Senb8604 02 03 - 44607 PDF

SENB8604-02
Testing and Adjusting To toggle to the next code, cycle the DIAG/RUN/
SETUP switch from DIAG to RUN and back to
DIAG. When you reach the end of the list (or if
Accessing Stored Fault Codes there are no stored codes), the word “DONE” will
appear.
The logics stores the thirty-two faults or warnings that
occurred on the lift truck. This information is useful for To get back to the beginning from the end of the
troubleshooting intermittent faults, determining which list, cycle the DIAG/RUN/SETUP switch from
motor has worn brushes, or which thermal switch over- DIAG to RUN to DIAG again.
heated. The stored information can also be useful in
determining the application in which the truck is being To clear the fault code memory, cycle the DIAG/
used. Example: pump motor thermal indication has RUN/SETUP switch from DIAG to SETUP, then
been ON; could mean that the truck is used in a heavy wait until the display starts to flash done, then
duty hydraulic application. switch back to DIAG.
The stored faults are accessed by the following proce- The following is a list of possible stored codes:
dure (called a “fault dump”): E1 - DRIVE HOT
1. Start with the key switch OFF. E2 - PUMP HOT
E3 - CONTROLLER HOT
2. Remove the logics cover. B1 - DRIVE BWI
3. Place the DIAG/RUN/SETUP switch to DIAG. B2 - PUMP BWI
4. Turn the key switch ON while pulling back on the AA-HEADCAP FAILURE
LIFT and TILT levers.
NOTE: These fault codes only show up during the
The fault codes will appear on the display, beginning fault code dump.
with the most recent.
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Troubleshooting Troubleshooting Checklist

The following Troubleshooting Check List is an aid in 1. Perform Preparations Tests and Checks.
troubleshooting MicroCommand II lift trucks. The trou- 2. Correct any display problems and “Run Time”
ble-shooting checklist, “Run Time” diagnostic indica- diagnostic faults.
tions, “Self” diagnostic tests, problem list and problem
3. Correct the “Self” diagnostic faults.
flow charts will assist in:
4. Perform Operational Checks.
1. Defining the problem and verifying that a problem
exists. 5. Correct “Other Problems” in the Troubleshooting
Problem List.
2. Performing the checks in a logical order.
6. Perform Operational Checks to verify repairs.
3. Making the necessary repairs.
4. Verifying that the problem has been resolved.
! WARNING
The lift truck can move suddenly. Battery voltage
and high amperage are present. Injury to personnel
or damage to the lift truck is possible. Safely lift both
drive wheels off the floor. Put blocks of wood under
the frame so the drive wheels are free to turn. During
any test or operation check, keep away from drive
wheels. Before any contact with the control panel is
made, disconnect the battery and discharge HEAD
CAP. Rings, watches, and other metallic objects
should be removed from hands and arms when trou-
bleshooting the MicroCommand II Control System.
NOTICE: Damage can be caused to the test equip-
ment. Make resistance and continuity checks only
after the battery is disconnected.
NOTICE: Damage can be caused to the control
panel. Do not use steam or solvent to clean the
controls. Use pressure from an air hose with a
maximum pressure of 205kPa (30 psi) to clean the
control panel when necessary. Make sure the air
pressure supply is equipped with a water filter.
NOTICE: Damage can be caused to the control
panel. Do not switch the direction lever from one
direction to the other (plug the lift truck) when
the drive wheels are off the ground and in rotation
at full speed.
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Preparation Tests and Checks Cell Voltage Test

With the truck powered up and the power steering
Battery Tests motor running, measure the voltage at each cell.
A weak battery can cause or contribute to problems in Normal voltage should be between 1.95V and 2.12V
the MicroCommand II control and power circuits. Verify per cell. If the voltage on each cell is below 1.95, the
the battery is good before investigating other possibilities. battery must be charged or repaired before continuing
to troubleshoot.
1. Verify proper polarity at the battery connector
and the MicroCommand II control panel. Positive NOTE: The indication between cells should not differ
cable should be at the line contactor and nega- more than 0.05 volts. If it does, the battery must
tive at the negative standoff or regen contactor. have an equalizing charge or be repaired.
2. If the lift truck is operational, perform a Hydrometer Test
battery load test.
Test each cell of the battery with a Battery Hydrometer.
3. If the truck is not operational and the battery is If the specific gravity indication is below 1.140, the
suspected, perform a cell voltage or specific battery must be charged. The battery is fully charged if
gravity test. the indication is 1.265 to 1.285.
Battery Load Test NOTE: The indication between cells should not differ
more than.020. If it does, the battery needs an
1. Turn the range switch on the multimeter to read equalizing charge or needs to be repaired.
battery voltage.
2. Connect the battery. Battery Maintenance
NOTE: It is important that all batteries be charged
and maintained according to the battery manufac-
turers instructions.
The care and maintenance of batteries is most impor-
tant to maximum battery life and efficient truck opera-
tion. Periodic inspection and service will increase the
life of batteries. Special attention should be given to
the rules that follow:
1. Keep batteries clean at all times. Cleaning will
prevent corrosion, current leakage, and shorts to
chassis. Tighten all vent plugs, wash the battery
with water and a brush, then dry with an air hose.
1 2 It may be necessary to use a baking soda solution
if water alone will not clean the top of the battery.
97C54-00300
2. Add enough water to cover the plates before
3. Connect the multimeter leads between positive(+) charging. This will ensure the proper chemical
cable connection (1), and negative (-) cable reaction over the entire plate surface. After
connection (2). charging is complete, add water until it is about
12.7 mm (.50 in) above the plates. Use distilled
4. In a safe area, operate the hydraulic system,
water or water that has tested free from minerals.
(hold tilt lever to maximum position momentarily)
while reading the voltage indicated on the multi- 3. Charge the battery correctly. A battery should be
meter. discharged to 80% of its capacity, then fully
recharged. It should cool four to eight hours to
5. If the indication is less than 33.1 volts for 36 volt
allow the voltage to stabilize before being put
trucks or 44.2 volts for 48 volt trucks, the battery
back in use. The battery should have an equalizing
needs to be charged or repaired before continuing
charge (an extra three or four hour charge at a
to troubleshoot.
low finish rate) once a month to make sure all
cells are in a fully charged condition. Properly
charged batteries should be identified to prevent
low batteries from being installed in trucks.
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4. Operation with a low battery must be prevented. Visual Checks

