1
INTRODUCTION
GENERAL
This section has the checks, adjustments and repair pro-
cedures for the parts of the electrical system that are
NOT
part of the EV-100LX motor controller. This sec-
tion also does NOT include the electrical components
covered in other sections such as motors and battery in-
dicators. This section applies to the electric SitDrive
models such as the J30-40XM. To check, adjust or repair
the parts of the motor controller see the section,
EV-100LX MOTOR CONTROLLER, 2200 SRM
460.
See the section BATTERY INDICATORS, 2200
SRM 138 to adjust the battery indicator. See the section
INSTRUMENT PANEL INDICATORS AND
SENDERS, 2200 SRM 143 to check and replace the
other instrument panel indicators and the senders. See
the section THE DC MOTOR MAINTENANCE, 620
SRM 294 for maintenance of the motors. See the section
THE INDUSTRIAL BATTERY, 2240 SRM 1 for in-
formation on the battery.
NOTE: This section does NOT include any compo-
nents of any of the motor controllers. Many of the com-
ponents in this section do have inputs to the EV-100LX
motor controllers, but are not part of the controller.
WARNING
Do not operate a lift truck that needs adjustment or
repairs. Report the need for adjustment or repairs
immediately. If adjustment or repair is necessary,
put a “DO NOT OPERATE” tag in the operator’s
area. Remove the key from the key switch.
Some of the checks and adjustments are done with
the battery connected. Never have any metal on your
fingers, arms or neck. These metal items can
accidentally make an electrical connection and cause
an injury.
Some components that have inputs to the controller
have installation adjustments. This section has the cor-
rect procedures for replacement, checks and adjustment
of these components. These components include the fol-
lowing:
1. Key Switch
2. Accelerator Switch Assembly
3. Stop Light Switch
4. Seat Switch
5. Switch for Optional Seat Brake
6. Parking Brake Switch
7. Direction (FWD REV) Switches
Monotrol Pedal
Direction Control (on Steering Column)
8. Hydraulic Cut Off Switch
9. Brake Fluid Switch
10. Motor Temperature Switches
11. Rocker Switches for Lights
12. Lights and Reverse Alarm
13. Horn and Horn Button
14. Printed Circuit Boards
!*+ *$)" )1 - ,-, ) %.,-( )-, +$, -#
+$/ 0# ', *!! -# !'**+ ) '*& -# '$!- -+.&
$) $2
-# + -# *+ -#
NOTE: Some checks and adjustments are difficult to
do unless another person can operate the controls. When
working alone, put a weight in the seat to close the seat
switch. If your lift truck has a seat brake, release the seat
brake when the operator in not in the seat. Put the volt-
meter in a position so that you can see it from the opera-
tor area. You can usually operate the controls with your
hand and also make the voltage measurements.
DESCRIPTION
INSTRUMENT PANELS
There are two instrument panel displays available on
these lift trucks:
• a standard display that gives the operator basic in-
formation about the operation of the lift truck and
• a premium display that also includes diagnostic
capabilities and performance settings.
Standard Display (See FIGURE 1)
When the key is first turned to the “ON” position, a start
program will cause each indicator light to illuminate to
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