Clark EV100 Control ET202 Troubleshooting Technical Training (ET202)

When you’re dealing with an EV100-controlled truck that spends its days shuttling pallets in warehouses, docks, and tight indoor aisles, this training manual is what teaches you how the control system “thinks.” It doesn’t just say what part to swap; it helps you trace signals through the ET202 setup, understand why a contactor won’t pull in, or why you’ve got drive in one direction but not the other. For example, when a truck intermittently loses travel after a hot shift, this guide helps you separate a pedal or switch issue from a control-board or wiring fault, step by step.

Applications & Use Cases

• Learn the EV100/ET202 architecture so you can read symptoms and narrow faults quickly.
• Trace wiring and signal paths to isolate bad switches, connectors, or control cards.
• Verify adjustments and settings after replacing components so the truck responds correctly.
• Develop a logical diagnostic routine instead of guessing and throwing parts at a problem.
• Train new techs on how to think through electrical faults safely and methodically.

FAQ

Q: Can I keep this manual on a tablet and still use it effectively in the shop?

A: Yes, it works well digitally—zoom in on diagrams, use search, and keep it clean from grease.

Q: Is it worth printing sections of this manual?

A: Many techs print key pages they use often, laminate them, and keep them on the service cart for quick reference.

Safety Note

Always de-energize and verify the truck is secure before probing or adjusting any EV100/ET202 control components.

Clark EV100 Control ET202 Index:

Contents
About this Class………………………………………………………………………………. 2
Safety……………………………………………………………………………………………… 3
Section 1. Introduction to Hydrostatic Drive………………………………………. 4
System Description………………………………………………………………… 4
Microprocessor……………………………………………………………………….. 5
LED Indicators………………………………………………………………………. 6
Dia-3 Tester…………………………………………………………………………… 7
Sensors, Switches, and Actuators…………………………………………….. 8
System Drawing…………………………………………………………………….. 9
Electrical Components……………………………………………………………. 10
Section 2. Programming the Susmic Dia-3…………………………………………. 18
DIA-3 Quick Reference……………………………………………………………. 18
Sensor Set-up Settings……………………………………………………………. 18
Sensor Error Codes………………………………………………………………… 19
Sensor Check Codes………………………………………………………………… 19
Programming Procedures………………………………………………………… 20
Susmic-Dia 3 Operation Manual Version …………………………………. 25
Custom Adjustments of Driving Characteristics Version 6.4……… 43
Custom Adjustments of Driving Characteristics Version 6.3……… 43
Sensor and Actuator Error Diagnosis………………………………………. 56
Sensor Check Procedure………………………………………………………….. 58
Section 3. Troubleshooting………………………………………………………………… 67
Using Dianostic LEDs…………………………………………………………….. 67
Driving Behavior Abnormal…………………………………………………….. 69
Does Not Reach Maximum Speed……………………………………………. 70
Section 4. Hydraulic System……………………………………………………………… 72
Hydrostatic Transmission Specifications…………………………………. 73
System Drawing…………………………………………………………………….. 74
Hydraulic Schematic………………………………………………………………. 75
Pump Components…………………………………………………………………. 76
Adjusting Charge Pressures……………………………………………………. 77
Adjusting Main Pressures………………………………………………………. 78
Towing a Disable Vehicle………………………………………………………… 80
Start-Up Procedures……………………………………………………………….. 80
Section 5. Component Removal and Replacement………………………………. 82
Hydrostatic System Plumbing…………………………………………………. 82
Drive Axle……………………………………………………………………………… 83
Hydrostatic Pump………………………………………………………………….. 84
Pump Mounting……………………………………………………………………… 85
Axle General Arrangement……………………………………………………… 86
Engine Adjustments……………………………………………………………….. 87
Engine Idle Speed Adjustment………………………………………………… 87
Maximum Governor Speed Adjustment…………………………………….

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