
for battery charge data) must not be changed by the
user to any number above zero. Any number above
zero can cause the instrument panel display to not
operate correctly and the lift truck can become dis-
abled.
Function Number 29
HOURMETER (Tens/Units)
(Push CONT and 14)
This register has the data for the accumulated operating
hours of the hydraulic system. This register is not nor-
mally changed unless a new control card is installed. If a
new control card is installed, the total hours from the old
control card must be entered so that the total operating
hours of the hydraulic system is correctly recorded.
Function Number 30
HOURMETER (Thousands/Hundreds)
(Push CONT and 15)
This register has the data for the accumulated operating
hours of the lift truck. This register is not normally
changed unless a new control card is installed. If a new
control card is installed, the total hours from the old con-
trol card must be entered so that the total operating hours
of the lift truck is correctly recorded.
Function Number 48
CONTROLLED ACCELERATION
(Push CONT and 1 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 1 (Turtle). The parameter
determines the time allowed to reach maximum SCR
speed from stop. Do not set the number in the register to
less than the parameter in the register for Function Num-
ber 52.
EV–T100 Motor Controller
Function Number 49
SPEED LIMIT 2
(Push CONT and 2 while the key switch and seat
switch are closed)
This register permits the adjustment of the speed limit
for the hydraulic pump in MODE 1. The minimum pa-
rameter is zero. Do not set the number in the register
greater than the number in the register for Function
Number 53.
Function Number 50
SPEED LIMIT 3
(Push CONT and 3 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register to
less than the parameter for Function Number 54. The
maximum number in the register is 255.
Function Number 52
CONTROLLED ACCELERATION
(Push CONT and 5 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 2. The parameter deter-
mines the time allowed to reach maximum SCR speed
from stop. Do not set the number in the register to less
than the parameter for Function Number 56. Do not set
the number in the register greater than the number in the
register for Function Number 48.
Function Number 53
SPEED LIMIT 2
(Push CONT and 6 while the key switch and seat
switch are closed)
This register permits the adjustment of the speed limit
for the hydraulic pump in MODE 2. Do not set the num-
ber in the register to less than the parameter for Function
Number 49. Do not set the number in the register greater
than the number in the register for Function Number 57.
Function Number 54
SPEED LIMIT 3
(Push CONT and 7 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
27
EV–T100 Motor Controller
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. Do not set the number in the register to
less than the parameter for Function Number 58. Do not
set the number in the register greater than the number in
the register for Function Number 50.
Function Number 56
CONTROLLED ACCELERATION
(Push CONT and 9 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 3. The parameter deter-
mines the time allowed to reach maximum SCR speed
from stop. Do not set the number in the register to less
than the parameter for Function Number 60. Do not set
the number in the register greater than the number in the
register for Function Number 52.
Function Number 57
SPEED LIMIT 2
(Push CONT and 10 while the key switch and seat
switch are closed)
This register permits the adjustment of the speed limit
for the hydraulic pump in MODE 3. Do not set the num-
ber in the register to less than the parameter for Function
Number 53. Do not set the number in the register greater
than the number in the register for Function Number 61.
Function Number 58
SPEED LIMIT 3
(Push CONT and 11 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. The maximum number in the register
is 255.
Function Number 60
CONTROLLED ACCELERATION
(Push CONT and 13 while the key switch and seat
switch are closed)
This register permits the adjustment of the maximum
rate of acceleration in MODE 4 (Rabbit). The parameter
determines the time allowed to reach maximum SCR
speed from stop. Do not set the number in the register to
28
less than 8. Do not set the number in the register greater
than the number in the register for Function Number 56.
Function Number 61
SPEED LIMIT 2
(Push CONT and 14 while the key switch and seat
switch are closed)
This register permits the adjustment of the speed limit
for the hydraulic pump in MODE 4. Do not set the num-
ber in the register to less than the parameter for Function
Number 57. Do not set the number in the register greater
than 110.
Function Number 62
SPEED LIMIT 3
(Push CONT and 14 while the key switch and seat
switch are closed)
This parameter permits adjustment of the speed limit
(maximum battery volts to the motor). The range is 0%
to 96%. There is no speed limit switch for this function.
This function will be disabled if the parameter in the reg-
ister is set to zero. The maximum number in the register
is 255.
TROUBLESHOOTING
Many electrical malfunctions of the lift truck will be
shown in the status code number on the digital display.
There is a digital display on the Hand Set or instrument
panel display (optional on some lift trucks). There is a
table, in this TROUBLESHOOTING section, for each
status code with a description of the malfunction, the
circuit that has the incorrect input, and the possible
causes.
NOTE: Make sure the parameters are correct for your
lift truck to make sure the trouble is not just a wrong
setting. See the “Parameter Tables” to set the parame-
ters for the correct values. If there is no status code dis-
play and the lift truck does not operate correctly, there
can be a fault in the control card.
See the procedures to connect and use the Hand Set.
The following Status Codes indicate possible faults in
these areas:
AREA OF FAULT — STATUS CODE #
Control Card Inputs — Blank through –17
Contactor Panel — 23 through –26
SCR Panel — 41 through –57

Regenerative Braking — 70 through –76
Truck Management — 90 through –99
Hydraulic Pump Control — 117 through –157
NOTE: 1. A blank display on the instrument panel dis-
play or the Hand Set, during operation, can mean that the
diode D7 for regenerative braking has a short–circuit.
The indication for this malfunction is an open traction
power fuse. If D7 has a short–circuit, there is a short–cir-
cuit across the battery as soon as the regenerative brak-
ing contactor closes and will cause the power fuse to
open. If D7 is open, the regenerative braking will not op-
erate and the plugging will be too quick.
NOTE 2. A short–circuit in the 1A contactor coil will
cause the lift truck to suddenly stop when operating at
the higher speeds. The lift truck operates correctly until
the 1A contactor is energized. When the 1A contactor is
energized, the traction motor then stops and the direc-
tion contactors will open.
NOTE 3. If the coil of the Field Weakening contactor
has a short–circuit, the lift truck will operate normally
until the FW contactor is energized. Then the lift truck
will lose power and the direction contactors will open.
The control card in the motor controller has a
troubleshooting system that continuously checks the
static and operating conditions of the control and power
circuits for the motor. The control card will indicate a
status code on a display connected to plug PY if the
troubleshooting circuits find a condition that is not nor-
mal. Some lift trucks can have an instrument panel dis-
play that will indicate the status codes from the control
cards for the traction motor and hydraulic pump motor.
Different control cards are used in the electric lift trucks.
A replacement control card must have the same part
number as the control card that was removed. A bad
control card can not be repaired by service persons and
must be replaced.
Status Codes (See TABLE 8.)
The status codes are code numbers for malfunctions that
the control card can sense. The control card will indicate
this code number on the digital display of the instrument
panel display (optional on some units) or the display on
a Hand Set. The control card will illuminate the numbers
of the status code on the display. The status codes are
twice illuminated (“flash”) on the display approximate-
EV–T100 Motor Controller
ly every two seconds. Every third “flash” of the display
will indicate the battery charge instead of the status
code.
The control card senses the following malfunctions:
• input voltages that are too high or too low,
• input voltages that have the wrong polarity,
• input voltages in the wrong sequence or
• correct input voltages that occur at the wrong
time.
NOTE: A status code display does not always mean that
there is a malfunction. A temporary operating condition
can cause a status code display.
The status codes all have a dash (–) before the numbers.
If the battery is disconnected, the dash (–) will be miss-
ing on the display of the Hand Set when a battery is con-
nected again. If a status code number is indicated on the
digital display, checks and adjustments cannot be done.
See TABLE 8. and the following Status Code Charts to
find and correct the malfunction. There are no checks or
adjustments for the status codes. These code numbers
are only codes to help identify a possible malfunction.
TABLE 8. has a short description of the different status
codes.
There is a Status Code Chart in this section for each
status code. These charts have a more complete descrip-
tion of the status code, the circuit that has generated the
input for the status code, the symptom and the possible
causes.
REGISTER MAPS
The information in the Register Maps shown in
TABLE 9. and TABLE 10. is not needed by most ser-
vice people. This additional technical information is for
service engineers who have special troubleshooting re-
quirements. These registers and their descriptions are
designed by the General Electric Company. Many of
these registers are programmed by Hyster Company to
do certain functions. These register maps as pro-
grammed by Hyster Company are shown in the section,
EV–T100 TRANSISTOR MOTOR CONTROL-
LER, Paramter Tables, 2200 SRM 596.
NOTE: The number of the EEPROM register is off–set
by one from the PC Register Number and the Function
Number in the Register Map Tables. The EEPROM be-
gins its count from zero (0) while the PC and Hand Set
begin their count from one (1).
29
EV–T100 Motor Controller

OTE: EEPROM = Electrically–Erasable–

Programmable–Read–Only–Memory
TABLE 8. STATUS CODES LIST
STATUS DESCRIPTION STATUS DESCRIPTION
CODE CODE
CARD INPUTS REGENERATIVE BRAKING
BLANK No input voltage to control card or display –70 Current sensor input missing (green wire)
–01 No input signal from seat switch –71 Current sensor input missing (yellow wire)
–02 FORWARD switch closed on initial start –72 Regenerative braking contactor does not close
–03 REVERSE switch closed on initial start –73 Regenerative braking contactor does not
–05 Start or brake switch did not close deenergize or deenergizes slowly (PMT fault)
–06 Accelerator depressed, no direction selected –74 Regenerative braking contactor
–07 Accelerator input voltage too high energizes too slowly (PMT fault)
–08 Accelerator input voltage too low or power to –76 C1 voltage too high during
control card after key switch ON regenerative braking
–09 Both FWD and REV switches closed –80 C1 voltage less than 14 volts after Contactor L
at same time has closed.
–11 The START switch is closed when the key switch –81 Battery voltage is less than 14 volts.
is closed and voltage is applied to the control
card. LIFT TRUCK MANAGEMENT*
–15 Battery volts too low –90 Temperature too high, traction motor*
–16 Battery volts too high –91 Temperature too high, hydraulic pump motor*
–17 Wrong control card installed –93 Brush wear, steering pump motor*
–21 Accelerator input is less than 0.25 volts. –94 Brush wear, traction motor*
–95 Brush wear, hydraulic pump motor*
CONTACTOR PANEL, TRACTION CIRCUIT –99 Maintenance Alert Code.
–23 Coil current low, Forward or Reverse contactor
–24 Voltage at T2 less than 88% of battery voltage TR1 CONTROLLER MODULE,
–26 Short–circuit in electronic driver for HYDRAULIC PUMP
RB, SP or FW contactor –117 Wrong control card installed
–27 Voltage in control card is less than 10 VDC. –124 Voltage at T2 is less than 88% of battery volts.
–127 Voltage in control card is less than 10 VDC.
TR1 CONTROLLER MODULE, TRACTION –141 Open thermal protector or
–41 Open thermal protector or motor temperature too high
motor temperature too high –142 Motor sensor input missing (green wire)
–42 Motor sensor input missing (green wire) –143 Motor sensor input missing (yellow wire)
–43 Motor sensor input missing (yellow wire) –144 TR1 did not go OFF correctly
–44 TR1 did not go OFF correctly –145 TR1 did not go ON correctly
–45 TR1 did not go ON correctly –146 Short–circuit across TR1 (SRO Fault).
–46 Short–circuit across TR1 (SRO Fault). –148 Check at T2 is greater than 88% of battery
–48 Check at T2 is greater than 88% of battery volts volts
–50 C1 voltage too low after Contactor L closes. –150 C1 volts low
–51 Capacitor C1 does not charge on start–up. –151 Capacitor C1 does not charge on start–up.
–53 TR1 does not go OFF during plugging. –157 Polarity check, current sensor output voltage
–54 Short–circuit, FWD, REV or 1A electronic driver –180 C1 voltage less than 14 volts after Contactor L
–57 Polarity check, current sensor output voltage has closed.
–181 Battery voltage is less than 14 volts.

* Not used on all models of lift trucks. Status Codes in this group will flash on the display.
NOTE: Motor speed is decreased when a status codes –41 or –141 are indicated.

30
 EV–T100 Motor Controller

TABLE 9. REGISTER MAP FOR CONTROL CARDS ZH AND ZY (TRACTION)

EEPROM PC Hand Description Access Restrictions
Register Register Set (HS) By:
Number Number Number

0 1 1 Fault Code HS or PC Erases when battery is discon-

nected
1 2 2 Creep HS or PC None
2 3 3 Controlled Acceleration HS or PC None
3 4 4 Current Limit HS or PC None
4 5 5 Current Limit (Plugging) HS or PC None
5 6 6 1A Dropout HS or PC None
6 7 7 FW Pickup HS or PC None
7 8 8 FW Dropout HS or PC None
8 9 9 Regenerative Braking Current Limit HS or PC None
9 10 10 Regenerative Start HS or PC None
10 11 11 Speed Limit 1 HS or PC None
11 12 12 Speed Limit 2 HS or PC None
12 13 13 Speed Limit 3 HS or PC None
13 14 14 Battery Voltage Compensation HS or PC None
14 15 15 Battery Voltage Selection HS or PC None
15 16 16 Pedal Position Plugging HS or PC None
16 17 17 Type of Control Card Selection HS or PC None
17 18 18 Steering Pump Time Delay HS or PC None
18 19 19 Maintenance Alert (Tens/Units) HS or PC None
19 20 20 Maintenance Alert HS or PC None
(Thousands/Hundreds)
20 21 21 Maintenance Speed Limit HS or PC None
21 22 22 Mode Reference HS or PC None
22 23 23 Hourmeter (minutes) HS or PC None
23 24 24 Hourmeter (seconds) HS or PC None
24 25 25 Fault Register Data HS or PC GE Temporary Storage
25 26 26 Battery Charge Data HS or PC GE Temporary Storage
26 27 27 Stop PLUGGING Set Point HS or PC None
27 28 28 Fault Count Pointer HS or PC None (Location of last fault re-
corded)
28 29 29 Hourmeter (Tens/Units) HS or PC None
29 30 30 Hourmeter (Thousands/Hundreds) HS or PC None
30 31 Auxiliary Hourmeter (Tens/Units) PC Only Reset to Zero only
31 32 Auxiliary Hourmeter PC Only Reset to Zero only
(Thousands/Hundreds)
32 33 Fault 1 PC Only Reset to Zero only
33 34 BDI 1 PC Only Reset to Zero only
34 35 Hours (Tens/Units) 1 PC Only Reset to Zero only
35 36 Hours (Thousands/Hundreds) 1 PC Only Reset to Zero only

31
EV–T100 Motor Controller

TABLE 9. REGISTER MAP FOR CONTROL CARDS ZH AND ZY (TRACTION) (Continued)

EEPROM PC Hand Function Access Restrictions
Register Function Set (HS) By:
Number Number Function
Number

