CLARK FORKLIFT ET202 Troubleshooting the EV 100 Control TECHNICAL TRAINING MANUAL

ET202 Troubleshooting the EV 100 Control

TECHNICAL TRAINING Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Contents About this Class............................................................................................

3

Class Objectives............................................................................................

3

Class Content................................................................................................

Sequence of Operations.................................................................................

Troubleshooting.............................................................................................

Quiz............................................................................................................... .......................................................................................

About Safety Section 1. EV-100S Control Sequence of Operations..................................

Identification of Abbreviations...........................................................

Identification of Schematic Symbols..................................................

Sequence 1. Drive Control..................................................................

Sequence 2. Connect the Battery........................................................

Sequence 3. Battery Indicator and Pump Motor................................

Sequence 4. Hour Meter, PIS Operation, and S.R.O........................

Sequence 5. Energizing the Directional Contactors ..........................

Sequence 6. Contactor Closing and Capacitor Precharge ...............

Sequence 7. #1 and #5 REC Tmn On ...............................................

Sequence 8. lC Capacitor Charging and Reactor Operation.............

Sequence 9. #2 REC Turn On and #1 REC Turn Off..........................

Sequence 10. Flyback............................................................................

Sequence 11. Accelerator , Thermal Protector (TP) and PMT............

Sequence 12. lA Contactor Operation ...............................................

Sequence 13. Plugging...........................................................................

Sequence 13. Plugging (continued).......................................................

Sequence 13. Plugging (continued).......................................................

Section 2. EV-l00S Control Troubleshooting ................................................

Symptom 1. Directional contactors will not close................................

Sym ptom 2. Directional contactors close, no power, no audible SCR hum, truck inoperable with accelerator in SCR range .................................................

Sym ptom 3. Directional contactors close, no power, audible SCR hum, truck inoperable with accelerator in SCR range .................................................

Symptom 4. Directional contactors close once or twice and then remain open, P.M.T. trips..................................

Symptom 5. One directional contactor closes with normal operation, but other will not close......................................

Symptom 6. Stiff plug and/or plugging distance will not adjust.............

4 4 4 4 5 6 6 7 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 39

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40 41 42 42 43

EV 100 page l

Symptom 7. 1A contactor will not close.................................................

Symptom 8. P.M.T. trips every time hydraulic switches are closed or open ...................... . .....................................

43

44 Symptom 9. Power steer motor does not operate.................................. 44 Symptom 10. Liftitilt attachments do not operate................................ 45 Symptom 11. Power Steering does not operate...................................... 45 Symptom 12. Hydraulic function does not operate................................ 46 Section 3. EV-100 LXT Diagnostics Control..................................................... 47 Diagnostic Status Codes............................................................................. 58 E357 Std. Programing Specifications...................................................... 91 E357 Hi-Proformance Programing Specifications.................................. 92 E357 Pump Programing Specifications.................................................. 93 E235 Programing Specifications............................................................. 94 TM247 Programing Specifications.......................................................... 95 ESM245/247 Programing Specifications................................................

96

NP246 Programing Specifications........................................................... 97 NP15/20/22 Programing Specifications................................................... 98 OP15 Programing Specifications............................................................. 99 E685 EV 200 Programing Specifications................................................

E912 EV200 Programing Specifications.................................................

Section 4. ............................................................................................................

100 101 102 Control Card Identification..................................................................... 102 Internal Resistance Compensation Worksheet...................................... 103 Hi-Proformance Schematic...................................................................... 104 Pump Control Schematic......................................................................... 105 TM Schematic........................................................................................... 106 LXT Schematic.......................................................................................... 107

©Copyright Clark Material Handling Company 1990.

Revised 1998

EV 100 page 2

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About this Class The most important part of an electric truck is the control that operates the electrical components. Knowledge of this control, how it works, and how it operates the other components, is vital to maintenance and service. This class is designed to teach you how the EV-100S SCR Control operates and how you can diagnose and troubleshoot problems with the control.

The EV-100S SCR Control consists of a control card and the electrical components it operates. The card monitors power demands and responds by controlling the power applied to system components.

The control operates a series of switching devices that enable it to direct the power load across different electrical circuits. These circuits control everything on the truck from the traction motors to forward and reverse drives and accessory devices. Your knowl­ edge of the control system, the components it operates, and how to diagnose and troubleshoot control problems helps you to keep a truck in top shape and avoid down time.

