CLARK FORKLIFT ET206 Troubleshooting the EV Tl00 Control TECHNICAL TRAINING MANUAL

ET206

Troubleshooting the EV Tl00 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.........................................................................................................

Cla Objectives.........................................................................................................

Cla s Content.............................................................................................................

About Safety..............................................................................................................

Section I. EV T 100 Sequence of Operation..............................................................

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

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

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

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

Sequence 3.Close the Key Switch..................................................................

Sequence 3.Close the Key Switch (Continued)..............................................

Sequence 4.Park Brake Switch & Static Return to Off (SRO) Checks...........

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

Sequence 5.Energizing the Directional Contactors (Continued).....................

Sequence 6.Turning 'ON'the Transistor..........................................................

F Sequence 7.Turning 'OF the Transistor, Capacitor Cbarging and FJyback..

Sequence 8.Accelerator, Thermal Protector and Pulse Monitor Trip (PMT)..

Sequence 9.1 A Contactor Operation...............................................................

Sequence IO.Plugging.......................................................................................

Sequence LO.Plugging (continued)...................................................................

Sequence LO.Plugging (continued)..................................................................

Sequence 11.Hydraulic Functions....................................................................

Section 2. Control Panel................................................................................................

Control Panel Description..................................................................................

Control Feature.................................................................................................

Control Panel Maintenance..............................................................................

Control Panel Troubleshooting........................................................................

Section 3. Handset [n tructions...................................................................................

Factory Card Settings-Standru·d.......... ......... ....................................................

Factory Card Settings-High Performance.........................................................

Factory Card Settings- Standard Pump Control...............................................

Factory Card Settings-High Pe1formance Pump Control.................................. lnternaJ Re istance Compen ation....................................................................

Internal Resistance Compensation Worksheet.................................................

Description of Traction Logic Card Funtions...................................................

Description of Pump Logic Card Funtions.................... ..................................

Section 4. Trouble Codes..............................................................................................

Status Code BJank and 01................................................................................

Status Code 02 and 03......................................................................................

Status Code 05 and 06......................................................................................

Status Code 07 and 08............. ........... ...... ........................................................

Status Code 09 and l I .......................................................................................

Status Code 15 and 16......................................................................................

Status Code 17 and 23.......................................................................................

Status Code 24 and 26.......................................................................................

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EV T J 00 Control page l

Status Code 27 and 4 1......................................................................................

Status Code 42.................... ............ ........................ .......... ............ ......................

Status Code 43 and 44........................................................................................

Status Code 45 and 46........................................................................................

Status Code 48 and 50........................................................................................

Status Code 51 and 53........................................................................................

Status Code 54 and 57........... ................ .......................................................... ...

Status Code 70 and 7 J ........................................................................................

Status Code 72 and 73........................................................................................

Status Code 74 and 76........................................................................................

Status Code 90 and 9 1........... .............................................................................

Status Code 92 and 93........................................................................................

Status Code 94 and 95........................................................................................

Status Code 117 and 123...................................................................................

Status Code 124 ...............................................................................................

Status Code 127 and 14 1....................................................................................

Status Code 142 and 143...................................................................................

Status Code 144 and 145.....................................................................................

Status Code 146 and 148.....................................................................................

Status Code 150 and 151....................................................................................

Status Code 154 and 157...................................................................................

Status Code Worksheet......................................................................................

Section 5. Misc Information.........................................................................................

Component Testing.............................................................................................

Schematic- Standard...........................................................................................

Schematic- Standard with Pump........................................................................

Schematic- High Performance............................................................................

Schematic- High Performance with Pump.........................................................

Schematic- On Demand Power Steering.............................................................

@Copyright Clark Material Handling Company 1996.

Revised 1998.

EV TL 00 Control 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 Tl00 Transistor Control operates and how you can diagnose and troubleshoot problems with the control.

The EV Tl00 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. So your knowledge 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: I.Trace each sequence of operations on a basic wiring diagram as a way to demonstrate your understanding of the control 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 T J 00 Control page 3

Class Content There are two major sections in this book that will be covered in the class; 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.

•diagnositic codes.

•where necessary, explanations, illustrations, and testing procedures related to troubleshooting a particular component.

Quiz At the completion of this 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 effectively.

For additional Information refer to service manual SM 615.

EV TL 00 Control page 4

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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 will result in death or serious injury if proper precautions are not taken.

When checking electrical components on an electric truck, always raise the drive wheels off the floor and put blocks under the truck, disconnect the battery, and discharge the capacitor. These actions prevent injury to yourself and damage to the truck.

Always familiarize yourself with the safety information in the Operator's Manual before you operate a truck.

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EV T J 00 Control page 5

Section 1.

EVTIOO 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 EVTl00 solid state transistor 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:

lA

Bypass Contactor Capacitor

F.W

Field Weakening Forward Forward Directional Switch Fuse Main Pump Contactor & Coil Power Steering Contactor & Coil Line Contactor & Coil Master Switch

lC

F

FWD

FU p PS

L

MS PD REC RES

R

REV TP

TRl

& Coil

Pump Driver Module Rectifier (Diode ) Resistor Reverse Reverse Directional Switch Thermal Protector Transistor

EV TL 00 Control page 6

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IDENTIFICATION OF SCHEMATIC SYMBOLS _..... ..,.._. MOMENTARYSWITCH � _____,.,__

.........,..

NORMALLY OPEN LIMIT SWITCH NORMALLY CLOSED LIMIT SWITCH

----ed""--- NORMALLY CLOSED LIMIT SWITCH HELD OPEN NORMALLY OPEN LIMIT SWITCH HELD CLOSED NORMALLY CLOSED CONTACT POINTS

-----..,....-- NORMALLY OPEN CONTACT POINTS PLUG-IN CONNECTION

--+>-

-cJ--

FUSE

----A,---

COIL (CONTACTOR COIL, SOLENOID COIL OR RELAY COIL

� RESISlOR

---©--

MOTOR ARMATURE

� INDUCTOR (MOTOR FIELD, REACTOR, CHOKE, ETC.)

10 A I

PERMANENT MAGNET MOTOR ACCELERATOR DIODE

---1(--

-,=r -, � �

CAPACITOR SENSOR TRANSISTOR HORN TWISTED PAIR WIRES FILTER THERMAL PROTECTOR

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EV T J 00 Control page 7

OPERATIONAL SEQUENCE #1 This standard schematic is shown with all switches and contactors in their normal 'OFF' position. No circuits are operating. The four basic areas of circuitry are identified

POWER DIRECTIONAL SPEED ACCESSORY

EV TL 00 Control page 8

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