36 37 Fault 2 PC Only Reset to Zero only

37 38 BDI 2 PC Only Reset to Zero only
38 39 Hours (Tens/Units) 2 PC Only Reset to Zero only
39 40 Hours (Thousands/Hundreds) 2 PC Only Reset to Zero only
40 41 Fault 3 PC Only Reset to Zero only
41 42 BDI 3 PC Only Reset to Zero only
42 43 Hours (Tens/Units) 3 PC Only Reset to Zero only
43 44 Hours (Thousands/Hundreds) 3 PC Only Reset to Zero only
44 45 Fault 4 PC Only Reset to Zero only
45 46 BDI 4 PC Only Reset to Zero only
46 47 Hours (Tens/Units) 4 PC Only Reset to Zero only
47 48 Hours (Thousands/Hundreds) 4 PC Only Reset to Zero only
48 49 Fault 5 PC Only Reset to Zero only
49 50 BDI 5 PC Only Reset to Zero only
50 51 Hours (Tens/Units) 5 PC Only Reset to Zero only
51 52 Hours (Thousands/Hundreds) 5 PC Only Reset to Zero only
52 53 Fault 6 PC Only Reset to Zero only
53 54 BDI 6 PC Only Reset to Zero only
54 55 Hours (Tens/Units) 6 PC Only Reset to Zero only
55 56 Hours (Thousands/Hundreds) 6 PC Only Reset to Zero only
56 57 Fault 7 PC Only Reset to Zero only
57 58 BDI 7 PC Only Reset to Zero only
58 59 Hours (Tens/Units) 7 PC Only Reset to Zero only
59 60 Hours (Thousands/Hundreds) 7 PC Only Reset to Zero only
60 61 Fault 8 PC Only Reset to Zero only
61 62 BDI 8 PC Only Reset to Zero only
62 63 Hours (Tens/Units) 8 PC Only Reset to Zero only
63 64 Hours (Thousands/Hundreds) 8 PC Only Reset to Zero only
64 65 Fault 9 PC Only Reset to Zero only
65 66 BDI 9 PC Only Reset to Zero only
66 67 Hours (Tens/Units) 9 PC Only Reset to Zero only
67 68 Hours (Thousands/Hundreds) 9 PC Only Reset to Zero only
68 69 Fault 10 PC Only Reset to Zero only
69 70 BDI 10 PC Only Reset to Zero only
70 71 Hours (Tens/Units) 10 PC Only Reset to Zero only
71 72 Hours (Thousands/Hundreds) 10 PC Only Reset to Zero only
72 73 Fault 11 PC Only Reset to Zero only
73 74 BDI 11 PC Only Reset to Zero only

32
 EV–T100 Motor Controller

TABLE 9. REGISTER MAP FOR CONTROL CARDS ZH AND ZY (TRACTION) (Continued)

EEPROM PC Hand Function Access Restrictions
Register Function Set (HS) By:
Number Number Function
Number

74 75 Hours (Tens/Units) 11 PC Only Reset to Zero only

75 76 Hours (Thousands/Hundreds) 11 PC Only Reset to Zero only
76 77 Fault 12 PC Only Reset to Zero only
77 78 BDI 12 PC Only Reset to Zero only
78 79 Hours (Tens/Units) 12 PC Only Reset to Zero only
79 80 Hours (Thousands/Hundreds) 12 PC Only Reset to Zero only
80 81 Fault 13 PC Only Reset to Zero only
81 82 BDI 13 PC Only Reset to Zero only
82 83 Hours (Tens/Units) 13 PC Only Reset to Zero only
83 84 Hours (Thousands/Hundreds) 13 PC Only Reset to Zero only
84 85 Fault 14 PC Only Reset to Zero only
85 86 BDI 14 PC Only Reset to Zero only
86 87 Hours (Tens/Units) 14 PC Only Reset to Zero only
87 88 Hours (Thousands/Hundreds) 14 PC Only Reset to Zero only
88 89 Fault 15 PC Only Reset to Zero only
89 90 BDI 15 PC Only Reset to Zero only
90 91 Hours (Tens/Units) 15 PC Only Reset to Zero only
91 92 Hours (Thousands/Hundreds) 15 PC Only Reset to Zero only
92 93 Fault 16 PC Only Reset to Zero only
93 94 BDI 16 PC Only Reset to Zero only
94 95 Hours (Tens/Units) 16 PC Only Reset to Zero only
95 96 Hours (Thousands/Hundreds) 16 PC Only Reset to Zero only
96 97 48 Instrument Panel Display CA–1 HS or PC None
97 98 49 Instrument Panel Display FWPU–1 HS or PC None
98 99 50 Instrument Panel Display SL1–1 HS or PC None
99 100 51 NOT USED  
100 101 52 Instrument Panel Display CA–2 HS or PC None
101 102 53 Instrument Panel Display FWPU–2 HS or PC None
102 103 54 Instrument Panel Display SL1–2 HS or PC None
103 104 55 NOT USED  
104 105 56 Instrument Panel Display CA–3 HS or PC None
105 106 57 Instrument Panel Display FWPU–3 HS or PC None
106 107 58 Instrument Panel Display SL1–3 HS or PC None
107 108 59 NOT USED  
108 109 60 Instrument Panel Display CA–4 HS or PC None
109 110 61 Instrument Panel Display FWPU–4 HS or PC None
110 111 62 Instrument Panel Display SL1–4 HS or PC None
111 112 NOT USED  

33
EV–T100 Motor Controller

TABLE 9. REGISTER MAP FOR CONTROL CARDS ZH AND ZY (TRACTION) (Continued)

EEPROM PC Hand Function Access Restrictions
Register Function Set (HS) By:
Number Number Function
Number

112 113 Secure Hourmeter (Tens/Units) PC Only Read Only

113 114 Secure Hourmeter PC Only Read Only
(Thousands/Hundreds)
114 115 Secure Auxiliary Hourmeter PC Only Read Only
(Tens/Units)
115 116 Secure Auxiliary Hourmeter PC Only Read Only
(Thousands/Hundreds)
116 117 GE Use Only  
117 118 GE Use Only  
118 119 GE Use Only  
119 120 GE Use Only  
120 121 NOT USED  
121 122 NOT USED  
122 123 NOT USED  
123 124 NOT USED  
124 125 NOT USED  
125 126 NOT USED  
126 127 NOT USED  
127 128 NOT USED  

34
 EV–T100 Motor Controller

TABLE 10. REGISTER MAP FOR CONTROL CARD ZP (HYDRAULIC PUMP)

EEPROM PC Hand Function Access Restrictions
Register Function Set (HS) By:
Number Number Function
Number

0 1 1 Fault Code HS or PC Erases when battery is discon-

nected
1 2 2 Internal Resistance Compensation HS or PC None
Start
2 3 3 Controlled Acceleration HS or PC None
3 4 4 Current Limit HS or PC None
4 5 5 NOT USED  
5 6 6 NOT USED  
6 7 7 Internal Resistance Compensation HS or PC None
Rate
7 8 8 NOT USED  
8 9 9 NOT USED  
9 10 10 NOT USED  
10 11 11 Speed Limit (SL1) HS or PC None
11 12 12 Speed Limit (SL2) HS or PC None
12 13 13 Speed Limit (SL3) HS or PC None
13 14 14 Speed Limit (SL4) HS or PC None
14 15 15 NOT USED  
15 16 16 Speed and Torque Compensation HS or PC None
16 17 17 Type of Control Card Selection HS or PC None
17 18 18 NOT USED  
18 19 19 NOT USED  
19 20 20 NOT USED  
20 21 21 NOT USED  
21 22 22 Mode Reference HS or PC Reference for instrument pan-
el display when battery power
is applied
22 23 23 Hourmeter (minutes) HS or PC None
23 24 24 Hourmeter (seconds) HS or PC None
24 25 25 Fault Register Data HS or PC GE Temporary Storage
25 26 26 NOT USED  
26 27 27 NOT USED  
27 28 28 Fault Count Pointer HS or PC None (Location of last fault re-
corded)
28 29 29 Hourmeter (Tens/Units) HS or PC None
29 30 30 Hourmeter HS or PC None
(Thousands/Hundreds)
30 31 Auxiliary Hourmeter PC Only None
(Tens/Units)
31 32 Auxiliary Hourmeter PC Only None
(Thousands/Hundreds)

35
EV–T100 Motor Controller

TABLE 10. REGISTER MAP FOR CONTROL CARD ZP (HYDRAULIC PUMP) (Continued)
EEPROM PC Hand Function Access Restrictions
Register Function Set (HS) By:
Number Number Function
Number

32 33 Fault 1 PC Only Reset to Zero only

33 34 NOT USED  
34 35 Hours (Tens/Units) 1 PC Only Reset to Zero only
35 36 Hours (Thousands/Hundreds) 1 PC Only Reset to Zero only
36 37 Fault 2 PC Only Reset to Zero only
37 38 NOT USED  
38 39 Hours (Tens/Units) 2 PC Only Reset to Zero only
39 40 Hours (Thousands/Hundreds) 2 PC Only Reset to Zero only
40 41 Fault 3 PC Only Reset to Zero only
41 42 NOT USED  
42 43 Hours (Tens/Units) 3 PC Only Reset to Zero only
43 44 Hours (Thousands/Hundreds) 3 PC Only Reset to Zero only
44 45 Fault 4 PC Only Reset to Zero only
45 46 NOT USED  
46 47 Hours (Tens/Units) 4 PC Only Reset to Zero only
47 48 Hours (Thousands/Hundreds) 4 PC Only Reset to Zero only
48 49 Fault 5 PC Only Reset to Zero only
49 50 NOT USED  
50 51 Hours (Tens/Units) 5 PC Only Reset to Zero only
51 52 Hours (Thousands/Hundreds) 5 PC Only Reset to Zero only
52 53 Fault 6 PC Only Reset to Zero only
53 54 NOT USED  
54 55 Hours (Tens/Units) 6 PC Only Reset to Zero only
55 56 Hours (Thousands/Hundreds) 6 PC Only Reset to Zero only
56 57 Fault 7 PC Only Reset to Zero only
57 58 NOT USED  
58 59 Hours (Tens/Units) 7 PC Only Reset to Zero only
59 60 Hours (Thousands/Hundreds) 7 PC Only Reset to Zero only
60 61 Fault 8 PC Only Reset to Zero only
61 62 NOT USED  
62 63 Hours (Tens/Units) 8 PC Only Reset to Zero only
63 64 Hours (Thousands/Hundreds) 8 PC Only Reset to Zero only
64 65 Fault 9 PC Only Reset to Zero only
65 66 NOT USED  
66 67 Hours (Tens/Units) 9 PC Only Reset to Zero only
67 68 Hours (Thousands/Hundreds) 9 PC Only Reset to Zero only
68 69 Fault 10 PC Only Reset to Zero only
69 70 NOT USED  

36
 EV–T100 Motor Controller

TABLE 10. REGISTER MAP FOR CONTROL CARD ZP (HYDRAULIC PUMP) (Continued)
EEPROM PC Hand Function Access Restrictions
Register Function Set (HS) By:
Number Number Function
Number

70 71 Hours (Tens/Units) 10 PC Only Reset to Zero only

71 72 Hours (Thousands/Hundreds) 10 PC Only Reset to Zero only
72 73 Fault 11 PC Only Reset to Zero only
73 74 NOT USED  
74 75 Hours (Tens/Units) 11 PC Only Reset to Zero only
75 76 Hours (Thousands/Hundreds) 11 PC Only Reset to Zero only
76 77 Fault 12 PC Only Reset to Zero only
77 78 NOT USED  
78 79 Hours (Tens/Units) 12 PC Only Reset to Zero only
79 80 Hours (Thousands/Hundreds) 12 PC Only Reset to Zero only
80 81 Fault 13 PC Only Reset to Zero only
81 82 NOT USED  
82 83 Hours (Tens/Units) 13 PC Only Reset to Zero only
83 84 Hours (Thousands/Hundreds) 13 PC Only Reset to Zero only
84 85 Fault 14 PC Only Reset to Zero only
85 86 NOT USED  
86 87 Hours (Tens/Units) 14 PC Only Reset to Zero only
87 88 Hours (Thousands/Hundreds) 14 PC Only Reset to Zero only
88 89 Fault 15 PC Only Reset to Zero only
89 90 NOT USED  
90 91 Hours (Tens/Units) 15 PC Only Reset to Zero only
91 92 Hours (Thousands/Hundreds) 15 PC Only Reset to Zero only
92 93 Fault 16 PC Only Reset to Zero only
93 94 NOT USED  
94 95 Hours (Tens/Units) 16 PC Only Reset to Zero only
95 96 Hours (Thousands/Hundreds) 16 PC Only Reset to Zero only
96 97 48 Instrument Panel Display CA–1 HS or PC None
97 98 49 Instrument Panel Display SL2–1 HS or PC None
98 99 50 Instrument Panel Display SL4–1 HS or PC None
99 100 51 NOT USED  
100 101 52 Instrument Panel Display CA–2 HS or PC None
101 102 53 Instrument Panel Display SL2–2 HS or PC None
102 103 54 Instrument Panel Display SL4–2 HS or PC None
103 104 55 NOT USED  
104 105 56 Instrument Panel Display CA–3 HS or PC None
105 106 57 Instrument Panel Display SL2–3 HS or PC None
106 107 58 Instrument Panel Display SL4–3 HS or PC None
107 108 59 NOT USED  

37
EV–T100 Motor Controller

TABLE 10. REGISTER MAP FOR CONTROL CARD ZP (HYDRAULIC PUMP) (Continued)
EEPROM PC Hand Function Access Restrictions
Register Function Set (HS) By:
Number Number Function
Number

108 109 60 Instrument Panel Display CA–4 HS or PC None

109 110 61 Instrument Panel Display SL2–4 HS or PC None
110 111 62 Instrument Panel Display SL4–4 HS or PC None
111 112 NOT USED  
112 113 Secure Hourmeter (Tens/Units) PC Only Read Only
113 114 Secure Hourmeter PC Only Read Only
(Thousands/Hundreds)
114 115 Secure Auxiliary Hourmeter PC Only Read Only
(Tens/Units)
115 116 Secure Auxiliary Hourmeter PC Only Read Only
(Thousands/Hundreds)
116 117 GE Use Only  
117 118 GE Use Only  
118 119 GE Use Only  
119 120 GE Use Only  
120 121 NOT USED  
121 122 NOT USED  
122 123 NOT USED  
123 124 NOT USED  
124 125 NOT USED  
125 126 NOT USED  
126 127 NOT USED  
127 128 NOT USED  

38
 EV–T100 Motor Controller

STATUS CODE CHARTS

Status Description Cause Of Status Indication

Code No display on the instrument panel display or No input voltage to the control card or the display
NONE the Hand Set unit.

Memory Indication of Fault

Recall No display on the instrument panel display or the
No Hand Set
Possible Cause
Emergency disconnect switch is open
Make sure the emergency disconnect switch is closed
correctly.
No control voltage EMERGENCY LINE
Circuit Make sure the key switch is ON and there is voltage DISCONNECT CONTACTOR
L
Traction between PB1 and battery negative. Check that there
and is voltage between TB4 and battery negative. POWER RB
FUSE 1
Hydraulic Open circuit between control card Plug Y and the
Pump instrument panel display or the Hand Set:
CONTROL
Check for an open circuit or loose connections FUSE 3
between each wire going to the plug on the control INTERRUPTOR
card and the instrument panel display or the Hand D7
Set.
Malfunction of the instrument panel display or the
Hand Set: TB4 PZ7
Replace the instrument panel display.
NOTE: A blank display, during operation, can
indicate that the regenerative braking diode has a
short–circuit. The symptom for this malfunction is;
no operation and traction power fuse open. If the
diode has a short–circuit, there is a short–circuit
across the battery as soon as the regenerative
braking contactor closes and the fuse will open. If
the regenerative braking diode is open, there will be
no indicated fault except that there will be stiff
plugging and no regenerative braking.

Status Description Cause Of Status Indication

Code No voltage from seat switch This Status Code will be indicated when TB3 is
–01 less than 50% of battery voltage.

Memory Indication of Fault

Recall Forward or Reverse contactor will not close.
KEY SEAT
No Possible Cause SWITCH SWITCH
Seat switch malfunction or needs adjustment.
Check that the seat switch closes correctly.
Open circuit between battery positive and TB3 TB4 TB3
Check for loose connections or broken wires
Circuit between the seat switch and TB3, between the key
Traction switch and the battery positive side of the seat
switch, between the seat switch and TB4.

39
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code FORWARD direction switch is closed when the This Status Code will be indicated when TB5 is
key switch is turned to ON. greater than 60% of battery voltage when the key
–02 switch is turned to ON.
Memory Indication of Fault
Recall Forward contactor will not close. Static Return to
No OFF (SRO) circuit activated.
Possible Cause
FORWARD direction switch is closed when the key START
SEAT
switch is turned to ON. SWITCH SWITCH
Move the direction control lever to NEUTRAL and
then select a direction.

Circuit FORWARD direction switch has a short–circuit.

