Hyster EV-100 Motor Controller Maintenance And Repair

Hyster EV-100 Motor Controller Maintenance And Repair - Image 2

Hyster EV-100 Motor Controller Maintenance And Repair - Image 3

Hyster EV-100 Motor Controller Maintenance And Repair - Image 4

Hyster EV-100 Motor Controller Maintenance And Repair - Image 5

hyster ev 100 motor controller maintenance and repair 2

hyster ev 100 motor controller maintenance and repair 3

Hyster EV-100 Motor Controller Maintenance And Repair

$30.00

Type Of Manual: Maintenance And Repair
Number of Pages: 1256
Size: 78.2MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- EV-100 Motor Controller

1. RM0287-(01-1994)-US-EN
2. RM0288-(01-1994)-US-EN
3. RM0294-(03-2008)-US-EN
3.1. General
3.2. Brush and Commutator Inspection
3.3. Brush Replacement
3.4. Stoning the Commutator
3.5. Motors Repair
3.6. Brush Alignment, Traction and Hydraulic Motors
3.7. Tests for Damaged Field and Armature
3.8. Troubleshooting
4. RM0312-(03-1997)-US-EN
5. RM0326-(03-2007)-US-EN
5.1. General
5.2. Description
5.3. Steering Axle Assembly Repair
5.4. Wheels and Hubs Repair (All Units)
5.5. Spindles and Bearings Repair (All Units)
5.6. Tie Rods Repair (All Units)
5.7. Steering Cylinder Repair
5.8. Troubleshooting
6. RM0338-(05-2009)-US-EN
6.1. Brake System
6.2. Safety Precautions Maintenance and Repair
6.3. General
6.4. Description and Operation
6.5. Brake Booster and Master Cylinder
6.6. Master Cylinder
6.7. Service Brake Assembly
6.8. Parking Brake
6.9. Seat Brake
6.10. Brake Shoe Assemblies Repair
6.11. Remove and Disassemble
6.12. Clean and Inspect
6.13. Assemble and Install
6.14. Master Cylinder Repair
6.15. Master Cylinder For Lift Truck Models S3.50-5.50XL (S70-120XL) (
6.16. Disassemble
6.17. Assemble
6.18. Install
6.19. Master Cylinder For Lift Truck Models E3.50-5.50XL (E70-120XL, E
6.20. Remove and Disassemble
6.21. Clean and Inspect
6.22. Assemble and Install
6.23. Brake Booster Repair
6.24. Disassemble
6.25. Clean and Inspect
6.26. Assemble
6.27. Install
6.28. Brake System Air Removal
6.29. Brake Pedal Adjustment
6.30. Brake Pedal for Lift Truck Models H3.50-5.00XL (H70-110XL) (F005
6.31. Brake Shoes Adjustment
6.32. Parking Brake Adjustment
6.33. Parking Brake Adjustment, Lift Truck Models S3.50-5.50XL (S70-12
6.34. Parking Brake Lever and Switch Adjustment E3.50-5.50XL (E70-120X
6.35. Seat Brake Assembly
6.36. Clean and Inspect
6.37. Install
6.38. Adjustments
6.39. Solenoid Adjustment
6.40. Traction cutoff Switch Adjustment
6.41. Cable Adjustment
6.42. Brake Booster Relief Valve Check
6.43. Troubleshooting
7. RM0413-(11-2006)-US-EN
7.1. Drive Axle, Speed Reducer, and Differential
7.2. Safety Precautions Maintenance and Repair
7.3. General
7.4. Description
7.5. Drive Axle, Speed Reducer, and Differential Repair
7.6. General
7.7. Traction Motor, Speed Reducer, and Differential
7.8. Disassemble
7.9. Speed Reducer
7.10. Differential
7.11. Inspect
7.12. Assemble
7.13. Speed Reducer
7.14. Differential
7.15. Drive Axle Housing
7.16. Inspect
7.17. Assemble
7.18. Troubleshooting
7.19. Table 1. Pinion Assembly Shims Adjustment
7.20. Table 2. Ring and Pinion Tooth Contact Adjustment
8. RM0414-(01-1992)-US-EN
