CLARK FORKLIFT ET202 Troubleshooting the EV 100 Control TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT ET202 Troubleshooting the EV 100 Control TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT ET202 Troubleshooting the EV 100 Control TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

• 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 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.

Table Of Contents:

CLARK FORKLIFT ET202 Troubleshooting the EV 100 Control TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

About this Class……………………………………………………………………………….. 3
Class Objectives……………………………………………………………………………….. 3
Class Content…………………………………………………………………………………… 4
Sequence of Operations……………………………………………………………………… 4
Troubleshooting………………………………………………………………………………… 4
Quiz………………………………………………………………………………………………… 4
About Safety . . . . .. . . .. . .. . . . . . .. . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . .. . . . . . .. .. . . . . .. . . . 5
Section 1. EV-100S Control Sequence of Operations……………………………. 6
Identification of Abbreviations………………………………………………….. 6
Identification of Schematic Symbols………………………………………….. 7
Sequence 1. Drive Control………………………………………………………… 8
Sequence 2. Connect the Battery……………………………………………….. 10
Sequence 3. Battery Indicator and Pump Motor………………………….. 12
Sequence 4. Hour Meter, PIS Operation, and S.R.O…………………… 14
Sequence 5. Energizing the Directional Contactors … .. … . … …….. .. . .. . 16
Sequence 6. Contactor Closing and Capacitor Precharge …………… 18
Sequence 7. #1 and #5 REC Tmn On ……………………………………….. 20
Sequence 8. lC Capacitor Charging and Reactor Operation…………. 22
Sequence 9. #2 REC Turn On and #1 REC Turn Off…………………….. 24
Sequence 10. Flyback…………………………………………………………………. 26
Sequence 11. Accelerator , Thermal Protector (TP) and PMT………… 28
Sequence 12. lA Contactor Operation .. .. .. .. … .. …. … . .. .. …. ……. .. … …… 30
Sequence 13. Plugging………………………………………………………………… 32
Sequence 13. Plugging (continued)………………………………………………. 34
Sequence 13. Plugging (continued)………………………………………………. 36
Section 2. EV-l00S Control Troubleshooting ………………………………………… 38
Symptom 1. Directional contactors will not close………………………….. 39
Symptom 2. Directional contactors close, no power,
no audible SCR hum, truck inoperable with
accelerator in SCR range …………………………………………. 40
Symptom 3. Directional contactors close, no power,
audible SCR hum, truck inoperable with
accelerator in SCR range …………………………………………. 41
Symptom 4. Directional contactors close once or twice
and then remain open, P.M.T. trips……………………………. 42
Symptom 5. One directional contactor closes with normal
operation, but other will not close……………………………….. 42
Symptom 6. Stiff plug and/or plugging distance will not adjust…………. 43

Please Note:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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