TB4 TB3
Traction Replace or adjust the direction switch so that it
opens when the direction control lever is in TB2
NEUTRAL. FORWARD
SWITCH
Short–circuit between TB2 and TB5.
TB5
Disconnect the wire from TB5 and check for a
short–circuit between TB2 and the wire.
Malfunction of the control card.
Disconnect the wire from TB5. Check for less than
60% of battery voltage at TB5.

Status Description Cause Of Status Indication

Code REVERSE direction switch is closed when the This Status Code will be indicated when TB6 is
key switch is turned to ON. greater than 60% of battery voltage when the key
–03 switch is turned to ON.
Memory Indication of Fault
Recall Reverse contactor will not close. Static Return to
No OFF (SRO) circuit activated.
Possible Cause
REVERSE direction switch is closed when the key
switch is turned to ON. SEAT
SWITCH
Move the direction control lever to NEUTRAL and
then select a direction. START
SWITCH
Circuit REVERSE direction switch has a short–circuit.
TB4 TB3
Traction Replace or adjust the direction switch so that it
TB2
opens when the direction control lever is in
NEUTRAL.
REVERSE
Short–circuit between TB2 and TB6. SWITCH
TB6
Disconnect the wire from TB6 and check for a
short–circuit between TB2 and the wire.
Malfunction of the control card.
Disconnect the wire from TB6. Check for less than
60% of battery voltage at TB6.

40
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

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

NEGATIVE

Status Description Cause Of Status Indication

Code Accelerator actuated and no direction switch is This Status Code will be indicated when TB5 and
selected. TB6 are less than 60% of battery voltage and TB1
–06 is less than 2.5 volts.
Memory Indication of Fault
Recall Forward or Reverse contactor will not close. SEAT
SWITCH
No Possible Cause
Accelerator pedal is actuated before a direction START
SWITCH
switch is closed.
TB4 TB3
The Status Code will be cleared when a direction
switch is closed or the accelerator pedal is released. TB2

Malfunction of the circuit for the FORWARD or REVERSE

Circuit REVERSE switches. FORWARD SWITCH
TB1 PZ6 TB5
SWITCH
Traction Check the direction switches to make sure they close
when the direction control lever is moved to that TB6
position.
Open circuit between the direction switches and
TB5 or TB6. ACCELERATOR
POTENTIOMETER
Check for an open circuit or loose connections in the
wires for the direction control circuits to TB5 or TB6.

NEGATIVE

41
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Accelerator input voltage is too high. This Status Code will be indicated when the
accelerator input voltage at TB1 is higher than
–07 3.7 volts and a direction contactor is closed.
Memory Indication of Fault
Recall Forward or Reverse contactor will close, but the motor
No controller will not operate when the accelerator pedal is
actuated or the –07 Status Code clears when the lift truck
begins to accelerate.
Possible Cause
Accelerator potentiometer has a malfunction or needs
adjustment.
TB1 PZ6
The correct output voltage at TB1 is 3.46 to 3.69 volts when
Circuit the START switch is closed. Repair or adjust the
Traction accelerator potentiometer or START switch so that the
voltage is correct when the accelerator pedal is actuated.
Open circuit between battery negative and TB1 in the ACCELERATOR
accelerator input circuit. POTENTIOMETER
Check for broken wires or loose connections in the
accelerator potentiometer circuit.
Short–circuit from battery positive to a wire in the
accelerator input circuit. NEGATIVE
Disconnect the wire from TB1 and measure the voltage
between the end of the wire and battery negative. The
correct voltage is zero for an accelerator with a
potentiometer.

Status Description Cause Of Status Indication

Code Accelerator input voltage is too low after the key This Status Code will be indicated when the
switch is closed. accelerator input voltage at TB1 is less than
–08 3.0 volts and the battery connector, or the
seat switch or the key switch are opened and
closed.
Memory Indication of Fault
Recall Forward or Reverse contactor will not close.
No Possible Cause
Accelerator potentiometer has a malfunction or needs
adjustment.
The correct output voltage at TB1 is more than 3.0 volts.
Repair or adjust the accelerator potentiometer so that it will TB1 PZ6
correctly change from 3.5 to less than 0.5 volts (minimum
0.30 volts) when the accelerator pedal is actuated.
Circuit
Short–circuit between battery negative and TB1 in the
Traction accelerator input circuit.
ACCELERATOR
Disconnect wire from TB1. Check for short–circuit from the POTENTIOMETER
end of the wire to battery negative. The correct resistance
is greater than 4.7k ohms.
Control card malfunction.
Disconnect the wire from TB1 and measure the voltage
between TB1 and battery negative. The correct voltage is NEGATIVE
greater than 4.5 volts. If the voltage is wrong, replace the
control card.

42
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Both FORWARD and REVERSE direction This Status Code will be indicated when TB5 and
switches are closed at the same time. TB6 are greater than 60% of battery voltage at the
–09 same time.
Memory Indication of Fault
Recall Forward or Reverse contactor will not close.
No Possible Cause
TB2
FORWARD or REVERSE direction switches are
welded closed or need adjustment. REVERSE
Replace or adjust the direction switches to make sure TB5 FORWARD SWITCH
that they are both open when the direction control TB1 PZ6 SWITCH
lever is in NEUTRAL.. TB6

Short–circuit between battery positive and TB5 or

Circuit
TB6.
Traction ACCELERATOR
Disconnect the wires from TB5 and TB6 and check for
POTENTIOMETER
a short–circuit between the end of the wire and the
battery positive side of the direction switch.
Control card malfunction.
Disconnect the wires and measure the voltage at TB5
and TB6. The correct voltage will be less than 60% of NEGATIVE
battery voltage.

Status Description Cause Of Status Indication

Code The START switch is closed when the key This Status Code will be indicated when TB2 is
switch is closed and voltage is applied to the greater than 60% of battery voltage when the key
–11 control card. switch is closed.
Memory Indication of Fault
Recall Forward or Reverse contactor will not close.
No Possible Cause
START switch needs adjustment or is damaged. SEAT
Input voltage must be less than 60% of battery voltage SWITCH
when the key switch is closed. Replace or adjust the
START switch. START
SWITCH
Short–circuit between battery positive and TB2 in
START switch circuit. TB4 TB3
Circuit
Disconnect the wire from TB2. Check for a TB2
Traction short–circuit between the end of the wire and the
battery positive. Resistance must be greater than 4.7 REVERSE
K ohms. TB5 FORWARD SWITCH
TB1 SWITCH
Control card malfunction. TB6
Disconnect the wire from TB3 and measure the
voltage from TB3 to battery negative. If the voltage is
not zero, replace the control card.

43
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Battery voltage is too low. This Status Code will be indicated when the
battery volts are less than 1.95 volts per cell when
–15 the key switch is turned to ON.
Memory Indication of Fault
Recall Forward or Reverse contactor will not close.
No Possible Cause
Discharged battery. MINIMUM
BATTERY
Check the battery for the correct open circuit voltage NOMINAL VOLTAGE AT
as shown in the illustration at right and charge the BATTERY 1.95 VOLTS
battery as required. VOLTS PER CELL

Bad connection at battery connector or in the power 36 35.1

48 46.8
cables.
Circuit 72 70.2
Check the power cables and the battery connector. 80 78.0
Traction
Battery malfunction.
Check each battery cell for the correct voltage (greater
than 1.95 volts per cell). Replace or repair the battery.
Control card needs adjustment.
Check Function 15 for the correct adjustment for the
battery that is being used. See the instructions for the
Hand Set. Make the correct adjustments.

Status Description Cause Of Status Indication

Code Battery voltage is too high. This Status Code will be indicated when the
voltage at TB5 is greater than 60% of battery
–16 volts when the key switch is turned to ON.
Memory Indication of Fault MAXIMUM
BATTERY
Recall Forward or Reverse contactor will not close. NOMINAL VOLTAGE AT
BATTERY 2.40 VOLTS
No Possible Cause VOLTS PER CELL

Control card needs adjustment. 36 43.2

48 57.6
Check Function 15 for the correct adjustment for the
72 86.4
battery that is being used. See the instructions for the Hand
80 96.0
Set. Make the correct adjustments.
Battery is charged wrong or wrong battery is installed.
Circuit Check the battery for the correct open circuit voltage (see
the table in the illustration at the right). If the battery voltage
Traction is too high, check the battery charger for the correct output
voltage.

Status Description Cause Of Status Indication

Code Selection for type of control card is wrong. This Status Code will be indicated when the
control card type selection is set to a wrong
–17 number.
Memory Indication of Fault
Recall Forward or Reverse contactor will not close.
No Possible Cause
Control card type selection is wrong.
Circuit
Check Function 17 in the instructions for the Hand Set.
Traction Make the correct adjustments for the type of control card.

44
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Voltage to 3–wire accelerator potentiometer is less than 0.36 This Status Code will be indicated
volts when the control card type
–21 selection is set to a wrong number.
Memory Indication of Fault
Recall The Motor Controller will not operate.
No Possible Cause
Accelerator potentiometer needs adjustment or is damaged. TB1 PZ6

Input voltage at TB1 must be greater than 0.36 volts.

Short–circuit between battery negative and TB1 in accelerator input
circuit.
ACCELERATOR
Disconnect wire from TB1 and check for short–circuit from end of wire POTENTIOMETER
Circuit to battery negative. The correct resistance is 3 to 9 kohms when the
accelerator pedal is not pressed.
Traction
Open–circuit between accelerator potentiometer and PZ6.
Check for +4.5 volts between PZ6 and battery negative. NEGATIVE

Status Description Cause Of Status Indication

Code Forward or Reverse contactor or any other contactor has a This Status Code will be indicated
short–circuit or low current to the coil. when there is a current draw in a
–23 contactor coil of less than 100 ma.
Memory Indication of Fault
Recall Forward or Reverse contactor will not close. The Status Code +
No can change between code –23 and code –24. Do all of the +
Possible Cause checks for this Status Code. If the problem is not F +
found, do the checks in code –24. R
1A +
Possible Cause PB4
+
PB5
L
Malfunction of the coil circuit for Forward and Reverse +
PS
contactors. PB6 +
FW
Check for open circuit or loose connection between PB4 and the PB2
Circuit positive side of the Forward contactor coil and between PB5 and the RB
Traction positive side of the Reverse contactor coil. PB3
Remove Plug B. Check the resistance in the wire from PB4 to the PA1
positive side of the Forward contactor coil. The correct value is 10 PZ8
to 14 ohms. Do the same check for the Reverse contactor coil.
Check for an open Forward–Reverse control fuse.
Malfunction of the coil circuit for 1A, RB, PS, or FW contactors. NOTE: The PS coil does not apply when the lift
truck has “On–Demand” power steering.
Remove Plug B. Check the resistance in the wire from the positive
side of each contactor coil to its plug connection. The correct value
is 10 to 14 ohms. The coil resistance for the power steering
contactor is 52 ohms.

45
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code T2 voltage is less than 88% of battery voltage. This Status Code will be indicated when T2
voltage is less than 88% of battery voltage
–24 and the circuit for the direction contactors is
energized.

Memory Indication of Fault

Recall The motor controller does not operate. The Status Code can
L

No change between code –23 and code –24. Do all of the Possible
C1 RB D4 D3
Cause checks for this Status Code. If the problem is not found,
do the checks in code –23.
Possible Cause
Most common cause is that the contacts on one of the direction +
contactors or the RB contactor does not close correctly to make
R
an electrical connection. – F
Circuit Clean the contact of the direction contactors and the RB contactor
F R
Traction with alcohol. New contacts can have a surface condition that D7
prevents conducting electric current. Check that the contacts
T2
close correctly. 1A
Malfunction of coil circuit for Forward and Reverse contactor. TR1
Check for welded contacts or contactors that do not close
correctly.
Malfunction of RB contactor. NOTE: The PS coil does not apply when the
lift truck has “On–Demand power steering.
Check that the contacts and contactor will close correctly.
Check for an open circuit or loose connections between the
positive side of the RB contactor coil and PB2. +
Open motor circuit. +
F +
R
Check for an open circuit or loose connections in the motor circuit 1A +
from the A1 connection to the A2 connection on the SCR control PB4 +
panel. L
PB5 +
PS
Malfunction of the 1A, RB, PS, or FW contactors. PB6 FW +
Do the checks described in Status Code –23. PB2 RB
PB3
PA1
PZ8

Status Description Cause Of Status Indication

Code Electronic driver in control card for the RB, PS, or FW This Status Code will be indicated when
contactor has a short–circuit. there is a short–circuit in the electronic
–26 driver for the FW, RB, or PS contactor coil.

Memory Indication of Fault

Recall The FW, RB, or PS contactor closes immediately when the
No key switch is closed.
+
Possible Cause +
FW
Malfunction of an electronic driver in the control card. +
RB
Replace the control card. PS
PA1
Circuit
PZ8
Traction
PB3

46
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Voltage in the control card is less than 10 VDC. This Status Code will be indicated when the
power supply in the control card is less than
–27 10 volts.
Memory Indication of Fault
Recall The FORWARD or REVERSE contactor open and close,
Yes and then can only be closed by opening and closing the key
switch.
T2
Possible Cause
Discharged battery.
PZ5
Check that the battery is correctly charged. The voltage can TP PZ2
decrease to less than 10 VDC during a heavy load. PZ9 BLUE
Circuit VIOL
TR1
Traction Loose connection at PB1. PZ4 RED
SUPPRESSOR
Check that the wire connection at PB1 is correct. PZ3 BROWN
Malfunction in the control card. PZ1 WHT/BRN
Replace the control card. 1A
NEG

Status Description Cause Of Status Indication

Code Possible fault of suppressor across D3. This Status Code can also be indicated if a
suppressor for D3 has a fault.
–27
Memory Indication of Fault
Recall POS
There can be a difference in sound during operation. The
Yes pitch of the sound can have a variation.
Possible Cause
D3
Missing suppressor
It can be necessary to install an additional suppressor across
diode D3 if only one suppressor is installed. SUPPRESSORS

Circuit A suppressor for D3 has a fault

T2
Traction If there are two suppressors, one suppressor can have a fault.
There is no good suppressor check, so replace both
suppressors.

47
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Open thermal protector or motor controller is too hot. This Status Code will be indicated when the
voltage between PZ2 and PZ5 is greater 0.8
–41 volts.
Memory Indication of Fault
Recall The traction motor has reduced power on no power in the
No TR1 range.
Possible Cause
Open circuit, thermal protector.
Check for a loose or broken wire between the following points: WHT/VIOL
PZ5
VIOL wire between thermal protector and PZ2
WHT/VIOL wire between thermal protector and PZ5.
Malfunction of thermal protector.
Circuit PZ2
Disconnect the wires from PZ2 and PZ5. When the THERMAL VIOL
Traction temperature is approximately 25°C (75°F), measure the PROTECTOR
resistance between the VIOL and WHT/VIOL wire. The
correct resistance is approximately 300 ohms. TR1 must be
replaced if the thermal protector is bad.
Thermal protector is operating because motor controller is
too hot.
Permit the motor controller to cool.