Low battery operation may damage the battery
and will cause higher than normal current in the 1. Verify all components and wires are in their proper
electrical system. High current draw due to a low place. Check fuses, components, contactor tips,
battery will damage contactor tips and shorten wires and connections. Verify that they are not
motor brush life. burned, broken, or loose.
5. The battery’s maximum temperature is critical. 2. Verify there is no mechanical binding or interfer-
The electrolyte temperature should never exceed ence in the contactors.
43°C (110° F) either while operating or charging. 3. Visually check the parking brake switch, the
Overcharging a battery will cause overheating service brake switch, hydraulic lift switch, and
and warp the battery plates. Maximum battery accelerator linkage for adjustment or interference
life will result from maintaining 25°C (77°F) problems.
electrolyte temperature. Most of the charging
equipment is fully automatic but should be Resistance To Chassis Checks
checked periodically to assure proper working Resistance between any point in the truck wiring and
order. the chassis should be a minimum of 10,000 ohms or
6. Keep accurate battery records. Regular battery more.
readings should be taken with a battery tester or
Many malfunctions are caused by shorts to chassis.
voltmeter and a written record kept. Specific
Usually, two shorts must exist before a malfunction will
gravity and voltage of each cell should be
occur. But, since batteries can have chassis leakage,
checked and recorded at least once each month.
only one short to chassis in the truck wiring can cause
This inspection should be made after an equaliz-
problems. To prevent problems because of shorts, do
ing charge. Readings should never be taken
the following:
directly after water has been added. Records of
all battery maintenance should be made and filed 1. Disconnect the battery and discharge the
so it will be known which batteries are being HEAD CAP.
abused or wearing out. 2. Measure from the chassis to both sides of the
Repairs should be made immediately, otherwise the line contactor, component connection or wiring
battery may become damaged. Batteries stored in a connection in respect to the lift truck chassis for
discharged condition may be difficult to recharge due a minimum resistance of 10,000 ohms. Any test
to sulfate formation. point with low resistance must have the short to
chassis removed.
3. Always keep batteries clean to minimize current
leakage to the chassis.
4. Routinely clean the brush dust from the motors.
5. Be sure that all attachments, such as horns and
lights, are designed for no chassis connection
(a two-wire system).
Removal Of Shorts To Chassis

When a short is found, it must be cleared even if the
machine has normal operation. It is necessary to narrow
the field of possible problem areas before inspection of
individual wires and components.
When a low resistance circuit is located, it should be
opened at various points. This will permit the shorted
wire or component to be pinpointed for repair or
replacement.
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Control And Power System Check 5: Reverse Drive Performance

1. Select reverse direction and depress the acceler-
Operational Checks ator slightly. The reverse contactor will activate
All operational checks are to begin with: programmable and the drive wheels will turn in reverse slowly.
features set to the default values, battery connected, 2. Slowly increase the amount of accelerator
directional switch in neutral, drive wheels off the depression. The reverse contactor will remain
ground, and the accelerator and parking brake activated. The drive wheels will turn in reverse
released. and slowly increase in speed.
NOTE: Perform all operational checks before 3. Depress the accelerator fully. The reverse contactor
returning to the Troubleshooting Check List. will remain activated and bypass contactor will
activate. The drive wheels will turn in reverse at
Check 1: Key And Seat Switch full speed.
1. Actuate the key and seat switch. The line contactor
Check 6: Electrical Braking Performance
activates and the hydraulic motor runs. After five
seconds the line contactor deactivates and the NOTICE: Do not perform this check with the lift
motor turns off. truck in bypass mode. Damage to the control panel
can result.
Check 2: Power Steering Performance
1. Turn the steering wheel. The pump motor should 1. Select forward direction and depress the acceler-
provide adequate hydraulic flow for the steering ator to the point just before bypass occurs. While
system. continuing to depress the accelerator, change the
direction switch to reverse. The forward contac-
Check 3: Lift, Tilt, and Auxiliary Performance tor should deactivate and the reverse contactor
should activate. There should be a smooth decel-
1. Slowly pull the lift control lever. The pump motor
eration of forward tire rotation and a smooth
will activate.
acceleration of reverse tire rotation.
2. Pull the lift control lever further and the motor
2. While continuing to depress the accelerator in
speed will increase to the maximum speed.
reverse direction change the direction switch to
3. Slowly pull and push the tilt and auxiliary levers. forward. The reverse contactor should deactivate
The pump motor increases speed with each lever and the forward contactor should activate. There
movement. should be a smooth deceleration of reverse tire
Check 4: Forward Drive Performance rotation and a smooth acceleration of forward tire
rotation.
1. Engage the parking brake. Select forward direc-
tion and depress the accelerator slightly. The for-
ward contactor will not activate and the drive
wheels will not turn. The park brake action light
will be on.
2. Release the parking brake, select forward direc-
tion and depress the accelerator slightly.
Depending upon the setting of Option 13, the
forward contactor may activate and the drive
wheels may turn forward slowly.
3. Slowly increase the amount of accelerator
depression. The forward contactor will remain
activated. The drive wheels will turn forward and
slowly increase in speed.
4. Depress the accelerator fully. The forward
contactor will remain activated and the bypass
contactor will activate. The drive wheels will turn
forward at full speed.
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Built-In Diagnostic Operation Brush Wear Indicator ON - lift truck operation

