Service Manual

EV100ZX SCR Motor Controller

2EC15
2EC18
2EC20
2EC25
2EC25E
2EC30

SENB8606-01
 SAFETY PRECAUTIONS

Cat Lift Trucks

Important Safety Information
Most accidents involving product operation, mainte-
nance and repair are caused by failure to observe
basic safety rules and precautions. An accident can
often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must
be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform
these functions properly.
Improper operation, lubrication, maintenance or repair
of this product can be dangerous and could result in
injury or death.
Do not operate or perform any lubrication, maintenance
or repair on this product, until you have read and
understood the operation, lubrication, maintenance
and repair information.
Safety precautions and warnings are provided in this
manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to
you or other persons.
The hazards are identified by the “Safety Alert Symbol”
and followed by a “Signal Word” such as “CAUTION”
or “WARNING” as shown below.
Mitsubishi Caterpillar Forklift America Inc. cannot
anticipate every possible circumstance that might
involve a potential hazard. The warnings in this publi-
cation and on the product are therefore not all-inclu-
sive. If a tool, procedure, work method or operating
technique not specifically recommended by Mitsubishi
Caterpillar Forklift America Inc. is used, you must sat-
isfy yourself that it is safe for you and others. You
should also ensure that the product will not be dam-
aged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this
publication are on the basis of information available at
the time it was written. The specifications, torques,
pressures, measurements, adjustments, illustrations,
and other items can change at any time. These
changes can affect the service given to the product.
Obtain the complete and most current information
before starting any job.
Mitsubishi Forklift Trucks dealers have the most cur-
rent information available.

! WARNING
The meaning of this “Safety Alert Symbol” is as follows:

Attention! Become Alert! Your Safety is involved.

The message that appears under the warning

explains the hazard and can be either written or
pictorially presented.

Operations that may cause product damage are

identified by NOTICE labels on the product and in this
publication.
 TABLE OF CONTENTS

1. GENERAL INFORMATION & FEATURES

Glossary....................................................................................................................................... 1-1
Nameplate and Serial Number Locations.................................................................................... 1-5
EV100ZX Motor Controller without SCR Hydraulics ................................................................... 1-6
EV100ZX Motor Controller with optional SCR Hydraulics........................................................... 1-7
Basics of Circuit Operation .......................................................................................................... 1-8
Traction Control Logic Flow Chart ............................................................................................... 1-9
Console (Display) ........................................................................................................................ 1-10
Features of the EV100ZX Control System .................................................................................. 1-11
General Maintenance for the EV100ZX Motor Controller............................................................ 1-15
Trouble-shooting the EV100ZX Motor Controller......................................................................... 1-15
EV100ZX SCR Control Wiring Schematic without SCR Hydraulics ............................................ 1-16
EV100ZX SCR Control Wiring Schematic with SCR Hydraulics ................................................. 1-18
EV100ZX SCR Control Wiring Schematic for Optional Equipment ............................................. 1-20

2. HANDSET
General Information ..................................................................................................................... 2-1
Handset Function ................................................................................................................... 2-1
Operation................................................................................................................................ 2-2
Function Set-Up Procedures for Traction SCR ...................................................................... 2-2
Accessing and Clearing Fault Codes ..................................................................................... 2-3
Bench Checks and Adjustments............................................................................................. 2-3
Function Numbers (Traction) ....................................................................................................... 2-4
Function Settings Chart (Traction Card) ...................................................................................... 2-8
Function Set-Up Procedures for Optional SCR Hydraulics ......................................................... 2-11
Function Numbers (Pump)........................................................................................................... 2-11
Function Settings (Pump Card) ................................................................................................... 2-15

3. CHECKS & REPAIRS

General Information ..................................................................................................................... 3-1
Fuses ...................................................................................................................................... 3-2
SCR’s...................................................................................................................................... 3-2
Thermal Protector................................................................................................................... 3-3
Reactor Assembly................................................................................................................... 3-4
Suppressors ........................................................................................................................... 3-4
Capacitor C1........................................................................................................................... 3-5
Diodes D3, D4 & D7 ............................................................................................................... 3-5
Motor Current Sensor ............................................................................................................. 3-6
Thermal Protector Test ........................................................................................................... 3-6
Contactors .............................................................................................................................. 3-7
Control Card ........................................................................................................................... 3-9
Control Card Plugs ................................................................................................................. 3-9
Brush Wear Indicators ............................................................................................................ 3-10
Motor Thermal Switches......................................................................................................... 3-10
Motors and Controls .................................................................................................................... 3-10
Truck Management Module (TMM) ........................................................................................ 3-11
Truck Management Module Connections (TMM1) ................................................................. 3-12
Thermal Transfer .................................................................................................................... 3-13
Trouble Shooting Tips............................................................................................................. 3-14
Unsatisfactory Brush Performance .............................................................................................. 3-15
Commutator Surfaces .................................................................................................................. 3-21
Motor Winding Specifications ...................................................................................................... 3-23

4. LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

Main Logic Card........................................................................................................................... 4-1
Component Locations .................................................................................................................. 4-2
Terminal Connections for ZX Logic Cards ................................................................................... 4-3
EV100ZX Logic Card Specifications............................................................................................ 4-4
 TABLE OF CONTENTS

4. LOGIC CARD CONNECTIONS & TROUBLESHOOTING BY SYMPTOM (continued)

EV100ZX Current Limit Curves ................................................................................................... 4-6
Secondary Troubleshooting.................................................................................................... 4-7
Failures that Cause Reduced or No Motor Torque with SCR Control.................................... 4-7
Failures that Cause Full or No Motor Torque with SCR Control ............................................ 4-9
Mis-operation of Other Features ............................................................................................ 4-10
Hydraulic Pump Control Troubleshooting .................................................................................... 4-12
Failures that Cause Reduced or No Motor Torque with SCR Control.................................... 4-12
Failures that Cause No Motor Torque with SCR Control ....................................................... 4-14

5. THEORY OF OPERATION
Electronic Speed Controls ........................................................................................................... 5-1
Silicon Controlled Rectifier (SCR) .......................................................................................... 5-1
Motor Circuit that Operates with Pulses................................................................................. 5-1
Traction Circuit........................................................................................................................ 5-3
Hydraulic Pump Motor ............................................................................................................ 5-3
SCR “OFF” Circuit .................................................................................................................. 5-4
Flyback Current from the Motor................................................................................................... 5-6
Control Cards............................................................................................................................... 5-6
Pulse Monitor Trip (PMT) (Traction Circuit Only) ................................................................... 5-6
SRO Circuit (Traction Circuit Only) ........................................................................................ 5-7
Sequence of Operation................................................................................................................ 5-7
Control Card Adjustments (Traction Circuit Only) .................................................................. 5-8
Accelerator Control................................................................................................................. 5-11
SCR Control (Hydraulic Pump Motor) ......................................................................................... 5-11
Contactors.................................................................................................................................... 5-12
Circuit Protection ......................................................................................................................... 5-13
Traction Circuit Fuse .............................................................................................................. 5-13
Current Limit ........................................................................................................................... 5-13
Thermal Protection ................................................................................................................. 5-13
Truck Management Module (TMM1) ........................................................................................... 5-13
Instrument Panel.......................................................................................................................... 5-14
Fault Code Memory ................................................................................................................ 5-16
Brush Wear Indicators ............................................................................................................ 5-16

6. WIRING
Power Cable Connections ........................................................................................................... 6-1
Standard Control .................................................................................................................... 6-1
Optional SCR Hydraulics Control ........................................................................................... 6-1
Traction Control Card Wire Harness Connections ...................................................................... 6-2
A & B Plugs ............................................................................................................................ 6-2
Y Plug ..................................................................................................................................... 6-3
Z Plug ..................................................................................................................................... 6-4
TMM1 (Truck Management Module 1) ................................................................................... 6-5
TB Connections ...................................................................................................................... 6-6
Control Card Wire Harness for Optional Hydraulic Pump SCR .................................................. 6-7
Panel Connector..................................................................................................................... 6-7
TB Connections ...................................................................................................................... 6-8
A & B Plugs ............................................................................................................................ 6-9
Y Plug ..................................................................................................................................... 6-10
Z Plug for Use on Option Card............................................................................................... 6-11
Pump Driver ................................................................................................................................. 6-12
Pump Time Delay ........................................................................................................................ 6-13

7. DIAGNOSTIC STATUS CODES

Basic Checks ............................................................................................................................... 7-1
On Board Diagnostics.................................................................................................................. 7-2
Status Codes ............................................................................................................................... 7-4

EV100ZX is a trade name of General Electric Company