Status Description Cause Of Status Indication

Code Input missing from motor current sensor. This Status Code will be indicated when the
voltage between PZ12 and PZ5 is greater
–42 than 0.8 volts and no current is flowing
through the traction motor circuit.
Memory Indication of Fault
Recall No power to the traction motor in the TR1 control range. WHITE
No Possible Cause
YELLOW
MOTOR PZ13
Open sensor wire circuit to PZ12.
CURRENT
SENSOR PZ12 PZ14
Check for a loose or broken wire (green wire) between the GREEN
current sensor and PZ12 on the control card.
A2
Circuit
Traction

Status Description Cause Of Status Indication

Code Input missing from motor current sensor. This Status Code will be indicated when the
voltage between PZ12 and PZ13 is less
–43 than 0.1 volts and no current is flowing
through the traction motor circuit.
Memory Indication of Fault
Recall No power to the traction motor in the control range. WHITE
No Possible Cause
YELLOW
MOTOR PZ13
Open sensor wire circuit to PZ13.
CURRENT
SENSOR PZ12 PZ14
Check for a loose or broken wire (yellow wire) between the GREEN
current sensor and PZ13 on the control card.
A2
Circuit
Traction

48
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Power Transistor TR1 does not go to OFF correctly. This Status Code will be indicated when
(PMT FAULT) TR1 does not go to OFF correctly
–44 during operation.
Memory Indication of Fault
Recall Forward or Reverse contactors open and close, then will only
T2
Yes close when the key switch is opened and closed.
Possible Cause
PZ5
Malfunction of TR1. TP PZ2
PZ9 BLUE
Check for an open circuit or loose connections between VIOL
TR1
transistor and PZ4 (RED wire). PZ4 RED
SUPPRESSOR
The OFF time for TR1 is not within specifications. No easy test PZ3 BROWN
is possible. Replace TR1 after the other checks have been done
Circuit and no other problem is found. PZ1 WHT/BRN
Traction 1A
NEG

Status Description Cause Of Status Indication

Code Power Transistor TR1 does not go to ON correctly. This Status Code will be indicated when
TR1 does not go ON correctly during
–45 operation.
Memory Indication of Fault
Recall Forward or Reverse contactors open and close, then will only
T2
Yes close when the key switch is opened and closed.
Possible Cause
PZ5
Malfunction of TR1 circuit. TP PZ2
PZ9 BLUE
Check for an open circuit or loose connections between TR1 VIOL
TR1
and PZ4 (RED wire). PZ4 RED
SUPPRESSOR
Check for an open circuit or loose connections between TR1 PZ3 BROWN
and D3 suppressor and PZ9 (BLUE wire).
Circuit PZ1 WHT/BRN
Malfunction of TR1.
Traction 1A
An open or bad gate circuit to TR1. No easy test is possible.
Replace TR1 after the other checks have been done and no NEG
other problem is found.

Status Description Cause Of Status Indication

Code Short–circuit across TR1. (SRO Fault) This Status Code will be indicated when the
voltage at T2 is less than 12% of battery
–46 voltage.
Memory Indication of Fault
Recall Line Contactor L will not close. Forward or Reverse
T2
No contactors will not close.
Possible Cause
PZ5
Malfunction of TR1 circuit. TP PZ2
PZ9 BLUE
Check for a short–circuit across TR1. VIOL
TR1
Malfunction of Contactor 1A. PZ4 RED
SUPPRESSOR
Check for welded contacts on Contactor 1A that will hold PZ3 BROWN
Circuit the contactor closed. PZ1 WHT/BRN
Traction Malfunction of Suppressor. 1A

Check for a short–circuit across the suppressor for TR1. NEG

49
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Voltage check at T2 is greater than 88% of battery This Status Code will be indicated when a
voltage. voltage check at T2 is greater than 88% of
–48 battery voltage.
Memory Indication of Fault
Recall Line Contactor L will not close. Forward or Reverse
L

No contactors will not close.

C1 RB D4 D3
Possible Cause
Malfunction of Forward or Reverse contactors.
Check for welded contacts that hold a Forward or Reverse
contactor closed. +
Check for slow operation of a Forward or Reverse R
contactor. – F
Circuit
Malfunction of diode D3 circuit. F R
Traction D7
Check for a short–circuit across D3.
T2
Check for a short–circuit across the suppressor for D3. 1A
TR1

Status Description Cause Of Status Indication

Code Low voltage on capacitor C1 after line contactor L This Status Code will be indicated when the
closes. capacitor C1 voltage is less than 85% of
–50 battery voltage at start–up.
Memory Indication of Fault
Recall Forward or Reverse contactor will close. Motor controller
No does not operate.
L
Possible Cause
WHITE
Malfunction of Line Contactor L C1
YELLOW PZ13
Check line contactor L for contacts that do not close
correctly. PZ12 PZ14
GREEN
Check for an open circuit or loose connection in the power RB
cable and bus bar connections. +
Circuit A2
Traction
Open Power Fuse F1. –
Check Fuse 1 for an open circuit. A1
No battery voltage at PZ14.
Check for battery voltage between Fuse 1 and PZ14.
Check for a loose connections at PZ14.

50
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Capacitor C1 does not charge on start–up. This Status Code will be indicated when the
capacitor C1 voltage is less than 85% of
–51 battery voltage at start–up.
Memory Indication of Fault
Recall Line contactor L does not close.
No Possible Cause
Circuit Capacitor bank has a problem.
Traction Check the capacitor bank for a bad capacitor. The
capacitor bank is charged through a resistor during
startup. If a capacitor does not charge correctly, the
resistor becomes hot. The control card checks the
temperature of the resistor and if the resistor
becomes too hot, the control card stops the
startup.
If many startups are made during troubleshooting,
the resistor becomes too hot and this status code
will occur.
NOTE: This status code “–51” will often occur
instead of “–151” when the fault is in the controller
L
for the hydraulic pump. A fault in in one capacitor
bank can indicate a fault in the other capacitor
C1 RB D3
bank. A status code “–51” will often occur before a D4
status code “–151”.
Check for open or loose connections in the
capacitor bank. +
Open control fuse. R
– F
Check for an open control fuse F3.
F R
Control card has a problem. D7
Replace the control card. 1A
Additional Possible Cause TR1
On units with the standard display panel and
contactor hydraulics, error code –51 can occur if
the Lift or Tilt levers are operated too soon after the
key is moved to the ON position.
Check for normal operation without moving the
control levers. The system is operating normally if
there is normal operation without moving the
control levers.
The fault normally occurs when the key is left in the
ON position and the Battery Disconnect Knob is
used to deenergize the lift truck. When the knob
energizes the lift truck again and the operator
quickly moves the control levers, the capacitors do
not have enough time to charge and the error
occurs.
See Parts–Service Gram F–G–32(E) to correct this
problem.

51
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code TR1 does not go OFF correctly during plugging This Status Code will be indicated when any
cycle. (PMT Fault) failure of TR1 to go OFF during the plugging
–53 cycle.
Memory Indication of Fault
Recall Forward or Reverse contactors open and close, then will
L

Yes only close when the key switch is opened and closed.
C1 RB D4 D3
Possible Cause
Malfunction of TR1.
Check for open circuit or loose connections between
transistor and PZ4 (RED wire). +
The OFF time for TR1 is not within specifications. No field R
test is possible. Replace TR1 after the other checks have – F
Circuit been done and no other problem is found.
F R
Traction D7
T2
1A
TR1

Status Description Cause Of Status Indication

Code Short–circuit in an electronic driver for the Forward, This Status Code will be indicated when the
or Reverse, or 1A contactor. control card has a short–circuit in one of the
–54 electronic drivers for the Forward, or
Reverse, or 1A contactor.
Memory Indication of Fault
Recall Motor controller will not operate. +
No Possible Cause F
+
+
R
Fuse 7 is open. 1A
PB4
Check for a short–circuit that can cause Fuse 7 to open.
PB5
Replace Fuse 7.
Circuit PB6
Control card malfunction.
Traction Replace the control card.

52
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Polarity check of the output voltage from the current This Status Code will be indicated when
sensor. the input voltage to PZ12 and PZ13 is the
–57 wrong polarity.
Memory Indication of Fault
Recall Forward or Reverse contactors open and close, then will
No only close when the key switch is opened and closed.
Possible Cause WHITE

The YELLOW and GREEN wires from the current sensor to

the control card are connected wrong. MOTOR YELLOW
PZ13
CURRENT
Check the YELLOW wire is connected to PZ13 and the SENSOR PZ12 PZ14
GREEN wire is connected to PZ12. GREEN

Circuit Check from the current sensor to the control card for open A2
or loose connections.
Traction
Power cables are connected wrong in motor circuit.
Check that the power cables are connected correctly in the
motor circuit.

Status Description Cause Of Status Indication

Code No voltage input from current sensor for regenerative This Status Code will be indicated when the
braking (GREEN wire).
–70 input signal to PZ10 is missing.

Memory Indication of Fault

RB SENSOR
Recall Motor controller will not operate.
Yes Possible Cause
YELLOW D7
Open circuit in current sensor circuit for the regenerative WIRE
braking. GREEN
WIRE
Check for a broken GREEN wire from the current RB sensor
Circuit to PZ10. Check for loose connections or a broken wire at the PZ11 PZ10
current sensor. Check PZ10 for a loose plug or pin connection.
Traction

Status Description Cause Of Status Indication

Code No voltage input from current sensor for regenerative This Status Code will be indicated when the
braking (YELLOW wire).
–71 input signal to PZ11 is missing.

Memory Indication of Fault

RB SENSOR
Recall Motor controller will not operate.
No Possible Cause
YELLOW D7
Open circuit in current sensor circuit for the regenerative WIRE
braking. GREEN
WIRE
Check for a broken YELLOW wire from the current RB sensor
Circuit to PZ11. Check for loose connections or a broken wire at the PZ11 PZ10
current sensor. Check PZ11 for a loose plug or pin connection.
Traction

53
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Regenerative braking contactor does not close. This Status Code will be indicated when the
control card is ready to operate and the
–72 voltage at PZ7 Is less than 50% of battery
volts.
Memory Indication of Fault
RB
Recall Regenerative braking control does not operate. CONTACTS
No Possible Cause
Open circuit.
Check for open circuit or loose connections between PZ7
and the A2 connection of the RB contactor.
Circuit A2 D7
Check for open circuit or loose connections between D7 TRACTION
Traction and the A2 connection (positive connection) of the RB MOTOR
contactor. PZ7
A1

Status Description Cause Of Status Indication

Code Regenerative braking contactor does not open or This Status Code will be indicated when the
opens slowly. (PMT Fault) RB contacts do not open within 100
–73 milliseconds after power is removed from
the RB contactor coil.
Memory Indication of Fault
RB
Recall Forward or Reverse contactors open and close, then will CONTACTS
Yes only close when the key switch is opened and closed.
Possible Cause
RB contactor malfunction.
Check the RB contactor for smooth operation and wear on
the moving parts. A2 D7
TRACTION
Short–circuit to battery positive voltage at the PZ7 MOTOR
input. PZ7
Circuit A1
Traction Check for a short–circuit between PZ7 and battery positive.

54
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Regenerative braking contactor closes slowly. This Status Code will be indicated when
(PMT Fault) the RB contacts do not close within 100
–74 milliseconds after power is applied to the
RB contactor coil.
Memory Indication of Fault
Recall Forward or Reverse contactors open and close, then will
Yes only close when the key switch is opened and closed.
Possible Cause RB
CONTACTS
RB contactor malfunction.
Check the RB contactor for smooth operation and wear on
the moving parts.
Input signal to PZ7 is not regular.
Circuit Check for open circuit or loose connections in the PA6
A2 D7
circuit from PZ7 to the A2 connection (positive connection) TRACTION
Traction of the RB contactor. MOTOR
PZ7
Malfunction of coil circuit for RB contactor.
A1
Check the resistance of the RB contactor coil. The correct
resistance is 10 to 14 ohms.
Check for loose connections from PZ8 to the negative side
of the RB coil.
Check for loose connections from battery positive to the
positive side of the RB coil.

Status Description Cause Of Status Indication

Code Voltage on C1 too high during regenerative braking. This Status Code will be indicated when the
(PMT Fault) voltage on C1 is greater than 96 volts during
–76 regenerative braking.
Memory Indication of Fault
Recall Forward or Reverse contactors open and close, then will
L

Yes only close when the key switch is opened and closed.
C1 RB D4 D3
Possible Cause
Bad connection or not regular connection in battery
power circuit.
Emergency power disconnect opened during +
regenerative braking.
R
Line contactor L opened during regenerative braking. – F
Circuit
Check the power fuse and battery connections that can F R
Traction open during regenerative braking. D7

1A
TR1

55
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Capacitor voltage is less than 14 volts after the This Status Code will be indicated when the
line contactor has closed. Capacitor C1 voltage is less than 14 volts.
–80 This fault typically occurs during operation.
Memory Indication of Fault LINE
EMERGENCY CONTACTOR POWER
Recall The Forward or Reverse contactor will not close. The lift DISCONNECT L FUSE 1
Yes truck will not operate.
Possible Cause RB

Contactor L opened during operation

Check the connections from PB2 to the coil (–) of KEY
Contactor L. CONTROL SWITCH
FUSE 3
Check the connections from battery positive to the coil D7
(+) of Contactor L.
Circuit
Check the fuses FU1 and FU3 for an open circuit.
Traction TB4 PB2 PZ7

Status Description Cause Of Status Indication

Code Battery voltage is less than 14 volts. This Status Code will be indicated when the
control card senses that the battery voltage is
–81 less than 14 volts.
Memory Indication of Fault LINE
EMERGENCY CONTACTOR POWER
Recall The Forward or Reverse contactor will not close. The lift DISCONNECT L FUSE 1
Yes truck will not operate.
Possible Cause RB

Contactor L opened during operation.

Check the connections from PB2 to the coil (–) of KEY
Contactor L. CONTROL SWITCH
FUSE 3
Check the connections from battery positive to the coil D7
(+) of Contactor L.
Circuit
Check the fuses FU1 and FU3 for an open circuit.
Traction TB4 PB2 PZ7

56
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Traction motor temperature too high. This Status Code will be indicated when
the voltage at terminal PA3 of the
–90 hydraulic pump control card (or TB1 of
the TMM1 module) is at zero volts.
Memory Indication of Fault
Recall PA5 PA4 PA3
Status Code is indicated as a flashing number on the instrument
No panel display. The lift truck speed will be reduced when either
the hydraulic pump motor or the traction motor are too hot.
ORN/PNK
Possible Cause
TEMPERATURE SWITCH
Traction motor is too hot. Temperature sensor has closed to TRACTION MOTOR
A1
battery negative..
Circuit ARMATURE
Permit traction motor to cool.
Traction BLK BLK
A2
and Other causes.
Hydraulic PA3 [or TMM1 (TB1)] has a short–circuit to battery negative.
DK BLU/PNK
Pump There is a short–circuit in the sensor wires. GRN/PPL
There is a short–circuit or other malfunction in the sensor. NEGATIVE

Status Description Cause Of Status Indication

Code Hydraulic pump motor temperature is too high. This Status Code will be indicated when the
voltage at terminal PA6 of the hydraulic
–91 pump control card (or TB3 of the TMM1
module) is at zero volts.
Memory Indication of Fault
Recall Status Code is indicated as a flashing number on the
No instrument panel display. The lift truck speed will be PB1 PB2 PA6
reduced when either the hydraulic pump motor or the
traction motor are too hot.
Possible Cause
Hydraulic pump motor is too hot. Temperature sensor has TEMPERATURE SWITCH
HYDRAULIC PUMP MOTOR
closed to battery negative.. S1
Permit the hydraulic pump motor to cool. ARMATURE
Circuit Other causes.
BLK
A2
Hydraulic PA2 [or TMM1 (TB3)] has a short–circuit to battery ORN/YEL
Pump negative. GRN/PNK

There is a short–circuit in the sensor wires. DK BLU/GRY

There is a short–circuit or other malfunction in the sensor.

57
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Steering pump motor brushes are worn and must be This Status Code will be indicated when the
replaced. voltage at terminal PA1 or PA2 of the
–93 hydraulic pump control card [or between
TMM1 (TB5 and TB6)] is at zero volts.
Memory Indication of Fault
Recall PA2 PA1
Status Code is indicated as a flashing number on the
No instrument panel display.
Possible Cause BRUSH WEAR SENSOR
STEERING PUMP MOTOR
Steering pump motor brushes are worn. The sensor has
closed to battery negative.. A1
Replace the brushes.
ARMATURE
Other causes.
A2
Circuit PA1 or PA2 [or TMM1 (TB5 or TB6)] has a short–circuit to
battery negative.
Steering GRN/GRY
Pump There is a short–circuit in the sensor wires. DK BLU/YEL
There is a short–circuit or other malfunction in the sensor.