is normal. See Troubleshooting Problem 5.
The logics and the display provide built-in diagnostic Possible cause, worn brushes on pump and/or
analyzer functions. Numerous diagnostic functions drive motor.
occur while the truck is in operation. These are called
“Run-time” diagnostics. The other diagnostics are Overtemperature Indicator ON - lift truck
called “Self” diagnostics. They are performed when the accelerates slower than normal. See
lift truck is not in operation by using a switch located in Troubleshooting Problems 6, 7, and 8. Fault
the logics. codes E1, E2, or E3 may be stored. Possible
causes, control panel, drive or pump motor
“Run-Time” Diagnostics overtemperature; faulty thermal switch.
(lift truck in Operation) Display = 20 - No lift truck operation.
The diagnostics functions that follow would occur dur- See Troubleshooting Problem 15. Possible cause:
ing normal lift truck operation and are shown on the current limit out of adjustment, Drive Pulsing Stall
LCD display. The speedometer portion of the LCD Timer option, or Bypass option set incorrectly.
display is used to indicate the fault codes.
Display = 60 - No lift truck operation.
There are a total of 31 possible Run-Time fault codes. See Troubleshooting Problem 32. Possible cause,
Listed below are some common codes and their possi- serial communications fault between the display
ble causes, with references to the Troubleshooting and the logics.
Problem list and flow charts found later in this section
of the manual. Refer to that list and the flow charts for Display = 65 - No lift truck operation.
the specific code, and the problem it indicates, that See Troubleshooting Problem 34. Possible cause,
you are trying to troubleshoot. truck size not initialized. (Programmable Setup
option 30).
Display = 68 or 69 - No lift truck operation.
See Troubleshooting Problem 36. Possible cause,
battery volts too low or too high for chosen jumper.
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“Self” Diagnostics
(Lift Truck Not In Operation) ! WARNING
The “Self” diagnostic procedure should be used to help The lift truck can move suddenly. Injury to personnel
troubleshoot after a problem has occurred. Self or damage to the lift truck is possible. Disconnect
Diagnostics are most useful for finding faulty circuits or the battery and disconnect the line fuse to prevent
components. Complete all the tests before returning to lift truck movement.
the Troubleshooting Check List. 4. Release the park brake to close the park brake
switch.
NOTE: The Self Diagnostics procedure as well as the
LCD display readouts for test pass and fail is printed 5. Loosen the two screws (2) and remove the logics
on a decal located on the inside door to the control cover (3).
panel. Following the procedure on the decal is
recommended.
Before beginning the Self Diagnostics tests, do the
following:
1. Turn the key switch OFF.
2. Disconnect the battery and check the head
capacitors for discharge below 5 volts. If the
head capacitors are not discharged, discharge
them by holding a discharge resistor in place for
20 seconds. See the topic, “Discharging the
Head Capacitor” in the Testing And Adjusting
section of this manual.
C0000 Logics Board
6. Move the switch to the DIAG position. This

2 places the controller in diagnostics when the key
3 2
switch is turned on. If any of the tests that follow
fail [except the line (drive) fuse test where the
display = “dd”], continue through the tests that
remain. Make a note of all failed tests for detailed
troubleshooting.
1
To bypass a failed test and allow the next test to be
performed, move the switch to the RUN position then
back to the DIAG position.
Location of Components
(1) Line fuse. (2) Screws. (3) Logics cover.
3. Disconnect the line fuse (1) to prevent lift truck

movement.
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Circuit Tests Test F: Service Brake Circuit

NOTE: It is not necessary for the park brake to be
Test A: Internal Circuitry released for this test.
Connect the battery and turn the key switch ON. Depress and release the service brake.
Display = “blank” See Troubleshooting Problems Display = 04 Service brake circuit defect.
1, 2, or 3. See Troubleshooting Problem 41.
Display = FF Logics failure. Replace logics. You Display = 05 Service brake switch circuit OK.
may also bypass this failure by toggling the
DIAG/RUN/SETUP switch to RUN and back to Test G: Accelerator Circuit
DIAG.
Fully depress and release the accelerator.
NOTE: This test does not check all the logics
circuits, so the logics may pass this test and Display = 05 Accelerator circuit defect.
still have a failure. See Troubleshooting Problem 42.
Display = dd Line fuse not disconnected or head Display = Flashing 00 Accelerator circuit OK,
capacitors not discharged below 5 volts. ready to perform the accelerator speed test.
Return to Step 2.
Test H: Accelerator Speed Check
Test B: Line (drive) Fuse Out Depress the accelerator again.
This test will take place automatically if Test A is Display shows flashing accelerator position, 00 - 15.
completed successfully. If some speeds are missing, at the beginning or the
Display = 01 Line (drive) fuse is out and head end of travel, for example, then the pedal probably
capacitors are discharged, as they should be f needs to be adjusted. To bypass the flashing speed
or these tests. The 01 display indicates a pass number and proceed to the next test, toggle the
for this test. DIAG/RUN/SETUP switch from DIAG to RUN and
back to DIAG.
Display = dd Line fuse not disconnected or
head capacitors not discharged below 5 volts. Test I: BDI Circuit
Return to Step 2.
This test is performed automatically after the
Test C: Seat Switch Circuit DIAG/RUN/SETUP switch is toggled in the preced-
ing test. The BDI test happens quickly; in fact, if the
Press and release seat to close and open seat BDI is OK, 06 (indicating a pass for Test H) may be
switch. bypassed too quickly to be seen.
Display = 01 Seat switch circuit defect. Move Display = 06 BDI circuit failure.
hand around on seat and press again. If still See Troubleshooting Problem 43.
01, see Troubleshooting Problem 37. Display = 07 BDI circuit OK.
Display = 02 Seat switch circuit OK.
Test D: Direction Switch Circuit

Cycle the direction lever from neutral to reverse to
neutral again and then to forward.
Display = 02 Direction switch circuit defect.
See Troubleshooting Problem 38.
Display = 03 Direction switch circuit OK.
Test E: Park Brake Circuit

Engage and release the park brake.
NOTE: The Park Brake action light may come on.
This does not indicate a problem.
Display = 03 Park brake circuit defect.
Display = 04 Park brake circuit OK.
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Test J: Lift Switch Circuit Test M: Aux2 Switch Circuit

