CLARK FORKLIFT ET204 Troubleshooting the EV T5 Control TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT ET204 Troubleshooting the EV T5 Control TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT ET204 Troubleshooting the EV T5 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-T5 MOSFETs Control operates and how you can diagnose and troubleshoot problems with the control. The EV-T5 CONTROL is an electronic device that controls electrical power supplied to the vehicle drive motor to provide smooth power to move the truck and to minimize power drain from battery.
• The control consists of a Transistor unit and a contactor assembly unit. The Transistor unit monitors power demand of the truck and then responds by controlling the power applied to drive components.
• The contactor panel contains switching devices to direct heavy power loads to the drive motor and its components.

Table Of Contents:

CLARK FORKLIFT ET204 Troubleshooting the EV T5 Control TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

About this Class…………………………………………………………………………………………….. 3
Class Objectives……………………………………………………………………………………. 3
Class Content………………………………………………………………………………………. 3
Sequence of Operations………………………………………………………………………… 3
Troubleshooting……………………………………………………………………………………… 4
Quiz……………………………………………………………………………………………………. 4
About Safety………………………………………………………………………………………… 5
Section 1. EV-T5 Control Sequence of Operations…………………………………………….. 6
Identification of Abbreviations………………………………………………………………. 6
Identification of Symbols……………………………………………………………………….. 7
Sequence 1. Drive Control…………………………………………………………………….. 8
Sequence 2. Connect the Battery…………………………………………………………… 10
Sequence 3.Close the KeySwitch…………………………………………………………… 12
Sequence 4. Energizing the Line Contactor……………………………………………. 14
Sequence 5. Energizing the Directional Contactors…………………………………. 16
Sequence 6. Turning ‘ON’ the MOSFETs. … .. . . …… … . … . . . .. … . … . … . … .. . . . . . … …… 18
Sequence 7. Turning ‘OFF’ the MOSFETs,Capacitor Charging and Flyback 20
Sequence 8. Accelerator, Thermal Protectors, and PMT………………………… 22
Sequence 9. 1A Contactor Operation……………………………………………………… 24
Sequence 10. Plugging…………………………………………………………………………… 26
Sequence 11.Emergency Reverse…………………………………………………………… 32
Section 2. EV-T5 Control Troubleshooting……………………………………………………….. 34
Symptom 1. Line contactors will not close………………………………………………. 36
Symptom 2. Line contactor closes, Directional Contactors Will Not Close… 37
Symptom 3. Directional contactors close, no power, and No audible Sound,
truck inoperable with accelerator in FET range…………………… 38
Symptom 4.One Directional contactors closes With Normal Operation But
Other Directional Contactor Will Not Close…………………………. 39
Symptom 5. PMT Trips After Operating In lA Mode and Returning to FET
Mode………………………………………………………………………………… 40
Symptom 6. Contactor Closes, Higher Than Normal Stall Currents in FET
Mode. C/L Pot Will Not Adjust. Contactors May Open Once
and Then Remain Open……………………………………………………… 40
Symptom 7. 1A contactor will not close on Rider…………………………………….. 41
Symptom 8. 1A Contactor Will Not Close on Walkie……………………………….. 42
Symptom 9. Stiff Plug and Distance Will Not Adust……………………………….. 43
Section 3. Component and Card Adjustment…………………………………………………….. 44
Card Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Component Identification………………………………………………………………………. 46
Internal Wiring……………………………………………………………………………………. 47
Checking Components (Battery)…………………………………………………………….. 48
Checking Components (MOSFETs)… ….. .. . .. .. . .. .. . … . . .. .. . .. .. . . . …….. .. . . … . . . .. .. .. … . 49
Checking Components (#3&4 REC)…………………………………………………………. 50
Checking Components (Capacitor)………………………………………………………….. 51
Checking Components (TP, Shunt & Snubber)………………………………………… 52

Please Note:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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