Status Description Cause Of Status Indication

Code Traction motor brushes are worn and must be This Status Code will be indicated when the
replaced. voltage at terminal PA4 or PA5 of the
–94 hydraulic pump control card [or between
TMM1 (Tb8 and TB10)] is at zero volts.
Memory Indication of Fault
Recall PA5 PA4 PA3
Status Code is indicated as a flashing number on the
No instrument panel display.
Possible Cause ORN/PNK

Traction motor brushes are worn. The sensor has closed to BRUSH WEAR SENSOR
battery negative.. TRACTION MOTOR
A1
Circuit Replace the brushes.
ARMATURE

Traction Other causes. BLK BLK

A2
and PA 4 or PA 5 [or TMM1 (TB8 or TB10)] has a short–circuit
Hydraulic to battery negative.
DK BLU/PNK
Pump There is a short–circuit in the sensor wires. GRN/PPL
There is a short–circuit or other malfunction in the sensor.
NEGATIVE

58
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Hydraulic pump motor brushes are worn and must be This Status Code will be indicated when the
replaced. voltage at terminal PZ10 or PZ11 of the
–95 hydraulic pump control card [or between
TMM1 (TB11 and TB12)] is at zero volts.
Memory Indication of Fault
Recall PZ10 PZ11 PA6
Status Code is indicated as a flashing number on the
No instrument panel display.
Possible Cause
Hydraulic pump motor brushes are worn. The sensor has BRUSH WEAR SENSOR
closed to battery negative.. HYDRAULIC PUMP MOTOR
S1
Replace the brushes.
ARMATURE
Other causes. BLK
A2
Circuit PZ10 or PZ11 [or TMM1 (TB11 or TB12)] has a ORN/YEL
short–circuit to battery negative.
Hydraulic GRN/PNK
Pump There is a short–circuit in the sensor wires. DK BLU/GRY
There is a short–circuit or other malfunction in the sensor.

Status Description Cause Of Status Indication

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

Status Description Cause Of Status Indication

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

59
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code T2 voltage is less than 88% of battery voltage. This Status Code will be indicated when T2
voltage is less than 88% of battery voltage.
–124
Memory Indication of Fault
Recall The motor controller does not operate. A2
No Possible Cause
Open motor circuit.
Check for an open circuit or loose connections in the
motor circuit from the A1 connection to the A2 A1
connection on the SCR control panel.

Circuit
Hydraulic
Pump P
Contactor
T2

Status Description Cause Of Status Indication

Code Voltage in the control card is less than 10 VDC. This Status Code will be indicated when the
power supply in the control card is less than
–127 10 volts
Memory Indication of Fault LINE
EMERGENCY CONTACTOR POWER
Recall The motor controller does not operate DISCONNECT L FUSE 1
Yes Possible Cause
Discharged battery
Check that the battery is correctly charged. The voltage CONTROL
can decrease to less than 10 VDC during a heavy load. FUSE 3
KEY
Circuit SWITCH
Loose connection at PB1.
Hydraulic Check that the wire connection at PB1 is correct.
Pump
Malfunction in the control card.
Replace the control card. TB4 PB1

Status Description Cause Of Status Indication

Code Possible fault of suppressor across D3. This Status Code can also be indicated if a
suppressor for D3 has a fault.
–127
Memory Indication of Fault
Recall POS
There can be a difference in sound during operation. The
Yes pitch of the sound can have a variation.
Possible Cause
D3
Missing suppressor
It can be necessary to install an additional suppressor across
diode D3 if only one suppressor is installed. SUPPRESSORS

Circuit A suppressor for D3 has a fault

T2
Traction If there are two suppressors, one suppressor can have a fault.
There is no good suppressor check, so replace both
suppressors.

60
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Open thermal protector or motor controller is too hot. This Status Code will be indicated when the
voltage between PZ2 and PZ5 is greater
–141 than 0.8 volts.
Memory Indication of Fault
Recall The hydraulic pump motor has reduced power or no power
No in the TR1 range.
Possible Cause
Open circuit, thermal protector.
Check for a loose or broken wire between the following points: WHT/VIOL
PZ2
WHT/VIOL wire between thermal protector and PZ2
VIOL wire between thermal protector and PZ5.
Malfunction of thermal protector.
Circuit PZ5
Disconnect the wires from PZ2 and PZ5. When the THERMAL VIOL
Hydraulic temperature is approximately 25°C (75°F), measure the PROTECTOR
Pump resistance between the WHT/VIOL and VIOL wire. The
correct resistance is approximately 300 ohms.
Thermal protector is operating because motor controller is
too hot.
Permit the motor controller to cool.

Status Description Cause Of Status Indication

Code Input missing from motor current sensor. This Status Code will be indicated when the
voltage between PZ12 and PZ13 is greater
–142 than 0.1 volts and no current is flowing
through the hydraulic pump motor circuit.
Memory Indication of Fault
Recall No power to the hydraulic pump motor in the TR1 range. WHITE
No Possible Cause
MOTOR YELLOW
Open sensor wire circuit to PZ12. PZ13
CURRENT
Check for a loose or broken wire (GREEN wire) between the SENSOR PZ12 PZ14
current sensor and PZ12 on the control card. GREEN
Circuit A2
Hydraulic
Pump

Status Description Cause Of Status Indication

Code Input missing from motor current sensor. This Status Code will be indicated when the
voltage between PZ12 and PZ13 is less
–143 than 0.1 volts and no current is flowing
through the hydraulic pump motor circuit.
Memory Indication of Fault
Recall No power to pump motor in the TR1 control range. WHITE
No Possible Cause
MOTOR YELLOW
Open sensor wire circuit to PZ13. PZ13
CURRENT
Check for a loose or broken wire (YELLOW wire) between the SENSOR PZ12 PZ14
current sensor and PZ13 on the control card. GREEN
Circuit A2
Hydraulic
Pump

61
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code TR1 in the hydraulic pump controller does not go to This Status Code will be indicated when
OFF correctly. TR1 does not go to OFF correctly during
–144 operation.
Memory Indication of Fault
Recall Hydraulic pump motor does not stop correctly
T2
Yes Possible Cause
Malfunction of SCR 1. PZ5
TP
Check for an open circuit or loose connections between the PZ9 BLUE PZ2
transistor and PZ4 (RED wire). VIOL
TR1
The OFF time for TR1 is not within specifications. No easy PZ4 RED
test is possible. Replace TR1 after the other checks have SUPPRESSOR
PZ3 BROWN
been done and no other problem is found.
Circuit PZ1 WHT/BRN
Hydraulic 1A
Pump NEG

Status Description Cause Of Status Indication

Code TR1 in the hydraulic pump controller does not go to This Status Code will be indicated when
ON correctly. TR1 does not go ON correctly during
–145 operation.
Memory Indication of Fault
Recall The hydraulic pump does not operate.
T2
Yes Possible Cause
Malfunction of TR1 circuit. PZ5
TP
Check for an open circuit or loose connections between PZ9 BLUE PZ2
TR1 and PZ4 (RED wire). VIOL
TR1
Check for an open circuit or loose connections between T2 PZ4 RED
and PZ9 (BLUE wire). SUPPRESSOR
PZ3 BROWN
Circuit Malfunction of TR1.
PZ1 WHT/BRN
Hydraulic An open or bad gate circuit to TR1. No easy test is 1A
Pump possible. Replace TR1 after the other checks have been
done and no other problem is found. NEG

Status Description Cause Of Status Indication

Code Short–circuit across TR1 in the hydraulic pump This Status Code will be indicated when the
controller. (SRO Fault) voltage at T2 is less than 12% of battery
–146 voltage.
Memory Indication of Fault
Recall Line Contactor L will not close.
T2
Yes Possible Cause
Malfunction of TR1 circuit. PZ5
TP
Check for a short–circuit across TR1. No field test is PZ9 BLUE PZ2
possible. Replace TR1 after the other checks have been VIOL
done and no other problem is found. TR1
PZ4 RED
SUPPRESSOR
Malfunction of Suppressor. PZ3 BROWN
Circuit Check for a short–circuit across the suppressor for TR1.
PZ1 WHT/BRN
Hydraulic 1A
Pump NEG

62
 EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Voltage check at T2 in the hydraulic pump controller This Status Code will be indicated when a
is greater than 88% of battery voltage. voltage check at T2 is greater than 88% of
–148 battery voltage.
Memory Indication of Fault
Recall L
Hydraulic pump control will not operate.
No Possible Cause C1 D3
Malfunction of diode D3 circuit. A2

Check for a short–circuit across D3.

+ A1
Check for a short–circuit across the suppressor for D3.

–
Circuit
Hydraulic
TR1
Pump

Status Description Cause Of Status Indication

Code Low voltage on capacitor C1 in the hydraulic pump This Status Code will be indicated when the
motor controller. capacitor C1 voltage is less than 85% of
–150 battery voltage during start–up.
Memory Indication of Fault WHITE
Recall Hydraulic pump motor will not operate.
YELLOW
No Possible Cause
MOTOR PZ13
CUTTENT
Contactor L does not operate correctly.
SENSOR PZ12 PZ14
GREEN
Check the condition of Contactor L. A2
Check for loose or open connections in the power cables.
Check the power fuse FU3.
No battery voltage at PZ14.
Circuit
Check for battery voltage at POS and PZ14. Check for
Hydraulic loose connections at PZ14.
Pump

Status Description Cause Of Status Indication

Code Voltage on C1 in Hydraulic pump controller is too This Status Code will be indicated when the
high when motor current is high. voltage on C1 is less than 85% of battery
–151 voltage at start–up.
Memory Indication of Fault
Recall L
Line contactor L will not close.
Yes Possible Cause C1 D3
A2
A capacitor is damaged or has a short–circuit.
Check the capacitor bank for a bad capacitor. See status A1
code –51. +
Check for open or loose connections in the capacitor bank.
–
Control fuse is open.
Circuit Check for an open control fuse F3.
TR1
Hydraulic Control card has a problem.
Pump
Replace the control card.

63
EV–T100 Motor Controller

Status Description Cause Of Status Indication

Code Polarity check of the output voltage from the This Status Code will be indicated when the input
current sensor.
–157 voltage to PZ12 and PZ13 is the wrong polarity.

Memory Indication of Fault

Recall Hydraulic pump control will not operate.
Yes Possible Cause WHITE
The YELLOW and GREEN wires from the current
sensor to the control card are connected wrong. YELLOW
MOTOR PZ13
Check the YELLOW wire is connected to PZ13 and CUTTENT
the GREEN wire is connected to PZ12. SENSOR PZ12 PZ14
GREEN
Check from the current sensor to the control card
A2
for open or loose connections.
Circuit
Power cables are connected wrong in motor circuit.
Hydraulic
Pump Check that the battery cables are connected
correctly in the motor circuit.

Status Description Cause Of Status Indication

Code Capacitor voltage is low after the line contactor has This Status Code will be indicated when the
closed. Capacitor C1 voltage is less than 14 volts.
–180 This fault typically occurs during operation.
Memory Indication of Fault LINE
EMERGENCY CONTACTOR POWER
Recall Hydraulic pump control will not operate. DISCONNECT L FUSE 2
No NOTE: This Status Code almost never occurs. A low
capacitor voltage in either controller module will normally give
an –80 Status Code because of the connections between the
traction and hydraulic pump controllers.
Possible Cause KEY
CONTROL SWITCH
Contactor L opened during operation FUSE 3
Check the connections from PB2 to the coil (–) of contactor
Circuit L
Hydraulic Check the connections from battery positive to the coil (+) TB4 PB2 PZ7
Pump of Contactor L.
Check the fuses FU1 and FU3 for an open–circuit.

Status Description Cause Of Status Indication

Code Battery voltage is less than 14 volts. This Status Code will be indicated when
the control card senses that the battery
–181 voltage at PB1 is less than 14 volts.
Memory Indication of Fault LINE
EMERGENCY CONTACTOR POWER
Recall Hydraulic pump control will not operate. DISCONNECT L FUSE 2
Yes NOTE: This Status Code almost never occurs. A low capacity
voltage in either controller module will normally give an –81
Status Code because of the connections between the traction
and hydraulic pump controllers.
Possible Cause KEY
CONTROL SWITCH
Contactor L opened during operation. FUSE 3
Check the connections from PB2 to the coil (–) of Contactor L.
Circuit
Check the connections from battery positive to the coil (–) of
Hydraulic Contactor L. TB4 PB2 PZ7
Pump Check the fuses FU1 and FU3 for an open circuit.

64
 EV–T100 Motor Controller

REPAIRS

TRANSISTOR CONTROL FOR TRACTION MOTOR AND

CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR
11 10 9 8 7 6 5

13
12

3
14

15 2
1
17

7 6 5
11 10 9 8
TRANSISTOR CONTROL FOR BOTH TRACTION
MOTOR AND HYDRAULIC PUMP MOTOR
16

12

1
17

1. TRANSISTOR MOTOR CONTROLLER 11. FUSE 2, HYDRAULIC PUMP CIRCUIT

2. FIELD WEAKENING CONTACTOR 12. STEERING PUMP CONTACTOR
3. FORWARD DIRECTION CONTACTOR (F) 13. HYDRAULIC PUMP CONTACTOR
4. REVERSE DIRECTION CONTACTOR (R) 14. ELECTRONIC DRIVER, HYDRAULIC
5. REGENERATIVE BRAKING CONTACTOR (RB) PUMP CONTACTOR
6. DIODE D7 ASSEMBLY, 15. TMM1 MODULE
REGENERATIVE BRAKING 16. TRANSISTOR CONTROLLER,
7. FUSE 4, REGENERATIVE BRAKING HYDRAULIC PUMP MOTOR
8. LINE CONTACTOR L1 (ALSO SEE FIGURE 3.)
9. FUSE 1, TRACTION CIRCUIT 17. FUSE PANEL (FU 7, FU 3, FU 5, FU 6)
10. 1A CONTACTOR (1A)
FIGURE 9. TYPICAL CONFIGURATIONS OF THE EV–T100 MOTOR CONTROLLER IN
J2.00–3.20XM (J45–65XM) LIFT TRUCKS

65
EV–T100 Motor Controller

TRANSISTOR CONTROL FOR BOTH TRACTION 1 10

MOTOR AND HYDRAULIC PUMP MOTOR 16

2
17

8
3 4 11 9 7

TRANSISTOR CONTROL FOR TRACTION MOTOR AND

CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR 1 10

14
6

5
13

2
17

8
3 4 11 9 7

10. CONTACTOR 1A
1. TRANSISTOR MOTOR CONTROLLER 11. FUSE 2, HYDRAULIC PUMP CIRCUIT
(ALSO SEE FIGURE 3.) 12. STEERING PUMP CONTACTOR
2. FIELD WEAKENING CONTACTOR (UNDER FUSE PANEL 17)
3. FORWARD DIRECTION CONTACTOR (F) 13. HYDRAULIC PUMP CONTACTOR
4. REVERSE DIRECTION CONTACTOR (R) 14. ELECTRONIC DRIVER, HYDRAULIC
5. REGENERATIVE BRAKING CONTACTOR (RB) PUMP CONTACTOR
6. DIODE D7 ASSEMBLY, 15. TMM1 MODULE
REGENERATIVE BRAKING 16. TRANSISTOR CONTROLLER,
7. FUSE 4, POWER STEERING CIRCUIT HYDRAULIC PUMP MOTOR
8. CONTACTOR L (ALSO SEE FIGURE 3.)
9. FUSE 1, TRACTION CIRCUIT 17. FUSE PANEL (FU 7, FU 3, FU 5, FU 6)
FIGURE 10. TYPICAL CONFIGURATIONS OF THE EV–T100 MOTOR CONTROLLER IN
E2.00–3.20XM (#45–65XM) LIFT TRUCKS

66
 EV–T100 Motor Controller

GENERAL
The parts in the EV–T100 motor controller module can
not be repaired. Any component that has a fault must be
replaced. The status codes will normally indicate the
component that has a fault. The procedures described in
this section for the motor controller module are to check
that the indicated fault is correct.
The replacement of the contactor contacts is a normal
maintenance procedure. Disassembled views of the
contactors are shown in this section.
The repair of the connectors to the control card is de-
scribed in this section.
WARNING
Some voltage measurements must be made with the
SRO circuit complete. Make sure the drive wheels
are raised from the surface before doing
troubleshooting. If you are working alone, put a
weight in the seat to close the seat switch. If your lift
truck has a seat brake, use a block behind the lower
actuator bar to release the seat brake when the op-
erator in not in the seat. Put the test equipment so
that you can see it from the operator area. You can
operate the controls with your hand and also make
the voltage measurements.
Make sure you disconnect the battery and separate
the connector before you disassemble any part of the
controller. The capacitor C1 stores electrical energy
and can cause injury if a person discharges a capaci-
tor through parts of the body. Capacitor C1 is physi-
cally three capacitors connected in parallel to be-
come one large capacitor. AFTER the battery is dis-
connected, make sure you also discharge the capaci-
tor C1. Put a 100 ohm 2 watt resistor across the posi-
tive (+) and negative (–) of the capacitor for a mini-
mum of three seconds.
NOTE: The bolts and screws connected to the elec-
tronic components are normally metric sizes. Make sure
that you use the correct fastener for the part that has been
disassembled.