Pull the lift lever back to maximum and release. NOTE: If AUX2 does not exist on the test truck,
Display = 07 Lift switch circuit defect. bypass by toggling the DIAG/RUN/SETUP switch.
See Troubleshooting Problem 44. Pull the aux2 lever back to maximum and release.
Display = 08 Lift switch circuit OK. Display = 10 Aux1 switch circuit defect.
Test K: Tilt Switch Circuit Display = Flashing 00 Aux2 switch circuit OK.
Pull the tilt lever back to maximum and release.
Display = 08 Tilt switch circuit defect. Test N: Hydraulic Speed Check
See Troubleshooting Problem 45. After a successful aux2 circuit test, the flashing
Display = 09 Tilt switch circuit OK. number in the display can show the speed associated
with each hydraulic function. For example, if you
Test L: Aux1 Switch Circuit pull back on the tilt lever, you will see the tilt speed
on the display. Only one lever should be tested
Pull the aux1 lever back to maximum and release. (pulled back) at a time. Exception: If you are using
Display = 09 Aux1 switch circuit defect. only the lift0 and lift1 switches, you can test them
See Troubleshooting Problem 46. both at the same time. The speed displayed repre-
Display = 10 Aux1 switch circuit OK. sents the second lift speed.
To exit the hydraulic speed check (bypass the flash-
ing 00), toggle the DIAG/RUN/SETUP switch from
DIAG to RUN and back to DIAG.
Display = 11 Ready for the next test.
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Tests “O” Through “T” Test R: Forward Contactor Circuit

The remaining tests check contactor operation. You Move the DIAG/RUN/SETUP switch to RUN.
will toggle the DIAG/RUN/SETUP switch from DIAG Display = 15 and the forward contactor (4) does
to RUN to activate the contactor being tested, then not close. Circuit is defective.
toggle the switch back to DIAG to deactivate it. You See Troubleshooting Problem 50.
must visually observe the contactors for proper Display = 15 and forward contactor (4) closes.
operation during these tests. Forward contactor circuit OK.
Move the DIAG/RUN/SETUP switch to DIAG.
Display = 16 and the forward contactor (4) opens.
Test S: Reverse Contactor Circuit

Move the DIAG/RUN/SETUP switch to RUN.
Display = 16 and the reverse contactor (5) does
not close. Circuit is defective.
Display = 16 and reverse contactor (5) closes.
Reverse contactor circuit OK.
Move the DIAG/RUN/SETUP switch to DIAG. If the
panel does not have regen, the display will =
donE. The self diagnostics are complete for non-
regen (plug only) panels. If the panel has regen,
1 the display = 17 and the reverse contactor (5)
3 4 6
2 5 opens. Go to Test T.
Contactor Locations. Panel with regen is shown.
Plug-only panels will not have regen contactor (6).
Test T: Regen Contactor Circuit
(1) Line contactor. (2) Pump bypass contactor. (3) Drive bypass contactor. Move the DIAG/RUN/SETUP switch to RUN.
(4) Forward contactor. (5) Reverse contactor. (6) Regen contactor. Display = 17 and the regen contactor (6) does
Test O: Line Contactor Circuit not close. Circuit is defective.
Move the DIAG/RUN/SETUP switch to RUN. See Troubleshooting Problem 50.
Display = 12 and the line contactor (1) does not Display = 17 and regen contactor (6) closes.
close. Circuit is defective. Regen contactor circuit OK.
See Troubleshooting Problem 50. Move the DIAG/RUN/SETUP switch to DIAG.
Display = 12 and line contactor (1) closes. Line Display = donE and the regen contactor (6) opens.
contactor circuit OK.
Display = 13 and the line contactor (1) opens.
Test P: Pump Bypass Contactor Circuit 2

Move the DIAG/RUN/SETUP switch to RUN. 3
Display = 13 and the pump bypass contactor (2)
does not close. Circuit is defective.
Display = 13 and pump bypass contactor (2) 1
closes. Pump bypass contactor circuit OK.
Display = 14 and the pump bypass contactor (2)
opens.
Location of components: 1.Line Fuse 2.Screws 3.Logics Cover
Test Q: Drive Bypass Contactor Circuit This completes the self-diagnostics tests. The contac-
Move the DIAG/RUN/SETUP switch to RUN. tor tests may be repeated by moving the
Display = 14 and the drive bypass contactor (3) DIAG/RUN/SETUP switch to RUN and back to DIAG.
does not close. Circuit is defective. If you are finished with self diagnostics, do the following:
See Troubleshooting Problem 50. 1. Disconnect the battery and install the line fuse (1).
Display = 14 and drive bypass contactor (3) 2. Move the DIAG/RUN/SETUP switch to the RUN
closes. Drive bypass contactor circuit OK. position.
Move the DIAG/RUN/SETUP switch to DIAG. 3. Install the logics cover (3) and tighten screws (2).
Display = 15 and the drive bypass contactor (3)
opens.
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Troubleshooting Charts
Problem # Problem Type
Display Problems
1 When seat switch is closed, speedometer area of display goes blank. No lift truck drive or pump motor operation.
2 Display does not work at all. Lift truck operation is normal.
3 Display does not work. No lift truck operation.
4 BDI # does not change with a change in battery voltage.
“Run Time” Diagnostic Problems
5 Brush wear indicator is on.
6 Overtemperature indicator is “ON”, lift truck accelerates slower than normal. Truck goes into bypass.
Pump motor speeds 6 and 7 are reduced. Fault code E3 is stored.
7 Overtemperature indicator is “ON” lift truck accelerates slower than normal. Truck goes into bypass.
Bypass contactor will not close.Pump motor operation normal. Fault code E1 is stored.
8 Overtemperature indicator is ON, lift speed slower than normal. Drive motor operation normal. Fault code E2 is stored.
9 Display = 10: Drive armature transistor fault (high). No lift truck operation.
10 Display = 11: Drive armature transistor fault (low). No lift truck operation.
11 Display = 15: D6D anode fault (low). No lift truck operation. (Trucks with regen).
11A Display = 15: D6D sense wire fault. No lift truck operation.
12 Display = 16: D6D anode fault (high). No lift truck operation.
13 Display = 18: Drive shunt field transistor drain fault (high). No lift truck operation.
14 Display = 19: Drive shunt field transistor drain fault (low). No lift truck operation.
15 Display = 20: Drive stall timer failure. No lift truck operation.
16 Display = 21: Drive current sensor failure. No lift truck operation.
17 Display = 24: Drive output overcurrent fault. No lift truck operation.
18 Display = 25: Accelerator fault (low). No lift truck operation.
19 Display = 26: Accelerator fault (high). No lift truck operation.
20 Display = 29: Speed sensor failure. No lift truck operation.
21 Display = 30: Pump armature transistor emitter fault (high). No lift truck operation.
22 Display = 31: Pump armature transistor emitter fault (low, B terminal). No lift truck operation.
23 Display = 32: Pump armature transistor emitter fault (low, B0 Terminal). No lift truck operation.
24 Display = 33: Combination of F31 and F32. No lift truck operation.
25 Display = 38: Pump shunt field transistor drain fault (high). No lift truck operation.
26 Display = 39: Pump shunt field transistor drain fault (low). No lift truck operation.
27 Display = 40: Pump stall timer failure. No lift truck operation.
28 Display = 41: Pump current shunt failure. No lift truck operation.
29 Display = 44. Pump output overcurrent fault. No lift truck operation.
30 Display = 50: Combination of F10 and F30. No lift truck operation.
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Problem # Problem Type