9. RM0460-(07-1999)-US-EN
10. RM0464-(01-1994)-US-EN
11. RM0485-(08-2003)-US-EN
11.1. Steering System for Electric Lift Trucks
11.2. Safety Precautions Maintenance and Repair
11.3. General
11.4. Description
11.5. Steering Wheel and Column Assembly Repair
11.6. Assembly Components, Remove
11.7. Assembly Components, Install
11.8. Power Steering Motor and Pump
11.9. Description
11.10. Remove and Disassemble, Models E1.25-3.00XL (E25-60XL), J2.00-3.
11.11. Remove and Disassemble, Models E3.50-5.50XL (E70-120XL, E70-120X
11.12. Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM
11.13. Remove and Disassemble, Models A1.00-1.50XL (A20-30XL)
11.14. Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40X
11.15. Assemble and Install – All models with a vertical mount except J
11.16. Assemble and Install, Models J2.00-3.20XM (J40-60XM, J40-60XM 2
11.17. Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM
11.18. Power Steering Pump, Repair
11.19. Seal, Replace
11.20. Hydraulic Steering Motor
11.21. Description
11.22. Hydraulic Steering Motor Repairs
11.23. Disassemble
11.24. Clean and Inspect
11.25. Assemble
11.26. Install
11.27. Steering System Air Removal
11.28. Steering Pressure Check
11.29. Steering Chain Tension Check (Unit With MDU Only)
11.30. Optical Encoder and Activator Circuits Check
11.31. Troubleshooting
12. RM0557-(08-2003)-US-EN
12.1. EV-100ZX SCR Motor Controller
12.2. Safety Precautions Maintenance and Repair
12.3. General
12.4. Model Number Data For EV-100ZX Controller
12.5. Register Parameters
12.6. General
12.7. Function Numbers
12.8. Control Card, Checks and Adjustments
12.9. Handset
12.10. How to Check and Adjust Registers
12.11. How to Scroll through Fault Codes and Clear Them
12.12. Checks and Adjustments on Workbench
12.13. When Handset Is Connected to Control Card Installed In Lift Truc
12.14. Function Numbers 1 through 15
12.15. Function Numbers 16 through 30
12.16. Function Numbers 48 through 62
12.17. Control Cards
12.18. Function Number Descriptions
12.19. Traction Control Cards (Label Letters – ZH and ZY)
12.20. Function Number 1 STORED STATUS CODE
12.21. Function Number 2 CREEP SPEED
12.22. Function Number 3 CONTROLLED ACCELERATION AND 1A TIME
12.23. Function Number 4 CURRENT LIMIT
12.24. Function Number 5 PLUGGING DISTANCE (CURRENT)
12.25. Function Number 6 1A DROP OUT CURRENT
12.26. Function Number 7 FIELD WEAKENING PICK UP
12.27. Function Number 8 FIELD WEAKENING DROP OUT
12.28. Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT
12.29. Function Number 10 REGENERATIVE BRAKING START
12.30. Function Number 13 SPEED LIMIT 3 (SL3)
12.31. Function Number 14 INTERNAL RESISTANCE COMPENSATION
12.32. Function Number 15 BATTERY VOLTS
12.33. Function Numbers GREATER THAN 15
12.34. Function Number 16 PEDAL POSITION PLUG
12.35. Function Number 17 CARD TYPE SELECTION
12.36. Function Number 18 STEERING PUMP TIME DELAY
12.37. Function Number 19 MAINTENANCE ALERT (Tens/Units)
12.38. Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)
12.39. Function Number 21 MAINTENANCE SPEED LIMIT
12.40. Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS
12.41. Function Number 29 HOURMETER (Tens/Units)
12.42. Function Number 30 HOURMETER (Thousands/Hundreds)