1. POWER
TRANSISTOR TR1
2. SUPPRESSOR
ASSEMBLY FOR TR1 1
3. CAPACITOR C1
(C1a, C1b, C1c)
4. CONTROL CARD
5. SUPPRESSOR
ASSEMBLY FOR 6, 7
DIODES D3 AND D4
6 & 7. LOCATION OF
DIODES D3 AND D4 2 5

3 3

3 CAP 1a CAP 1b CAP 1c

FIGURE 11. CONFIGURATION OF THE EV–T100 MOTOR CONTROLLER MODULE

67
EV–T100 Motor Controller

1
2

18

3 1. CAPACITOR C1 (3)
2. CONTROL CARD
3. BASE PLATE
17 4. SUPPRESSOR, POWER
TRANSISTOR
16 5. POWER TRANSISTOR TR1
ASSEMBLY
6. HEAT SINK, DIODES
15 7. DIODE MODULE D3
8. DIODE MODULE D4
14 9. TERMINAL POST
10. FLEXIBLE BUS BAR
11. CURRENT SENSOR
13 12. FLEXIBLE BUS BAR
4 13. TERMINAL POST
12 7
14. BUS BAR
8 15. BUS BAR
6 5
16. BUS BAR
17. SUPPRESSOR, DIODES D3
9
AND D4
18. CAPACITOR SUPPORT
ASSEMBLY (2)
11 10 10
FIGURE 12. CONFIGURATION OF THE EV–T100 MOTOR CONTROLLER MODULE

FUSES Thermal Protector (TP)

The TR1 has a thermal protector that is part on the TR1

The fuses are found on the EV–T100 control panel. See
FIGURE 9. The power fuses for the traction circuit (500
amperes) and for the hydraulic pump (325 amperes) is
found on the (+) bus bar. The condition of the fuses can
normally be checked by looking at them or they can be
checked with an ohmmeter.
THE POWER TRANSISTOR (TR1)
ASSEMBLY
assembly and can not be removed. The thermal protec-
tor is a resistor that changes resistance when the tem-
perature changes. If the temperature of TR1 begins to
reach its design limits, the signal from the thermal pro-
tector will cause the control card to lower the maximum
current flow through TR1. The speed of the lift truck
will be deceased until the temperature in the TR1 assem-
bly decreases. The correct resistance across the termi-
nals of the thermal protector is less than 750 ohms at
room temperature.
Remove The TR1 Assembly

1. Make notes of the positions of the suppressors and re-

The TR1 assembly cannot be disassembled. If a Status
Code –53 is indicated, check for an open circuit or loose
connections between TR1 and PZ4 on the control card.
If a fault is not found in the wire or connectors, remove
TR1. A procedure to check the TR1 assembly is de-
scribed in following paragraphs.
move the suppressors from the mount over TR1. Dis-
connect the electric connections to the TR1 assembly.
2. Remove the thermal protector from the heat sink. Re-
move the two capscrews that connect the power cables
to the heat sinks (make a note of the cathode sensor

68
 EV–T100 Motor Controller

wire). Remove the two mounting screws that hold the

TR1 assembly to the base plate. 1 2
D S
How To Check The TR1 Assembly
S
Use an Ohmmeter to check between the source S and the
drain D. A good TR1 will indicate infinity (∞) on any
G
scale between the *** and ***. An indication of 5 K
ohms to 20 K ohms on the 10 000 scale is correct for the
opposite direction. 1 2
D S
Check between the gate G and the drain D with the ohm- TP
meter on the 10 000 scale. The correct reading is infinity
(∞) in both directions.
S
Check between the gate G and the source S with the
ohmmeter on the 10 000 scale. The correct reading is in-
finity (∞) in both directions. G
D = DRAIN
S = SOURCE
G = GATE
TP = THERMAL PROTECTOR

1 2 FIGURE 14. IGBT ARRANGEMENT

D S
Install The TR1 Assembly
G S
1. Install the new TR1 assembly. Make sure the heat
sinks make full contact with the insulator and base plate.
Check the resistance between both heat sinks and the
base plate with an ohmmeter. A correct installation will
indicate infinity on the ohmmeter.
1 2

D S 2. Install the electrical connections to the TR1 assembly.

TP Install the thermal protector on the heat sink.
3. Install the mount and the suppressors over the TR1 as-
sembly. Make sure the connections are made correctly.
G S Check Capacitor C1
D = DRAIN
S = SOURCE Discharge Capacitor C1 and disconnect the terminals
G = GATE before checking C1 for a short–circuit. Measure the re-
TP = THERMAL PROTECTOR
sistance between the terminals. The ohmmeter will indi-
FIGURE 13. MOSFET ARRANGEMENT cate a low resistance and increase to more than 100 000
ohms. A capacitor with a short–circuit must be replaced.

69
EV–T100 Motor Controller

a thin layer of silicone grease (Part No. 5042242–52) be-

+ – tween the surfaces of the heat sink and replacement di-
+ – ode. Tighten the diode to a torque of 3.4 N.m (30 lbf in).

NOTE: Diodes D3 and D4 have a suppressor connected

in parallel to the diode. Replace the suppressor and test
CAPACITOR C1 (Three One of the three
the operation if troubleshooting indicates that the sup-
electrolytic capacitors electrolytic capacitors pressor is bad.
connected in parallel) for CAPACITOR C1
FIGURE 15. CAPACITOR C1 TEST SUPPRESSORS

Suppressors are included in the controller to prevent

DIODES D3 AND D4
The heat sink assembly for the diodes D3 and D4 is also
the connection for the (–) power cable. The heat sink as-
sembly is connected to the base plate. A thin insulator
with a silicone surface separates the heat sink assembly
from the base plate.
NOTE: The optional SCR controller used for the hy-
draulic pump only has a diode D3.
Check The Diodes D3 And D4
You will need an ohmmeter to check the diodes. Discon-
nect the cathode cables from the connectors. The diodes
can stay attached to the heat sinks to make checks.
Touch the probes of the ohmmeter to the heat sink and
the cathode cable. Measure the resistance. Change the
probe connections to the reverse direction and measure
the resistance. A good diode will indicate 7–14 ohms on
the R x 1 Scale in one direction and greater than 50 000
ohms in the other direction.
3 3
1 3
2
1. ANODE 1
2. ANODE 2
3. COMMON CATHODE CONNECTION
FIGURE 16. CONFIGURATION FOR DIODES D3
AND D4
electrical noise from entering transistors, diodes and the
control card and damaging the parts. The suppressors
can be a variation of diodes, resistors and capacitors in a
small plastic block. Sometimes a suppressor will not in-
dicate a defect except when in an operating circuit and
will cause a fault that does not occur regularly during lift
truck operation.
The best method to check for a bad suppressor is to re-
place it and then check the operation of the lift truck.
Check the suppressor with and ohmmeter. The correct
indication is infinity (∞) on the R100 scale.
MOTOR CURRENT SENSOR
(See FIGURE 17.)
The motor current sensor is a short piece of the circuit
bus bar with two sensor wires connected to it. All of the
traction motor current flows through this power connec-
tor. The metal between the connection points of the sen-
sor wires has a small resistance. This small resistance
between the two sensor wires sends a voltage signal to
the control card. The voltage signal increases as the mo-
tor current increases. The control card compares the
voltage with the ”C/L” current limit adjustment. The
control card controls the current flow so that the traction
circuit is not damaged.
1

Replacement, Diodes D3 and D4 2

1. SENSOR WIRES
Disconnect the cathode cable. Use a deep socket to re- 2. SENSOR SHUNT
move the diodes. Put the wire through the top of the
socket and use a handle or wrench to turn the socket. Use FIGURE 17. MOTOR CURRENT SENSOR

70
 EV–T100 Motor Controller

CONTACTORS The other contactors used in the motor controller have

The FORWARD and REVERSE (direction) contactor
assemblies control the direction of current flow through
the traction motor. The contactor is a heavy–duty switch
that opens and closes the power circuit. The traction cir-
cuit has a FORWARD and REVERSE contactor as-
sembly. Each contactor assembly has the following
parts: two sets of normally open (NO) contacts, two sets
of normally closed (NC) contacts, and a coil. The coil is
an electromagnet that moves the NO contacts to the
closed position against spring pressure. The coil is in the
control circuit. The contactor tips are in the traction cir-
cuit.
When a contactor coil is energized, the normally open
(NO) contacts close and the normally closed (NC) con-
tacts open. This action gives direction control to the
traction motor. The contacts normally have a long serv-
ice life because the current flow through the contacts is
stopped before the contacts open. The TR1 is OFF be-
fore the contactor coil is deenergized. The only condi-
tion where the contacts open during a large current flow
is a Pulse Monitor Trip (PMT).
1 2 1
one set of NO contacts. These contactors are not the
same, but their operation is similar. A typical contactor
of this kind is shown in FIGURE 19.
Contactor Repair (See FIGURE 20.)
Make an identification and disconnect the wires and ca-
bles from the contactor assembly. Remove the mounting
screws and remove the contactor assembly.
Contactor Contacts. The contacts in a contactor 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 necessary. DO NOT USE A FILE ON
THE CONTACTS. DO NOT LUBRICATE THE CON-
TACTS.
CAUTION
ALWAYS replace all of the contacts in a contactor at
the same time. Replace the contacts in the contactor
for the hydraulic pump after 1000 hours of
operation. Replace the contacts in the other
contactors when the thickness of any area of a
contact is less than 30% of the thickness of a new
contact or if there is any transfer of contact material.

2
1
1 6
3

4 4

4
5
3 3
12180

2 1
5
6 1. POWER TERMINALS
1. POWER TERMINALS 2. CONTACTS
2. NC CONTACTS 3. SUPPRESSOR
3. NO CONTACTS 4. COIL TERMINALS
4. COIL TERMINALS 5. MOUNT BRACKET
5. MOUNT BRACKET 6. COIL
6. COIL
FIGURE 19. TYPICAL CONTACTOR
FIGURE 18. DIRECTION CONTACTOR ASSEMBLY (REGENERATIVE BRAKING
SHOWN)

71
EV–T100 Motor Controller

5
4 9
11

8
14
4 10

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

FIGURE 20. DIRECTION CONTACTOR

Coil. Check the coil with an ohmmeter for an open cir-
cuit or a short–circuit. Replace the coil if it is damaged.
Make sure the coil wires are connected again to the cor-
rect terminals. The coils in the contactors for the hydrau-
lic pump and the regenerative braking have an external
suppressor. The coil and the suppressor can be checked
separately with an ohmmeter. [A suppressor diode (and
sometimes a resistor in series) is part of the coil. The di-
ode will cause the ohmmeter to indicate a difference in
resistance in one direction. Reverse the probes of the
ohmmeter to the opposite terminals and measure the re-
sistance. Use the highest resistance indication.]
CONTROL CARD
NOTE: Do NOT remove the circuit board from the case
when replacing a control card. There are no internal re-
pairs that can be made by service personnel. The control
card and case must be replaced as a unit. There are spe-
cial repair services available that can repair damaged
control cards. See your dealer for Hyster lift trucks.

72
 EV–T100 Motor Controller

1
7
2

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

12668 3 12671

FIGURE 21. CONTROL CARD CONNECTIONS

CONTROL CARD PLUGS 1. PLUG

(See FIGURE 22.) 2. RUBBER SEAL
3. PIN CONNECTOR
(REMOVED FROM PLUG)
4. LOCK

PART NO. 897408

All control card connections are made at plugs A, B, Y 6
5. PIN CONNECTOR
or Z or at the six screws of TB terminals. If a wire of one (INSTALLED IN PLUG)
of the plugs must be replaced, the operation to remove a 6. TOOL (HYSTER PART
pin connector must be done carefully. A special tool NO. 897408) (UNLOCKS
PIN CONNECTOR FOR 1
(Hyster Part No. 897408), must be used to remove the REMOVAL)
pin connector from the plug. How the pin connectors are
5
held in the plug is shown in FIGURE 22. Use the tool as
shown to release the lock so that the pin connector can
be removed from the plug. If a pin connector must be re-
moved, the service person must work carefully so that
the pin connectors and the plug are not damaged.

When a new pin connector is installed in the plug, make

sure it is not damaged and is locked into the correct posi- 2
tion in the plug. If the pin connection becomes loose 11559
during operation of the lift truck, the malfunction is not
regular and is very difficult to find and repair. 4
3

FIGURE 22. CONTROL CARD PLUG

73
EV–T100 Motor Controller
Brush Wear Indicators
The brush wear indicators illuminate when the motor
brushes must be replaced. The sensor wires for the brush
wear indicators are an insert in the brush material when
it is made. The sensor wires are insulated from the brush
material. When the brush wears within approximately
1.5 mm (0.060 in) of the brush lead, the insulation be-
tween the sensor wire and the brush material is de-
stroyed. The connection between the brush and the sen-
sor wire causes the indicator to illuminate.
The operation of the brush wear indicators can be
checked during periodic maintenance. The battery must
be removed from the lift truck for access to the motors.
Disconnect the sensor wires from the outside of the mo-
tor case. Touch the ends of the sensor wires together.
The warning light will illuminate if the circuit is operat-
74
ing correctly. The thermal switch can be replaced if it is
damaged. However, the motor must be disassembled to
replace the thermal switch.
WARNING
Prevent damage and injury if the lift truck moves.
Raise the drive wheels from the floor during these
tests.
Disconnect the sensor wires, one at a time, from outside
of the motor case. Touch the end of the sensor wire to
battery negative. The warning light will illuminate if the
circuit is operating correctly. The motor brushes must be
replaced when they are worn. If equipped with brush
wear indicators, the condition of the commutator and
the motor brushes must still be checked during periodic
maintenance.
 EV–T100 Motor Controller

THEORY OF OPERATION (EV–T100 MOTOR CONTROLLER)

ELECTRONIC SPEED CONTROLS
+
NOTE: The description of the current flow in the elec- 2
3
trical circuits in this section uses the ”Conventional
Theory of Current Flow”. This theory describes the 5
current as flowing from positive to negative. An elec- + 1 5 4
tric lift truck uses a two–wire electrical system. There
is no common ground through the frame. Both the –
positive supply and the negative return current flow 5
through wires and cables. There must be a minimum
resistance of 50 000 ohms between the electrical cir-
cuits and the frame of the lift truck. 6
–
NOTE: Earlier production of the EV–100 series of 1. BATTERY
motor controllers use an SCR (silicon controlled recti- 2. LINE CONTACTOR
fier) as the basic control device. The use of a high fre- 3. TRACTION MOTOR ARMATURE
4. TRACTION MOTOR FIELD
quency power transistor in the EV–T100 motor con-
5. DIRECTION CONTACTOR
troller instead of an SCR permits a more simple design. 6. TRANSISTOR “SWITCH” TR1
The power transistor does not require an “OFF” circuit
Source
to stop the current flow through the device. When the
gate signal is removed from the power transistor, the 6
current flow through it stops.