Class Objectives There are two primary objectives for this class. Upon completion of the manual and the class you will be able to: 1. Trace each sequence of operations on a basic wiring diagram as a way to demon­ strate your understanding of the conti·ol and its operation 2. Make preliminary diagnosis of and troubleshoot problems related to the control and its components.

These objectives are intended to give you a sound understanding of how the Control works and lay a groundwork for problem diagnosis and troubleshooting.

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EV 100 page 3

Class Content There are two major sections in this book, the Sequence of Operations and Troubleshooting.

Sequence of Operations This section includes: A list of abbreviations used in the text and on the wiring diagram A legend defining the symbols used on the diagrams A list of the control sequence of operations A wiring diagram for each sequence.

To meet one of the objectives of the course, you will be required to trace the operation sequence on the diagram as a way to completely understand how the control works.

Troubleshooting This sections includes: A list of basic, required steps necessary to initiate troubleshooting Troubleshooting diagrams listed according to preliminary symptoms of the problem Where necessary, explanations, illustrations, and testing procedures related to troubleshooting a particular component.

At the completion of the class, you will be required to take a quiz. This is a way to help determine if you are meeting the objectives of the course.

If you follow both the Sequence of Operations and the Troubleshooting materials closely, system operation will be clearer. This will help you to understand the electrical system more completely and diagnose and troubleshoot Control problems more effec­ tively.

EV 100 page4

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About Safety The following messages may be used to emphasize important information: Note:This message is used when special information, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities and other special data.

Important: This message is used when special precautions should be taken to ensure a correct action or to avoid damage to or malfunction of the truck or a component.

Caution: This message is used as a reminder of safety practices which can result in personal injury if proper precautions are not taken.

Warning: This message is used when a hazard exists which can result in injury or death if proper precautions are not taken.

Danger: This message is used when an extreme hazard exists which can result in serious injury or death if proper precautions are not taken.

When checking electrical components on an electric true� always raise the drive wheels off the floor and put blocks under tne truck, disconnect the battery, and discliarge the capacitor. These actions prevent injury to yourself and dama_ge to tlie truck. Al­ ways familiarize yourself with the safety information in the Operator's and Service Manuals before you operate or repair a truck.

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EV 100 page 5

Section 1. EV-l00S Control

Sequence of Operations

This sequence of operation is designed to provide a complete step-by-step description of the operation of Clark lift trucks equipped with GE model EV-l00S solid state control.

Please read each operation sequence and then trace the sequence onto the diagram as described.

If you will follow the steps carefully, and not skip around you should be familiar with the entire operation of the lift truck electrical system. Then, if you wish to review any particular part or sequence, consult the Table of Contents and refer to the particular sequences involved.

Identification of Abbreviations The following abbreviations are used in the text and in the wiring diagrams: BDI lA lC F

FWD

FU HM p lMS PSD REC R REV SCR PS TP FBS

EV 100 page 6

Battery Indicator Bypass Contactor Circuit & Components Capacitor Forward Forward Directional Switch Fuse Hour Meter Main Pump Master Switch Power Steering Driver Module Rectifier (Diode or SCR) Reverse Reverse Directional Switch Silicon Controlled Rectifier Steering Pump Thermal Protector Foot Brake Switch

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IDENTIFICATION OF SCHEMATIC SYMBOLS _.._

MOMENTARY SWITCH

�

NORMALLYOPEN SWITCH

�

NORMALLY CLOSED SWITCH

--ed'--'11

NORMALLYCLOSED SWITCH HELD OPEN NORMALLYOPEN SWITCH HELD CLOSED

----I"'-.- NORMALLYCLOSED POWER POINTS �

--+>-----c::J---[J-

----Ar--

�·0•:

-0�

. �. �

.-H�.

--w� ·-----1

75

H

NORMALLYOPEN POWER POINTS PllJG.IN CONNECTION FUSE

RESISTOR COIL (CONTACTOR COIL OR RELAY COIL) PERNINENT MAGNET MOTOR MOTOR ARMA1\JRE INDUCTOR (MOTOR RELD, REACTOR, CHOKE, ETC.) THERMAL PROTECTOR SCR (SILICON CONTROLLED RECTIRER) DIODE

CAPACITOR CURRENT MONITORING SHUNT ACCELERATOR) HORN

TWISTED PAJR WIRES

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EV 100 page 7

Sequence 1. Drive Control Standard schematic is shown with all switches and contacts in normal off position. No circuits are operating. Please identify the four basic areas of circuitry.

1. Power 2.Speed 3. Directional 4. Accessory

EV 100 page 8

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