12.43. Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE
12.44. Function Number 48 CONTROLLED ACCELERATION AND 1A TIME
12.45. Function Number 49 FIELD WEAKENING PICK UP
12.46. Function Number 50 SPEED LIMIT 1
12.47. Function Number 52 CONTROLLED ACCELERATION AND 1A TIME
12.48. Function Number 53 FIELD WEAKENING PICK UP
12.49. Function Number 54 SPEED LIMIT 1
12.50. Function Number 56 CONTROLLED ACCELERATION AND 1A TIME
12.51. Function Number 57 FIELD WEAKENING PICK UP
12.52. Function Number 58 SPEED LIMIT 1
12.53. Function Number 60 CONTROLLED ACCELERATION AND 1A TIME
12.54. Function Number 61 FIELD WEAKENING PICK UP
12.55. Pump Control Card (Label Letter ZP)
12.56. Function Number 1 STORED STATUS CODE
12.57. Function Number 2 INTERNAL RESISTANCE COMPENSATION START
12.58. Function Number 3 CONTROLLED ACCELERATION
12.59. Function Number 4 CURRENT LIMIT
12.60. Function Number 7 CONTROLLED ACCELERATION COMPENSATION
12.61. Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) – Tilt and S
12.62. Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) – Slow Lif
12.63. Function Number 13 SPEED LIMIT 3 (SL3)
12.64. Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift
12.65. Function Numbers Greater Than 15
12.66. Function Number 16 INTERNAL RESISTANCE COMPENSATION
12.67. Function Number 17 CARD TYPE SELECTION
12.68. Function Numbers 18 through 28 TEMPORARY DATA REGISTERS
12.69. Function Number 29 HOURMETER (Tens/Units)
12.70. Function Number 30 HOURMETER (Thousands/Hundreds)
12.71. Function Number 48 CONTROLLED ACCELERATION
12.72. Function Number 49 SPEED LIMIT 2
12.73. Function Number 50 SPEED LIMIT 3
12.74. Function Number 52 CONTROLLED ACCELERATION
12.75. Function Number 53 SPEED LIMIT 2
12.76. Function Number 54 SPEED LIMIT 3
12.77. Function Number 56 CONTROLLED ACCELERATION
12.78. Function Number 57 SPEED LIMIT 2
12.79. Function Number 58 SPEED LIMIT 3
12.80. Function Number 60 CONTROLLED ACCELERATION
12.81. Function Number 61 SPEED LIMIT 2
12.82. Function Number 62 SPEED LIMIT 3
12.83. Register Parameters
12.84. Troubleshooting
12.85. General
12.86. Status Codes
12.87. Register Maps
12.88. Status Code Charts
12.89. EV-100ZX SCR Motor Controller Repair
12.90. SCR, Check
12.91. SCR Assembly
12.92. Thermal Protector
12.93. SCR 1 Assembly, Replace
12.94. OFF Circuit for SCR 1
12.95. Reactor Assembly, Check
12.96. Suppressors for SCR 2 and SCR 5, Check
12.97. SCR 2 and SCR 5, Check
12.98. SCR 2 and SCR 5, Replace
12.99. Capacitor C1, Check
12.100. Diodes D3 and D4
12.101. Diodes D3 and D4, Check
12.102. Diodes D3 and D4, Replace
12.103. Motor Current Sensor
12.104. Contactors
12.105. Contactor, Repair
12.106. Control Card
12.107. Control Card Plugs
12.108. Brush Wear Indicators
12.109. Theory of Operation
12.110. Electronic Speed Controls
12.111. Silicon Controlled Rectifier (SCR)
12.112. Motor Circuit That Operates With Pulses
12.113. Traction Circuit
12.114. Hydraulic Pump Motor
12.115. SCR 1 OFF Circuit
12.116. Induction Current from Motor
12.117. Control Cards
12.118. Pulse Monitor Trip (PMT) (Traction Circuit Only)
12.119. SRO Circuit (Traction Circuit Only)
12.120. Sequence of Operation