A transistor controller is used to control the speed of Gate

the traction and hydraulic motors in some lift trucks.
The operation of a transistor controller is the same for a
traction motor and a hydraulic motor. The transistor
controller for a traction motor has more functions
which are described in the section for the traction cir-
cuit.
The EV–T100 series of motor controllers have solid–
state electronic circuits that control the operation of a
DC motor. The speed of DC motors is controlled by the
average applied voltage. The higher the average ap-
plied voltage, the faster the motor will rotate. If a
switch is put in the traction motor circuit, and the
switch is changed to OFF and ON quickly, the traction
motor will rotate. See FIGURE 23. The speed of rota-
tion increases as the time the switch is ON increases.
The speed of rotation will decrease if the switch is
OFF for a longer time than it is ON. The speed of the
motor can be controlled using this principle.
The Power Transistor “Switch”
NOTE: This main power transistor “switch” is called
TR1 in this manual.
Drain
When a signal is applied at the gate, current will flow
from the source to the drain.
When the signal is removed from the gate, the
current flow stops.
FIGURE 23. BASIC MOTOR CIRCUIT
An MOSFET* or IGBT** power transistor (TR1) is a
solid–state device that operates like a very fast switch.
Transistors are electronic devices that permit electric-
ity to flow through them when an electronic signal is
applied to an additional element called a gate. A tran-
sistor will not permit an electric current to flow
through the device until an electronic signal is applied
*MOSFET = Metal Oxide Silicon Field Effect Transistor. A tran-
sistor in which a transverse electric field (called the “gate”) is used
to control the main electric current flowing through the electronic
device. A MOSFET is used in 24 to 48 volt controllers.
**IGBT= Isolated Gate Bi–polar Transistor. The IBGT does the
same operations as a MOSFET, but can have a different internal
design. The IGBT is more efficient at higher voltages and higher
current flows. An IGBT is used in 24 to 80 volt controllers.

75
EV–T100 Motor Controller

to the gate. When the gate signal is applied, the transis- frequency is high, there is more heat generated in the
tor permits current flow. When the gate signal is MOSFET or IGBT and more power loss. The control-
stopped, the current flow through the transistor stops. ler for the hydraulic pump operates at a lower frequen-
cy of 2 kHz because the operation of the hydraulic sys-
NOTE: Too much heat will quickly destroy a power
tem prevents hearing the lower frequency noise.
transistor. A difficult design problem has been to de-
velop a semi–conductor material that will permit a
large current flow (example: 400 amperes) and be able 1 2
to quickly start and stop the current flow. Most of the
D S
heat generated within a power transistor comes from
the transition between the ON and OFF conditions. S
The transition time for a good power transistor is
approximately 75 nanoseconds (a nanosecond = one
billionth of a second). G

All high frequency power MOSFETs or IGBTs used in

lift trucks are a combination of several semiconductor 1 2
devices in parallel. The devices can be several individ- D S
ual silicon chips or they can be integrated on a single TP
piece of silicon. See FIGURE 24. and FIGURE 25.
The TR1 is a single unit and its components can not be
disassembled. S

1 2 D = DRAIN
D S S = SOURCE
G = GATE
TP = THERMAL PROTECTOR
G S
FIGURE 25. TYPICAL IGBT ARRANGEMENT

A Motor Circuit That Operates With Pulses

The controller must operate with pulses (cycles ON
1 2 and OFF) to control the speed of the motor because the
D S TR1 “switch” is either fully ON or OFF. The frequen-
TP cy of the pulses also adds to the heat generated within
the power transistor. A high frequency operation gen-
erates more heat than a lower frequency. An efficient
heat sink must be a part of a power transistor.
G S
A potentiometer on the accelerator pedal sends a signal
D = DRAIN
(4.5 volts decreasing to 0 volts) to the controller. The
S = SOURCE
G = GATE controller has a constant frequency oscillator. The con-
TP = THERMAL PROTECTOR trol card controls the ON time of the pulse. The oscilla-
tor frequency of the traction controller operates at a
FIGURE 24. TYPICAL MOSFET
higher frequency (12 kHz) than the frequency of the
ARRANGEMENT
controller for the hydraulic pump (2 kHz).
A MOSFET or IGBT that operates at 12 kHz reduces A low average voltage applied to the motor is the result
the control noise and motor noise because that frequen- of a short ON time and a long OFF time. (See
cy is not as easily heard by most personnel. When the FIGURE 26.)

76
 EV–T100 Motor Controller

LOW tion and permits cooler operation of TR1. These func-

ON ON ON SPEED
100% tions are described later in this section.

Traction Circuit
OFF OFF OFF
50% The control card supplies approximately 5.0 volts to
AVERAGE
MOTOR the accelerator potentiometer for the traction circuit.
BATTERY VOLTAGE
VOLTAGE (SPEED) When the accelerator potentiometer is connected and
10%
correctly adjusted, the voltage is 3.5 to 3.7 volts when
0% measured between the accelerator potentiometer and
TIME LOW SPEED battery negative. This voltage is measured at the slow-
50% est speed (CREEP speed) of the lift truck and the ac-
SPEED celerator potentiometer is at its highest resistance. The
100%
ON ON ON accelerator potentiometer decreases this voltage by de-
AVERAGE
OFF OFF MOTOR creasing the resistance between the control card and
VOLTAGE
(SPEED) battery negative. This accelerator voltage controls the
50% oscillator in the control card when the accelerator po-
BATTERY tentiometer is moved by the operator. The oscillator
VOLTAGE controls the ON time of TR1 and controls the travel
speed of the lift truck. When the accelerator pedal is
0% pushed farther down, the control voltage to the control
TIME card decreases. The maximum ON time (fast travel
MEDIUM SPEED
speed) occurs when the control voltage is 0.0 to 0.2
MAXIMUM
OFF OFF SPEED volts. Most lift trucks are equipped with a by–pass cir-
100% 96%
cuit (1A) that is energized when the accelerator voltage
ON ON ON decreases to less than 1.0 volts. The 1A by–pass circuit
AVERAGE disables the TR1 control and applies battery voltage di-
MOTOR
50% VOLTAGE rectly to the traction motor.
(SPEED)

BATTERY Hydraulic Pump Motor

VOLTAGE
Some lift trucks are equipped with an transistor con-
0% troller to control the speed of the hydraulic pump mo-
TIME tor. The switches fastened to the linkage for the main
HIGH SPEED
control valve connect one or more terminals on the
FIGURE 26. AVERAGE MOTOR VOLTAGE control card to battery negative. These voltage signals
to the control card change the pulse width that controls
the motor speed. The changes in motor speed is con-
When the control card sends equal ON and OFF times, trolled in three steps instead of the continuous varia-
approximately 50% of the average battery voltage is tion when the voltage is controlled with a potentiome-
available to the motor. ter.

The maximum average voltage to the motor gives the BASIC CIRCUIT OPERATION
highest operating speed. This voltage occurs when the
The controller is energized when the battery is con-
ON time is long compared to a short OFF time. This
nected. A resistor across the terminals of the line con-
maximum speed sends approximately 96% of the bat-
tactor L is an electrical path to charge the capacitor C1
tery voltage to the motor. Most EV–T100 motor con-
in approximately two seconds. The controller then
trollers have a 1A by–pass contactor and a field weak-
makes start–up checks.
ening contactor to increase the maximum travel speed
of the lift truck. The 1A by–pass contactor also permits NOTE: Capacitor C1 is physically three capacitors
full battery power to the motor during full speed opera- connected in parallel to become one large capacitor.

77
EV–T100 Motor Controller
NOTE: This motor controller is equipped with a line
contactor between the positive power cable of the bat-
tery and the motor controller. This line contactor is the
primary battery disconnect if an electrical fault is
sensed by the motor controller.
SRO Circuit (Traction Circuit Only)
The lift truck is equipped with a safety circuit, called
the ”Static Return to OFF” (SRO) circuit, that prevents
the operation of the lift truck if the starting sequence is
not correct. The function of the SRO circuit is to make
sure the operator is in the seat and ready to operate the
controls. The starting sequence:
a. The operator must be on the operator’s seat and
the seat switch closed. (The seat switch closes
when the weight of the operator is on the seat.)
b. The direction lever must be in NEUTRAL. Turn
the key switch to the ON position. The key switch
supplies a signal voltage to the control card.
c. Move the direction lever to FORWARD or RE-
VERSE. Move the accelerator pedal to close the
START switch after steps 1 and 2 are complete.
If step 3 is done before steps 1 and 2, the lift truck will
not travel in either direction. The seat switch and key
switch each send a signal voltage to a timer circuit.
Both voltages must be sent to the timer circuit before
the timer will send a voltage signal to terminal TB3 on
the control card. The timer circuit has a six second de-
lay if the seat switch is opened. This delay permits the
operator to change position in the seat without causing
the lift truck to stop. The voltages from the parts to the
SRO circuit are sent to the control card. The SRO cir-
cuit is reset when the START switch or a direction
switch is momentarily opened.
The control card must sense battery voltage at termi-
nals TB4 and TB3 (seat switch closed), and at TB2
(START switch), before a voltage signal at TB5 or TB6
or the control card will not permit a direction contactor
to close.
78
Pulse Monitor Trip (PMT)
(Traction Circuit Only)
The PMT circuit is part of the control card function.
When the SRO checks are complete, the control card
checks for three conditions that can cause uncontrolled
operation of the lift truck:
• The PMT circuit checks that the voltage across
TR1 is between 12% and 88% of the battery volt-
age. If the voltage across TR1 stays at a low volt-
age, there is a fault in the traction circuit. A short–
circuit across TR1 or the contacts on contactor
1A welded closed, will cause this fault. The line
contactor L will not close.
• If the control card senses a short–circuit (low
voltage) across diode D3, the line contactor L
will not close. A direction contactor will not
close.
• The PMT circuit also checks the traction circuit
for faults during lift truck operation. If TR1 stays
ON for greater than two pulses, or the contactor
1A does not open correctly, the PMT circuit
opens the line contactor L and the direction con-
tactor. The control card immediately closes the
line contactor L again. If the fault occurs again,
the control card opens the line contactor L until
the fault is corrected or the PMT circuit is reset.
The circuit is reset when the key switch is turned
to OFF and then to ON again.
NOTE: In the following illustrations,
ÉÉÉ
indicates positive voltage.
ÉÉÉ indicates battery negative.
INDUCTION CURRENT FROM THE
MOTOR
When a DC motor is controlled by a pulsed circuit, the
magnetic field in the armature and motor field is con-
tinuously expanding and decreasing. This expansion
and decrease of the magnetic field can be lost energy
for doing work unless the controller is designed to use
this energy. A capacitor C1 and a diode D3 is added to
the circuit for this purpose.
Capacitor C1 is charged as a temporary storage for part
of the battery energy during the TR1 OFF time.
 EV–T100 Motor Controller

TR1 ON TIME: Capacitor C1 discharges and adds
to the battery current to motor. At a current draw of
100 amps and 50% ON time, approximately 50
amps comes from the battery and 50 amps comes
from the capacitor C1.
50 amps 50 amps
2 battery voltage into a higher motor current at lower
When TR1 goes OFF, the decreasing magnetic field
generates a voltage and current in the motor. Diode D3
permits the current to flow through the field and arma-
ture again to do work. See FIGURE 27. (This current is
often called the “flyback current.”) The torque of a DC
motor is directly proportional to the amount of current
flow through it. This control changes battery current at

ÉÉ
3
100 amps motor voltage. Motor current will be higher than bat-
6
+
ÉÉ1 tery current draw except when TR1 is operating at

ÉÉ
4 maximum ON time. Most of the motor current comes

É ÉÉ
–
É
F R from the battery at high speeds. (High current draw

É ÉÉ ÉÉ
5
from the battery is to be avoided if possible, because it

É ÉÉ ÉÉ ÉÉ
É
F R is less efficient.) The 1A by–pass contactor is closed at

É ÉÉ ÉÉ
maximum speeds to by–pass TR1 and connect the bat-

ÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉ ÉÉ
tery voltage directly across the motor. The 1A by–pass
circuit is described later in this section.

ÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉ ÉÉ
7 8

É
TR1 OFF TIME: Capacitor C1 charges from the
battery. The decreasing magnetic field in the motor
circuit generates a voltage and current. Diode D3
permits the current to flow through the field and
armature again to do work.
When TR1 is ON, capacitor C1 discharges its energy
and adds to the current flow from the battery through
the motor.
CONTROL CARDS
The control cards for the traction circuit and the hy-
draulic circuit will be described separately in the fol-
lowing paragraphs.
NOTE: The configuration of the controller divides the

É
2 base plate into three groups:
50 amps 3

É
100 amps
6 a. Traction controller group

É
+ 1
4 b. Contactor group

ÉÉ É c. Controller group for the hydraulic pump motor

ÉÉ É
F R
– 5

ÉÉ É F
The three groups of components are fastened to the
R

ÉÉ É
mounting plate on the counterweight. Typical control-

ÉÉ É
ler configurations are shown in FIGURE 3. (If the tran-

ÉÉ É
sistor controller for the hydraulic pump motor is not
used, a single contactor for the hydraulic pump motor

ÉÉÉÉÉÉ
ÉÉ É
7
8 is installed in that position.)
The control card makes the SRO and PMT checks as
1. BATTERY 5. MOTOR FIELD
2. LINE CONTACTOR 6. DIODE D3 part of the logic sequence. The control card only per-
3. CAPACITOR C1 7. TR1 mits lift truck operation when no fault is sensed. The
4. MOTOR ARMATURE 8. CONTACTOR 1A control card checks and controls the functions de-
NOTE: The current flows in this illustration are an scribed in the following paragraphs.
example. Actual current flows depend on the Control Card Adjustments (Traction Circuit)
operating conditions.
The control card checks the current in the traction cir-
FIGURE 27. INDUCTION CURRENT
cuit and controls the current to prevent damage. The
control card has several control adjustments.

79
EV–T100 Motor Controller

The control card for the traction circuit has a control
adjustment called “CREEP”. This adjustment controls
the minimum current level in the traction circuit when
the direction contactors are closed. This adjustment
can be changed to meet the needs of a specific applica-
tion. The CREEP adjustment controls how far the ac-
celerator pedal moves between the closing of the
START switch and the application of enough power to
move the lift truck. This adjustment is only made after
the adjustment between the accelerator pedal and the
accelerator potentiometer is correct.
The “C/A” (Controlled Acceleration) adjustment
controls the maximum rate that the average voltage is
increased by the controller to accelerate the traction
motor. This maximum rate of acceleration is not con-
trolled by the accelerator pedal for maximum accelera-
tion. A high rate of acceleration increases the wear on
the brushes of the traction motor. The acceleration time
can be adjusted for the operating conditions of the user.
The acceleration rate can be adjusted to give a smooth
acceleration for better load handling.
1 available to the traction motor through the 1A circuit
nected between the positive terminal and the contactor
A1 terminal.
The 1A By–pass Circuit permits the battery to be con-
nected directly to the traction motor. This circuit dis-
connects the control of the TR1 circuit and is used for
maximum power from the traction motor. When the
battery is connected to the traction motor through the
1A by–pass circuit, the maximum voltage available to
the traction motor is increased by approximately 4%.
The control card controls the operation of the 1A cir-
cuit. A 1A TIME adjustment permits the controller to
begin the operation of the traction motor before the 1A
contactor closes. This time delay prevents full battery
current being applied across the traction motor when it
is not rotating. (Full battery voltage applied across a
stalled traction motor causes a large current draw. This
large current draw causes a large amount of heat in the
motor and wastes battery energy.) This adjustment also
permits smoother operation of the lift truck. The con-
trol card begins 1A TIME when the accelerator volt-
age is decreased to less than 1.0 volts. 1A TIME is
normally 1 to 3 seconds. The full battery power is
after the time delay 1A TIME.