31 Display = 51: Combination of F11, F31, F32, and F33. No lift truck operation.
32 Display = 60: Serial communications fault. No lift truck operation.
33 Display = 61: EEPROM error. No lift truck operation.
34 Display = 65: Truck size not initialized. No lift truck operation.
35 Display = 66: Watchdog timer failure. No lift truck operation.
36 Display = 68 or 69: Battery volts too low for chosen jumper. No lift truck operation.
“Self” Diagnostic Problems
37 Seat switch circuit defect.
38 Direction switch circuit defect.
39 Foot-operated direction switch defect.
40 Park brake circuit defect.
41 Service brake circuit defect. Note: Must be repaired before moving on!
42 Accelerator circuit defect.
43 BDI circuit defect.
44 Lift switch circuit defect.
45 Tilt switch circuit defect.
46 Aux 1 switch circuit defect.
47 Aux 2 switch circuit defect.
48 Hydraulic speed check.
49 Incorrect contactor operation.
Other Problems
50 Any contactor closes when key switch is closed.
51 Drive motor does not operate or operates with low power or is erratic. Pump system operation normal.
52 Poor acceleration, loss of power on ramps.
53 Lift truck has long electrical braking distance or sudden stop at end of braking cycle. Pump system operation normal.
54 Current limit and/or electrical braking limit adjustment cannot be made.
55 Auxiliary lighting and/or alarm does not function correctly. Lift and drive systems operation normal.
56 Slow steering, but pump motor does turn. Drive and lift systems operation normal.
57 Steering idle speed runs fast. (Pump motor runs at high power steering speed continuously.)
Pump motor runs continuously in neutral (no chat mode).
58 Lift truck speed reduced to 2.0 mph (no code).
59 Display = FFFF.O: Change display.
60 Code H: Hydraulic Switch is closed when key is turned on.
61A & B Code E: Accelerator depressed before key is turned on. Seat Switch open when it should be closed.
Note: Check for shorts to chassis or open wiring at the start of any problem. Use a 6V4042 Wiring Harness Test
Group to find a wire-to-wire short, shorts to chassis, and continuity. Always follow the sequence defined here
using the display and built-in analyzer functions to aid in troubleshooting.
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PROBLEM 1
Speedometer portion of display works until seat switch is closed, then blank. No lift truck drive or pump motor operation.
POSSIBLE CAUSE
Line contactor defect: line fuse open circuit: wire #34 at P2-12 open circuit: logics defect.
CHECKS
Does the line contactor remain closed?
YES NO
Check voltage at bottom of line fuse with line contactor activated. See problem 49,
Incorrect
Contactor
Battery Voltage Less Than Battery Voltage Operation.
Check voltage at top of line fuse with line contactor activated. Repair or replace line contactor tips
or power connection.
Battery Voltage Less Than Battery

Check voltage at logics connector Voltage
P2-12 (wire #34) on the silver area. Check for possible shorts in
Do not disconnect the logics the power circuit (Head
connector. capacitor, diodes, shorted
cables) and replace line fuses.
If repeat failures occur, check
drive motor current limit and/or
lift truck.
Battery Voltage Less than
Battery Voltage
Replace logics.
Repair open
circuit between
line fuse and
P2-12, wire #34.
59
SENB8604-02
PROBLEM 2
Display does not work at all: lift truck operation normal. If only part of the display works, replace the whole display unit.
POSSIBLE CAUSES
Disconnected display connector P6: open circuit from P6-1 to battery negative: open circuit from key switch to P6-2: defective display unit.
CHECKS
Is display connector P6 connected?
YES NO
Connect multimeter positive lead to P6-2 (wire #4) and negative lead to P6-1 (wire #1.) Connect P6
Measure the voltage. connector to display
unit.
Battery Volts 0 Volts
Replace the display unit. Repair or replace open circuit between key switch and
P6-2 wire (wire #4) or between P6-1 (wire #1) and
battery negative.
60
SENB8604-02
PROBLEM 3
Display does not work: no lift truck operation.
POSSIBLE CAUSES
Battery polarity not correct on control panel: key fuse open circuit: key switch defect: logics defect: defective display unit.
CHECKS
With battery connected, check control panel battery connections for correct polarity. Positive battery is connected to negative heat sink.
If Correct If Not
Disconnect battery and check key fuse for continuity. Correct
Continuity No Make correction

