Yale Forklift EV-100ZX™ SCR Motor Controller Service Manual – PDF DOWNLOAD

Description

Yale Forklift EV-100ZX™ SCR Motor Controller Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift EV-100ZX™ SCR Motor Controller Service Manual – PDF DOWNLOAD

Language : English
Pages :512
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Yale Forklift EV-100ZX™ SCR Motor Controller Service Manual – PDF DOWNLOAD

General 1
Model Number Data For EV-100ZX Controller 2
Register Parameters 16
General 16
Function Numbers 16
Control Card, Checks and Adjustments 16
Handset 17
How to Check and Adjust Registers 17
How to Scroll through Fault Codes and Clear Them 17
Checks and Adjustments on Workbench 18
When Handset Is Connected to Control Card Installed In Lift Truck 19
Function Numbers 1 through 15 20
Function Numbers 16 through 30 20
Function Numbers 48 through 62 20
Control Cards 21
Function Number Descriptions 21
Traction Control Cards (Label Letters – ZH and ZY) 21
Function Number 1 STORED STATUS CODE 21
Function Number 2 CREEP SPEED 21
Function Number 3 CONTROLLED ACCELERATION AND 1A TIME 21
Function Number 4 CURRENT LIMIT 22
Function Number 5 PLUGGING DISTANCE (CURRENT) 22
Function Number 6 1A DROP OUT CURRENT 22
Function Number 7 FIELD WEAKENING PICK UP 22
Function Number 8 FIELD WEAKENING DROP OUT 22
Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT 22
Function Number 10 REGENERATIVE BRAKING START 23
Function Number 13 SPEED LIMIT 3 (SL3) 23
Function Number 14 INTERNAL RESISTANCE COMPENSATION 23
Function Number 15 BATTERY VOLTS 24
Function Numbers GREATER THAN 15 24
Function Number 16 PEDAL POSITION PLUG 24
Function Number 17 CARD TYPE SELECTION 24
Function Number 18 STEERING PUMP TIME DELAY 24
Function Number 19 MAINTENANCE ALERT (Tens/Units) 25
Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds) 25
Function Number 21 MAINTENANCE SPEED LIMIT 25
Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS 25
Function Number 29 HOURMETER (Tens/Units) 25
Function Number 30 HOURMETER (Thousands/Hundreds) 25
Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE 25
Function Number 48 CONTROLLED ACCELERATION AND 1A TIME 26
Function Number 49 FIELD WEAKENING PICK UP 26
Function Number 50 SPEED LIMIT 1 26
Function Number 52 CONTROLLED ACCELERATION AND 1A TIME 26
Function Number 53 FIELD WEAKENING PICK UP 26
Function Number 54 SPEED LIMIT 1 27
Function Number 56 CONTROLLED ACCELERATION AND 1A TIME 27
Function Number 57 FIELD WEAKENING PICK UP 27
Function Number 58 SPEED LIMIT 1 27
Function Number 60 CONTROLLED ACCELERATION AND 1A TIME 27
iii
Table of Contents EV-100ZX™ SCR Motor Controller
TABLE OF CONTENTS (Continued)
Function Number 61 FIELD WEAKENING PICK UP 27
Pump Control Card (Label Letter ZP) 27
Function Number 1 STORED STATUS CODE 28
Function Number 2 INTERNAL RESISTANCE COMPENSATION START 28
Function Number 3 CONTROLLED ACCELERATION 28
Function Number 4 CURRENT LIMIT 28
Function Number 7 CONTROLLED ACCELERATION COMPENSATION 28
Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) – Tilt and Slow Auxiliary (Auxiliary and
Slow Rotate for N30XMH) 28
Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) – Slow Lift and Medium Auxiliary
(Slow Lift And Fast Rotate for N30XMH) 28
Function Number 13 SPEED LIMIT 3 (SL3) 28
Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift 29
Function Numbers Greater Than 15 29
Function Number 16 INTERNAL RESISTANCE COMPENSATION 29
Function Number 17 CARD TYPE SELECTION 29
Function Numbers 18 through 28 TEMPORARY DATA REGISTERS 29
Function Number 29 HOURMETER (Tens/Units) 29
Function Number 30 HOURMETER (Thousands/Hundreds) 29
Function Number 48 CONTROLLED ACCELERATION 30
Function Number 49 SPEED LIMIT 2 30
Function Number 50 SPEED LIMIT 3 30
Function Number 52 CONTROLLED ACCELERATION 30
Function Number 53 SPEED LIMIT 2 30
Function Number 54 SPEED LIMIT 3 30
Function Number 56 CONTROLLED ACCELERATION 30
Function Number 57 SPEED LIMIT 2 30
Function Number 58 SPEED LIMIT 3 30
Function Number 60 CONTROLLED ACCELERATION 31
Function Number 61 SPEED LIMIT 2 31
Function Number 62 SPEED LIMIT 3 31
Register Parameters 31
Troubleshooting 31
General 31
Status Codes 32
Register Maps 34
Status Code Charts 45
EV-100ZX SCR Motor Controller Repair 86
Fuses 86
SCR, Check 86
SCR Assembly 88
Thermal Protector 88
SCR 1 Assembly, Replace 88
OFF Circuit for SCR 1 89
Reactor Assembly, Check 89
Suppressors for SCR 2 and SCR 5, Check 89
SCR 2 and SCR 5, Check 89
SCR 2 and SCR 5, Replace 90
Capacitor C1, Check 90
Diodes D3 and D4 90
Diodes D3 and D4, Check 90
iv
EV-100ZX™ SCR Motor Controller Table of Contents
TABLE OF CONTENTS (Continued)
Diodes D3 and D4, Replace 90
Motor Current Sensor 90
Contactors 91
Contactor, Repair 91
Control Card 93
Control Card Plugs 94
Brush Wear Indicators 94
Theory of Operation 95
Electronic Speed Controls 95
Silicon Controlled Rectifier (SCR) 96
Motor Circuit That Operates With Pulses 97
Traction Circuit 98
Hydraulic Pump Motor 98
SCR 1 OFF Circuit 98
SCR 1 OFF Operation 99
Induction Current from Motor 101
Control Cards 102
Pulse Monitor Trip (PMT) (Traction Circuit Only) 102
SRO Circuit (Traction Circuit Only) 102
Sequence of Operation 103
Control Card Adjustments (Traction Circuit) 103
Accelerator Control 107
SCR Control (Hydraulic Pump Motor) 107
Contactors 107
Circuit Protection 108
Traction Circuit Fuse 108
Current Limit 108
Thermal Protection 108
Suppressors 109
Truck Management Module (TMM1) 109
Display Panels 110
Display Panel 110
Optional Basic Display Panel 110
Features of the Optional Basic Display Panel 110
Description of Features on the Optional Basic Display Panel 111
Standard Display Panel 111
Features of the Standard Display Panel 111
Description of Features on the Standard Display Panel 112
Premium Display Panel 113
Features on the Premium Display Panel 113
Description of Features on the Premium Display Panel 114
Curtis 1215 Display Panel 116
Description and Features 116
Operation 117

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S.M 07/24