2 2

ÉÉ
3
1. SENSOR WIRES
6

ÉÉ
2. SENSOR SHUNT
+ 1

É ÉÉ
4
FIGURE 28. MOTOR CURRENT SENSOR

É ÉÉ ÉÉ F R
– 5
The “C/L” (Current Limit) adjustment will control
É ÉÉ ÉÉ É
ÉÉ
ÉÉÉÉ
É ÉÉ ÉÉ É
ÉÉ
F R
the pulse length if the current flow reaches the limit set
by the adjustment. The traction circuit has a current
É ÉÉ ÉÉÉÉ
É
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉ
sensor in the power circuit in series with the traction

É
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉ
motor. All of the current that flows through the traction 7 8

É É
motor flows through the current sensor. The current
sensor is a shunt with two sensor wires connected. See
FIGURE 28. The metal of the shunt has a small resis- 1. BATTERY
2. LINE CONTACTOR
tance between the two sensor wires. This small resis- 3. CAPACITOR C1
tance sends a signal voltage to the control card. This 4. MOTOR ARMATURE
signal voltage increases as the motor current increases. 5. MOTOR FIELD
The control card compares the signal voltage with the 6. DIODE D3
7. TR1
C/L current limit adjustment. When the signal voltage 8. CONTACTOR 1A
reaches the limit set on the C/L, the control card re-
duces the pulse width. The current sensor is found con- FIGURE 29. 1A BY–PASS CIRCUIT

80
 EV–T100 Motor Controller

“PLUG”. The “PLUGGING” function uses the trac-
tion motor as an electric brake to slow or stop a lift
truck. When a lift truck is being stopped, the motion of
the lift truck causes the traction motor to rotate and op-
erate like a generator. The voltage generated across the
motor armature changes polarity. Plugging uses the re-
verse polarity of the current flow generated by the ar-
mature of the traction motor to decrease the speed of
the lift truck. Plugging generates heat in the traction
motor.
current through the armature again. This reduction of
the opposite induction current permits the lift truck to
stop more smoothly.
The control card for the traction circuit has a PLUG
adjustment. This adjustment controls the maximum ap-
plication of the plugging current. The position of the
accelerator pedal controls the plugging distance up to
the maximum application. This adjustment can be
changed as needed for an operator. The shorter the
plugging distance, the faster is the wear on the traction
motor brushes.

The “regenerative braking current limit” controls the

2 10

É
maximum application of regenerative braking during
operation. The position of the accelerator pedal by the

É
9 6
operator controls the plugging distance up to the limit

É
+ 1 3
4 set by the REGEN C/L adjustment.

É É F R

É É
– 5
Regenerative Braking. When a lift truck is being

É É ÉÉÉ
ÉÉ F R stopped, energy is generated by the traction motor. The

É
É É ÉÉÉÉ
lift truck causes the traction motor to rotate and operate

É ÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉ
like a generator. Plugging uses battery energy in oppo-

É 7
sition to the energy generated by the traction motor.

É É ÉÉ
8 This energy generates heat in the traction motor. Lift
trucks used in heavy duty operations can generate
1. BATTERY enough heat to damage the traction motors and cause
2. LINE CONTACTOR the motor brushes to wear rapidly.
3. CAPACITOR C1
4. MOTOR ARMATURE
5. MOTOR FIELD
Regenerative braking returns the energy generated by
6. DIODE D3
7. TR1 the traction motor to the battery. The regenerative
8. CONTACTOR 1A braking contactor opens during regenerative braking.
9. DIODE D4 When the voltage generated by the traction motor is
10. CURRENT SENSOR, TRACTION CIRCUIT
less than the battery voltage, the lift truck will be mov-
FIGURE 30. PLUGGING CIRCUIT ing slowly. The contactor for regenerative braking then
closes and plugging is used to stop the slower moving
lift truck. Regenerative braking generates less heat in
the traction motor and reduces brush wear. Another
Plugging is energized when the direction switches in
electric circuit must be added to the motor controller to
the direction control lever is moved to the opposite di-
control this operation. The energy generated during re-
rection from which the lift truck is traveling. The direc-
generative braking must be controlled within limits so
tion contactors will change to their opposite positions
that the parts of the electric circuit are not damaged.
and reverse the current flow through the motor field.
The adjustments used to control regenerative braking
The current generated in the traction motor now flows
are:
opposite to the current flow from the battery. The lift
truck will stop very quickly if the induction current is
not controlled. A diode D4 permits part of the induc- REGEN C/L (Regenerative Braking Current Limit)
tion current from the armature to flow with the battery REGEN D.O. (Regenerative Braking Drop Out)

81
EV–T100 Motor Controller

closes during regenerative braking. The regenerative

braking contactor closes when the key switch is turned
10
2 3 11 to ON. During regenerative braking, the contactor
opens and the energy generated by the traction circuit
is sent to the battery. When the voltage level is less
than the level set by the REGEN D.O., the regenera-
9 6
tive braking contactor closes and the remainder of the
+ 1
4 lift truck speed is decreased by plugging. When the
R
plugging function is in operation, the voltage gener-
– F 5 ated by the traction motor is normally less than battery
F R
voltage.
12 Field Weakening. Many lift trucks have a “field weak-
ening” circuit. The field weakening circuit permits a
faster travel speed than the 1A circuit. The traction mo-
13 7
8 tor must be operating during 1A conditions of high
speed and small load before the field weakening circuit
1. BATTERY is used.
2. LINE CONTACTOR
3. CAPACITOR C1 The field weakening contactor connects a by–pass
4. MOTOR ARMATURE shunt around the motor field. This shunt gives a second
5. MOTOR FIELD
path for the current flow and weakens the magnetic
6. DIODE D3
7. TR1 field in the motor field. The increased current flow
8. CONTACTOR 1A through the armature causes the motor to turn faster.
9. DIODE D4 See FIGURE 32. This increased speed caused by field
10. CURRENT SENSOR, TRACTION CIRCUIT
11. REGENERATIVE BRAKING (RB)
weakening is only possible when the traction motor
CONTACTOR has a small load. For example, high speed travel on a
11. DIODE D7 flat surface. The field weakening decreases the power
12. CURRENT SENSOR, REGENERATIVE available from the traction motor so that the travel
BRAKING
speed is increased.
When the regenerative braking function is started,
the controller begins the plugging function first. The field weakening contactor is controlled by two ad-
The controller checks the voltage in the plugging justments on the control card:
circuit during three pulses of TR1. If the voltage in
the plugging circuit is greater than the battery F.W.P.U. (Field Weakening Pick Up)
voltage, the controller opens the regenerative F.W.D.O. (Field Weakening Drop Out)
braking contactor. The current generated in the
traction motor flows through diode D7. TR1 When the lift truck is operating at high speed with a
continues to operate as selected by the operator small load, the armature current will decrease to a
(accelerator position). minimum current of approximately 185 amperes. The
When TR1 is ON, the current flows through TR1 F.W.P.U. is adjusted to close the field weakening con-
and then through the field and armature again. tactor at approximately 1.3 times this minimum arma-
When TR1 is OFF, the current flows through ture current. The field weakening shunt is a strip of
diodes D3 and D4 and then to the battery. The metal that connects the field weakening contactor to
energy generated during regenerative braking is the FORWARD and REVERSE contactors. The field
used to charge the battery. weakening shunt is calibrated at less than 1.0 ohm and
FIGURE 31. REGENERATIVE BRAKING is parallel to the field of the traction motor in the cir-
cuit. The field weakening contactor closes after the 1A
contactor closes. The 1A contactor closes after the ac-
The “regenerative braking drop out” adjusts the volt- celerator potentiometer voltage is less than 1.0 volts
age level where the regenerative braking contactor and the 1A TIME function has occurred.

82
 EV–T100 Motor Controller

card will not apply enough power during PLUGGING

É
11 to make the lift truck go up the slope.

É
2 3
Accelerator Control

ÉÉ É 6

ÉÉ É
The control card supplies approximately 5.0 volts
+ 1

É ÉÉ É
4 through terminal PZ6 to the accelerator potentiometer.

É ÉÉ É
F R The voltage from the accelerator potentiometer (volt-
– age divider) is sensed at terminal TB1 of the control

É ÉÉ ÉÉÉÉ É FW 5 card. The control card uses this variation in voltage

É ÉÉ ÉÉ É
RES
10 signal at terminal TB1 to control the speed of the lift

É ÉÉ ÉÉÉÉ ÉÉÉÉÉÉ
ÉÉ É
F R
truck.

É ÉÉ ÉÉÉÉÉÉ É
É
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉ
The voltage signal from the accelerator potentiometer
9 is 0–5 volts. The voltage is normally adjusted to

É
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉ 7
8 3.5–3.7 volts. At 3.50–3.7 volts, the lift truck will

É ÉÉ
1. BATTERY É
2. LINE CONTACTOR
3. CAPACITOR C1
4. MOTOR ARMATURE
5. MOTOR FIELD
6. DIODE D3
7. TR1
8. CONTACTOR 1A
9. FIELD WEAKENING (FW) CONTACTOR
10. FIELD WEAKENING (FW) RESISTOR
11. CURRENT SENSOR, TRACTION CIRCUIT
FIGURE 32. FIELD WEAKENING CIRCUIT
If the lift truck begins to travel up a ramp, the armature
current will increase. When the armature current in-
creases 2.75–3.0 times the minimum armature current,
the F.W.D.O. will open the field weakening contactor.
If the accelerator pedal is moved to a slower speed, the
control card will open the field weakening contactor.
“RAMP START” is a function of the EV–T100 con-
trol card for the traction circuit. This function permits
an operator to stop a lift truck with a load when going
up a slope. If the operator does not change the direction
controls, the lift truck can be started again on the slope.
A lift truck will often roll backward a little distance
when starting again on a slope. If the operator does not
change the direction controls, the control card will not
sense the reverse operation of the motor armature and
will apply enough power to go up the slope. If the op-
erator has changed the direction controls, the control
card will sense that the expected operation is PLUG-
GING when the lift truck rolls backward. The control
move at CREEP speed. The 1A TIME will begin its
cycle at 1.0 volts so that the 1A contactor can close.
The maximum speed of the lift truck when operating in
the transistor control range occurs when the voltage is
0.0–0.2 volts. The 1A contactor applies battery voltage
directly to the traction motor.
TRANSISTOR CONTROL
(HYDRAULIC PUMP MOTOR)
The control card for the hydraulic pump motor is not
the same as the control card for the traction circuit.
This control card has a different label. The electronic
function for speed control is the same, but the many
functions necessary for control of a traction circuit are
not needed for the hydraulic pump motor. A contactor
is not used in the power circuit. The 325 ampere fuse
for the hydraulic pump circuit is found on the bus bar
near above the contactor 1A.
This control card does not have an SRO check nor a
PMT check. The TR1 is in parallel with the TR1 of the
traction circuit. If TR1 for the hydraulic circuit has a
short–circuit, the line contactor L1 will open. The main
control valve is an open center valve and the hydraulic
function will stop when the hand lever is returned to
the NEUTRAL position. The transistor controller for
the hydraulic pump motor controls the motor at three
speeds:
Speed 1 is for the TILT function and for optional func-
tions that require the third or fourth spool of the main
control valve (slow speed for some attachments).
Speed 2 is for the low speed LIFT function and high
speed operation of an optional function that requires
the third spool of the main control valve.

83
EV–T100 Motor Controller

Speed 4 is only for the high speed LIFT function.
This speed applies full battery voltage across the hy-
draulic pump motor. The SPD 3 adjustment is not used.
The control card sends three reference voltages to the
switches controlled by the linkage to the main control
valve. When a contact on a switch is closed, the refer-
ence voltage is connected with battery negative and the
control card senses the change in the reference voltage.
The voltage controlled oscillator in the control card
causes TR1 to operate at a certain frequency (see the
paragraphs that describe Electronic Speed Controls).
The speeds of operation can be adjusted for an operat-
ing application.
2 and REVERSE) each have two sets of NC and NO
1
6 gized, the NO contacts close and the NC contacts open.
3
4
spring holds the contacts of a switch closed, the switch
is called normally closed (NC).
Some lift trucks have an transistor control for the hy-
draulic pump motor. Some lift trucks also have an elec-
tronic driver that energizes the coil for the hydraulic
pump contactor.
Lift trucks are equipped with contactors for regenera-
tive braking, 1A, and field weakening circuits. These
contactors have contactors with one set of normally
open contacts. See FIGURE 33. When the lift truck
does not have an transistor controller for the hydraulic
pump motor, the hydraulic pump contactor also has
one set of NO contacts.
A typical set of direction contactors are shown in
FIGURE 34. The direction contactors (FORWARD
contacts. When a coil for a direction contactor is ener-
This design prevents the contacts from being closed in
the wrong sequence.
1 3 1

2 1 1
5
1. POWER TERMINALS
2. CONTACTS 4 4
3. SUPPRESSOR
4. COIL TERMINALS
5. MOUNT BRACKET 5
6. COIL 2 2
12180
FIGURE 33. TYPICAL CONTACTOR
ASSEMBLY (REGENERATIVE BRAKING
SHOWN)
6
1. POWER TERMINALS
2. NC CONTACTS
CONTACTORS 3. NO CONTACTS
4. COIL TERMINALS
Contactors are switches, controlled by electromagnets, 5. MOUNT BRACKET
that close and open a power circuit. The control card 6. COIL (THE SUPPRESSOR IS ADDED
has internal electronic drivers and the electronic driv- TO THE OUTSIDE OF THE COIL)
ers control the current to the coils of the electromag- FIGURE 34. DIRECTION CONTACTOR
nets for the contactors. The electromagnetic field in the
coil moves the armature against spring pressure to CIRCUIT PROTECTION
close the contact. When the coil is deenergized, the
Traction Circuit Fuse
spring pressure moves the armature and opens the con-
tacts. When a spring holds the contacts of a switch The 500 ampere fuse for the traction circuit is found on
open, the switch is called normally open (NO). If a the motor controller between the (+) bus bar and the

84
 EV–T100 Motor Controller

anode of TR1. If the current flow becomes great will damage power transistors and diodes. Suppressors
enough to damage the traction circuit because of a are included in the controller to prevent electrical noise
short–circuit or electrical overload, the fuse will fail. from entering transistors, diodes and the control card
and damaging the parts. The suppressors can be a vari-
Current Limit ation of diodes, resistors and capacitors in a small plas-
tic block.
TR1 will become damaged from heat unless the cur-
rent flow has limits. A current sensor is installed in the
TRUCK MANAGEMENT MODULE (TMM1)
traction circuit between the armature and battery nega-
tive. The current sensor sends a voltage signal to the The Truck Management Module is a multi–function
control card. The control card compares the adjustment accessory card that can be used to give additional sta-
C/L with the signal from the current sensor. If the cur- tus codes or operator warnings on the instrument panel
rent flow reaches the limit, the control card overrides display. If a lift truck has brush wear indicators and
the other signals to the oscillator. The pulse width and motor temperature switches and does not have a tran-
frequency are decreased to decrease the average motor sistor controller for the hydraulic pump motor, a
current. TMM1 card is added to the controller. The TMM1 re-
ceives the signals from the brush wear sensors and mo-
Thermal Protection tor temperature switches and sends the signals through
the traction controller to the instrument panel display.
The parts of the traction circuit will be damaged by too
much heat. A heat sensor is connected to the TR1 heat
sink. When the temperature increases towards the de-
sign limit [85°C (185°F)], the resistance in the sensor
increases. This increase in resistance decreases the
TR1 ON time by decreasing the the pulse width and
frequency to TR1. The average motor current is de-
creased to prevent damage. When the heat sink cools,
the thermal protection will return the control to normal
operation. This input signal overrides all other input
signals (except the 1A signal) to the oscillator during
lift truck operation.

Suppressors

Electrical noise is high voltage pulses caused by other FIGURE 35. TRUCK MANAGEMENT
electric parts operating momentarily. Electrical noise MODULE (TMM1)

85
EV–T100 Motor Controller

NOTES

86
EV–T100 Motor Controller

87