Check for continuity from key fuse holder to control panel battery positive connection at Continuity to cables.
the line contactor (wire #3). Also check continuity from key fuse to holder to wire #3 Check for
on key switch. shorts and
replace fuse.
Continuity No Continuity
Close key switch. Measure voltage on P3-18 and P6-2. Repair or replace
open circuit.
Battery Voltage Less Than Battery

Voltage
Check continuity from battery
negative to logics P1-21, P2-21, Replace key switch or
P3-21, P3-20, and display P6-1 repair broken wire #4
between key switch and P6-
(wire #1). 2 or key switch and P3-18.
No
Continuity Continuity
Replace logics Repair or
or display unit. replace open
wire.
61
SENB8604-02
PROBLEM 4
Battery Discharge Indicator (BDI) number does not change with a change in battery voltage.
POSSIBLE CAUSES
BDI setting is out of adjustment: BDI jumper positioned incorrectly: defective logics.
CHECKS
Check BDI jumper for proper positioning:
J1 = 36V J2 = 48V J3 = 72V J4 = 80V
Follow BDI adjustment procedure to verify correct BDI settings. (Be sure to cycle key switch between adjustments.)
See the topic “Battery Discharge Indicator (BDI) Adjustment” in the Systems Operation section of this manual.
Cannot Adjust to Specifications

Replace logics.
62
SENB8604-02
PROBLEM 5
Brush Wear Indicator (BWI) is ON.
POSSIBLE CAUSES
Worn brushes on pump and/or drive motor: display unit defect.
CHECKS
Check the stored fault code area to determine if the indication is for the pump motor or the drive motor.
b2 - Pump Neither b1
b1 - Drive
nor b2
Check drive motor brushes. Check pump motor brushes.
Replace display.
Look OK Worn Look OK Worn
to low Disconnect the pump motor wear
to low
Disconnect the drive motor wear
indicator (wires #107 and #108) at the limit indicator (wires #109 and #110) at the motor. limit
motor. Turn the key switch OFF, then Replace Turn the key switch OFF, then ON. Replace
ON. Check display for BWI. brushes. Check display for BWI. brushes.
Display OK BWI Still ON Display OK BWI Still ON
Check for short Check for continuity Check for Check for continuity from
to battery from wires #109 and short to bat- wires #109 and #110 to
negative #110 to battery tery negative battery negative.
inside the motor. negative. inside the
motor.
Continuity No
Continuity Continuity No
Repair Continuity
shorted Replace Repair shorted
wire. display wire. Replace display
unit. unit.
63
SENB8604-02
PROBLEM 6
Overtemperature indicator ON. Truck accelerates slower than normal. Truck goes into bypass.
Pump motor speeds 6 and 7 are reduced. E3 stored in fault code area.
POSSIBLE CAUSES
Control panel overheated: thermal switch defect: open wiring: logics defect: display unit defect.
CHECKS
Open control panel compartment. Allow truck to cool 15 minutes.
Overtemperature Indicator Still ON Display OK

Check stored fault codes. Verify E3 is present. Control Panel was over-
heated. Resume normal
E3 No E3 operation. If condition
repeats, check the
Check stored fault codes. Verify E3 is present. Replace display unit.
following:
High Low • Current Limit
Calibration
Disconnect the battery. With the control panel at close Replace
• BDI Calibration
to room temperature, disconnect the thermal switch logics.
connector P8. Check continuity of thermal switch. • Operating Cycle for
Should have continuity below 69°C (156°F). excessive ramp
climbing, towing, or
Continuity No
pushing
Check continuity from P3-3 on the Continuity
logics board (silver area) to P8-2 • Brake drag, park
Replace
(wire #46). thermal switch. brake adjustment
Continuity No • Service Brake
Check continuity from Continuity interrupt switch
P8-1 to battery negative Repair or operation.
(wire #1). replace wire
and/or
connector
P3.
Continuity No
Continuity
Repair or
replace Verify
wire. problem
still exists.
64
SENB8604-02
PROBLEM 7
Overtemperature indicator ON. Truck accelerator slower than normal. Bypass contactor will not close.
Pump motor operation normal. E1 stored in fault code area.
POSSIBLE CAUSES
Drive motor overheated: drive motor thermal switch defect; open wiring; logics defect; display unit defect.
CHECKS
Allow truck to cool 15 minutes.

Check stored fault codes. Verify E1 is present. Drive motor was over-
heated: resume normal
E1 No E1 operation. If condition
Measure the voltage at P3-1 (wire #76) on the logics board (silver area). repeats, check the
Replace display unit. following:
Scrape coating off board if needed. Do NOT disconnect from logics.
• Current limit
High Low calibration
Disconnect the battery. With the drive motor at close to room Replace • BDI calibration
temperature, disconnect the thermal switch connector P8. Check display
continuity of thermal switch. Should have continuity below • Operating cycle for
69°C (156°F). unit.
excessive ramp
climbing, towing, or
pushing
Disconnect P3 from the Replace
display unit. Check continuity from P3-1 to thermal switch. • Brake drag, park
battery negative (wire #1). brake adjustment
Continuity No Continuity • Service brake
interrupt switch
Find short to battery Verify
negative in the problem still exists. operation.
harness. Repair or
replace wire.
65
SENB8604-02
PROBLEM 8
Overtemperature indicator ON. Lift speed slower than normal. Drive motor operation normal. E2 stored in fault code area.
POSSIBLE CAUSES
Pump motor overheated: pump motor thermal switch defect; open wiring; logics defect; display unit defect.
CHECKS
Allow truck to cool 15 minutes.