12.121. Control Card Adjustments (Traction Circuit)
12.122. Accelerator Control
12.123. SCR Control (Hydraulic Pump Motor)
12.124. Contactors
12.125. Circuit Protection
12.126. Traction Circuit Fuse
12.127. Current Limit
12.128. Thermal Protection
12.129. Suppressors
12.130. Truck Management Module (TMM1)
12.131. Display Panels
12.132. Display Panel
12.133. Basic Display
12.134. Performance Display
12.135. Brush Wear Indicators
12.136. Table 1. Terminal and Plug Wire Connections for Control Card ZY,
12.137. Table 2. Terminal and Plug Wire Connections for Control Card ZH,
12.138. Table 3. Terminal and Plug Wire Connections for Control Card ZH,
12.139. Table 4. Terminal and Plug Wire Connections for Controller with
12.140. Table 5. Status Codes List
12.141. Table 6. Register Map for Control Cards ZH and ZY (Traction)
12.142. Table 7. Register Map for Control Card ZP (Hydraulic Pump)
12.143. Table 8. Terminal and Plug Wire Connections for TMM1 Module
13. RM0560-(07-2005)-US-EN
13.1. Electrical System
13.2. Safety Precautions Maintenance and Repair
13.3. General
13.4. Description
13.5. ZX Series Display Panels
13.6. Display Panel
13.7. Basic Display Panels
13.8. Performance Display
13.9. Brush Wear Indicators
13.10. SEM Display Panels – Features
13.11. Descriptions of Common Features
13.12. Additional Features of Premium Display Panel
13.13. Descriptions of Additional Features
13.14. SEM Display Panel Indicators
13.15. All Indicator Symbols
13.16. Hourmeter Indicator Symbol
13.17. Wrench Symbol
13.18. Battery Symbol
13.19. Battery Discharge Indicator (BDI)
13.20. Brake Fluid Too Low Symbol
13.21. Parking Brake Symbol
13.22. Fasten Seat Belt Symbol
13.23. LCD Screen (Standard Display Panel)
13.24. Additional Components of Premium Display Panel
13.25. Alpha Numerical Screen
13.26. STAR Push Button
13.27. Push Buttons 1 Through 5 – SEM
13.28. Other Control Components
13.29. Display Panel Components Replacement
13.30. ZX Panel Replacement
13.31. Display Panel Assembly
13.32. Key Switch, Replace
13.33. Indicator LEDs
13.34. Battery Indicators
13.35. Digital Display (Performance Display Panel Only)
13.36. Status Code or Performance Level Switches and Indicator LEDs (Pe
13.37. Basic Display Panel, Replace Parts
13.38. Performance Display Panel, Replace Parts
13.39. SEM Display Panel Replacement
13.40. Motor Controller (SR or SP) Replacement
13.41. Install
13.42. Control Components Replacement
13.43. Start Switch, Replace
13.44. Brake Light Switch, Replace
13.45. Seat Switch, Replace
13.46. External Seat Switch, Adjust
13.47. Switch for Optional Seat Brake, Replace
13.48. Parking Brake Switch, Replace
13.49. Direction Switches (MONOTROL Pedal), Replace
13.50. Direction Control Switches (Steering Column), Replace
13.51. Direction Control Switches, E70-120XL 3 (Steering Column)
13.52. Brake Fluid Switch, Replace
13.53. Brush Wear and Overtemperature Sensors
13.54. Rocker Switches for Lights
13.55. Accelerator Position Sensor, Replace
13.56. On-Demand Steering Components
13.57. Lights, Converter, Relay, and Reverse Alarm
13.58. Incandescent Brake, Tail, and Reverse Light Assembly, Replace
13.59. LED Brake, Tail, and Reverse Light Assembly, Replace

Rate this product