Check stored fault codes. Verify E2 is present. Pump motor was
over-heated: resume
E2 No E2 normal operation. If
condition repeats, check
Measure the voltage at P3-2 (wire #77) on the logics board (silver area). Replace display unit. the following:
• Pump motor brushes
High Low
• BDI calibration
Disconnect the battery. With the pump motor at close to room Replace
temperature, disconnect the thermal switch connector P8. Check • Attachment pressures
logics.
continuity of thermal switch. Should have continuity below
69°C (156°F). • Heavy hydraulic
application.
No Continuity Continuity
Disconnect P3 from the Replace
display unit. Check continuity from P3-1 to thermal switch.
battery negative (wire #1).
No Continuity Continuity
Verify Find short to battery
problem still exists. negative in the
harness. Repair or
replace wire.
66
SENB8604-02
PROBLEM 9
Display = “10” : (!) action light flashing: no lift truck operation. Line contactor closes and opens.
POSSIBLE CAUSES
Shorted T1D or T2D: Shorted bypass contactor tips: open wiring: failed drive driver board: failed logics.
Slow bypass contactor.
CHECKS
Disconnect the battery: check bypass contactor for welded or shorted tips. Check contactor for free tip movement.
Tips not shorted Tips shorted

Disconnect battery: remove logics cover: check continuity of wire #37 at emitter Repair or replace
bus bar of power transistor to logics P2-6. contactor. Check BDI
Continuity No Continuity adjustment. Check
current limit adjustment.
Check T1D, T2D for failure. Repair or replace wiring. Check bypass dropout
current.
Test OK Failed
Test Drive Driver Board. Replace
failed
compo-
nents.
Test OK Failed
Replace logics.* Replace
drive driver board.*
* = See NOTICE.
NOTICE: Damage to the control panel could Field Failure Notes:

result. To prevent further damage, before
1. Field failures indicate that a traction motor
T1D, T2D, or the drive driver board are
shunt field to series field short may also cause
replaced, complete the following checks.
this code.
1. Check diode D4D for failure.
2. Also, slow bypass contactors.
2. Check diode D5D for failure.
3. Current sensor.
3. Check T1D, T2D for failure.
4. Check drive driver board for failure.
5. Check head capacitors for failure.
6. Check for continuity from emitter bus bar of
power transistors (wire #37) to logics P2-6.
7. Check drive motor for shorts, shorts between
shunt and series field, shorts to frame, and opens.
67
SENB8604-02
PROBLEM 10
Display = “11” : (!) action light flashing: no lift truck operation. Line contactor opens and closes.
POSSIBLE CAUSES
Faulty wire connections: T1D or T2D failed: current limit set too low: failed D4D or D5D: failed drive driver board: failed logics.
CHECKS
Disconnect the following wires. Visually inspect them for burnt or discolored terminals, loose connections, smashed or compressed
connectors, corrosion or foreign material.
Wire #31 at P2-5.
Wire #37 at P2-6 and emitter bus bar of drive power transistors.
Wire #31 and #32 at resistor R312.
Wire #34 from drive driver board to positive heatsink.
Wire #1 from drive driver board to negative heatsink.
Wire #42 from logics P3-8 to current sensor.
Wire #85 from logics P3-6 to current sensor.
Wire #2 from logics P3-7.
Repair any defects, then reconnect the wires.
Display = “11” Display Normal
Check T1D, T2D for failure. Return truck to operation.
Not Failed Failed
Perform Rapid Tune-up procedure for current limit and regen potentiometers. Replace failed transistor.
Display
Display = “11” Normal
Measure voltage at P3-8 (wire #42) with the key switch closed. Recalibrate current
limit, regen current
adjustments to
specifications.*
Voltage = 3.6 tp to 4.0V Any Other
Check continuity from P3-3 on the Voltage *NOTICE: Damage to the control panel could result. To
logics board (silver area) to P8-2 Perform steps 1 prevent further damage, before T1D, T2D, or the drive
(wire #46). through 5 of the driver board are replaced, complete the following
Current Sensor checks:
Tests.
Not Failed Failed All All 1. Check diode D4D for failure.
Test drive driver board for a Replace failed Checks Checks 2. Check diode D5D for failure.
failure. OK not OK 3. Check T1D, T2D for failure.
components.
Not Failed Recalibrate Replace Replace 4. Check drive driver board for failure.
Failed
Replace failed current limit and the logics.
current 5. Check for continuity from emitter bus bar of
Replace components. regen to sensor. power transistors (wire #37) to logics P2-6.
logics. Recalibrate specifications.*
6. Check drive motor for shorts, shorts to frame, and
current limit
opens.
and regen to
specifications.*
68
SENB8604-02
PROBLEM 11
FOR TRUCKS EQUIPPED WITH REGEN. FOR TRUCKS WITHOUT REGEN, SEE PROBLEM 11A.
Display = “15” and (!) action light flashing: no lift truck operation: line contactor closes and opens.
POSSIBLE CAUSES
Logics not programmed correctly: open circuit on sensing wire between logics pin P2-11 and regen diode D6D (wire #97):
regen contact failure: diode D6D failure.
Burned contact at A2, contact drops out and picks up after regen closes and arcs.
Low battery “ON” without regen.
CHECKS
Verify Option #30 is set correctly.
Correct Not Correct

Verify Option #21 is set correctly. Set Correctly.
Correct Not Correct

Check regen contactor for normal operation or welded tips. Set correctly.
Not Failed Failed

Check regen diode D6D for shorted
condition. Replace
regen contactor.
Not Shorted Shorted Display = Display

Replace logics. Replace “15” Normal
regen diode D6D. Replace logics. Return truck to
operation.
Field Notes
Other Checks:
1. Check ohms of Regen direction and line contactors (should be 35 to 40 ohm).
2. Check for any wear on direction contactors on armature guide plate. (Replace if wear is found).
3. Check for correct position of wires 68 and 92, they could be reversed.
4. Check for the correct position of wires 101 and 102.
5. Check cable connection at motor S1, S2, A1 and A2.
6. Replace current sensor, if all other tests are OK.
69
SENB8604-02
PROBLEM 11A
FOR TRUCKS EQUIPPED WITH REGEN. FOR TRUCKS WITHOUT REGEN, SEE PROBLEM 11.
Display = “15” and (!) action light flashing: no lift truck operation: line contactor closes and opens.and closes.
POSSIBLE CAUSES
Logics not programmed correctly: P2-11 (wire #97) open or shorted: logics failure.
CHECKS
Battery Voltage
Verify C set correctly.
Correct Not Correct

Correct Not Correct

Check continuity and connections on wire #97 between P2-11 and positive heat sink. Set correctly.
Replace logics. Repair open wiring.
Field Failure Notes:

1. Slow regen contactor operation incorrect ohm coil.
2. Wire 97 stacked incorrectly in between bus bars.
70
SENB8604-02
PROBLEM 12
Display = “16”: (!) action light flashing: no lift truck operation: line contactor closes and opens.
POSSIBLE CAUSES
Logics not programmed correctly: open circuit on sensing wire between logics pin P2-11 and regen diode D6D (wire #97):
regen contactor failure: diode D6D failure.
CHECKS
Verify Option #30 is set correctly.
Correct Not Correct


Check continuity and connections on wire #97 between P2-11 and diode D6D Return truck to operation.
anode. Replace wire if no continuity. Repair loose connection if found.
Not Failed Failed

Check regen diode D6D for Using Problem 49 as a guide,
shorted condition. troubleshoot the regen contactor.
Repair as needed.
Not Shorted Shorted

Replace logics. Replace
regen diode D6D.
Field Notes
Other Checks:
6. Replace current sensor, if all other tests are OK.
71
SENB8604-02
PROBLEM 13
Display = “18”: (!) action light flashing: no lift truck operation: line contactor opens and closes.
POSSIBLE CAUSES
Open wire #96: shorted diode D371: Open T371 transistor: short in drive motor: logics defect.
CHECKS
Remove logics connector P2. Inspect P2-2 and P2-1 for corrosion, foreign material, poor crimp or loose contact with logics pin.
Also check the following for continuity:
Wire #92 from P12-7 to P32-1 to P2-2.
Wire #96 from P12-9 to P2-1.
Wire #1 from P12-10 to negative HS.
Wire #34 from P12-3 to positive HS.
Wires OK Wires Defective

Check resistance of the drive motor shunt field at wires #68 and #92 at connector P32-1 and P32-6. Repair or replace defect.
Measure the diameter of the drive motor, then see the table “Drive and Pump Motor Shunt Field
Resistances” in the Specifications section for the correct resistance.
See the topic Driver Board Tests, Shunt Field Tests.
Tests OK Low Resistance

Disconnect P32. Check for short from drive SE to A1, A2, S1, S2, and motor. Replace drive motor.
OK Short
Check drive driver board Repair motor.
(drive shunt field components only.)
Not Failed Failed

drive driver board.
72
SENB8604-02
PROBLEM 14
Display = “19”: (!) action light flashing: no lift truck operation: line contactor opens and closes.
POSSIBLE CAUSES
Logics not programmed correctly: open drive shunt field fuse: poor wire connections: open drive shunt field: shorted T371 transistor: logics defect.
CHECKS
connectors, corrosion or foreign material. Also check the following:

Check drive shunt field fuse. Return truck to operation.
Not Failed Failed

Check continuity of wire #34 from positive Replace drive shunt field fuse. Verify drive motor shunt field
heatsink to logics P2-2, wire #92. resistance. Measure the diameter of the drive motor, then see
36/48V =12.35 - 13.65 ohms No the table “Drive and Pump Motor Shunt Field Resistances” in
Continuity the Specifications section for the correct resistance.
72/80V = 11.40 - 38.85 ohms
Display Still “19” Display Normal
Check drive driver board. Repair or
(Shunt field components replace open Check continuity of wire #34 from positive Return truck to
only.) wire or heatsink to logics P2-2, wire #92. operation.
connection.
36/48V =12.35 - 13.65 ohms No
Not Failed Failed
72/80V = 11.40 - 38.85 ohms Continuity
Replace Replace
logics. drive driver Check drive driver board. Repair or
board. (Shunt field components replace open
only.) wire or
connection.
Not Failed Failed
Replace Replace
logics. drive driver
board.
73
SENB8604-02
PROBLEM 15
Display = “20”: (!) action light flashing: no lift truck drive operation.
POSSIBLE CAUSES
Current limit potentiometer P1 out of adjustment. Excessive drive motor current due to severe ramps, abuse, or misapplication.
Drive Pulsing Stall Timer Option set too short for application. 80% Bypass Option ON (Option #15). Current sensor defects: logics defect.
CHECKS
Verify current limit setting.
Do problem #16 procedure.
Increase value of Option #12 (pulse stall timer).
Disable Option #15 if ramp application requires more current than set with P1 current limit potentiometer. (Change setting to “0”).
SENB8604-02
PROBLEM 16
Display = “21”: (!) action light flashing: no lift truck operation. Line contactor closes and opens.
POSSIBLE CAUSES
Wiring defect: current sensor defect: logics defect.
CHECKS
Disconnect current sensor.
Check continuity from P16-1 to P3-7 (wire #2).
Continuity OK Continuity
Check for short to battery negative (wire #1) in wire #2.
not OK
Check for short to battery negative (wire #1) in wire #85. Repair or
Check for short between wire #42 and wire #85. replace open
wires.
No Shorts Shorts
With current sensor and logics plugged in and truck powered up, measure the voltage between P3-6 Repair
(wire #85) and P3-7 (wire #12). It should measure between 7.15 and 7.5 volts. Shorts.
Voltage OK Voltage Not OK
Plug in known good current sensor. Power up truck. With current sensor and logics plugged in,
power up truck. Measure the voltage
between P3-8 (wire #42) and P3-7 (wire #2).
It should measure between 3.6V and 4.0V.
Truck Powers Up Normally Display = “21” Voltage Voltage Not ON

With known good current sensor Replace logics. OK Plug in known good sensor.
plugged in and logics plugged in, Truck OK, Power up truck.
power up truck. Measure the voltage return to
between P3-6 (wire #85) and P3-7 operation.
(wire #2). It should measure between
7.15 and 7.5 volts.
Voltage OK Voltage Not ON Truck Powers Up Normally Display =
“21”
Truck OK, Replace logics. With known good current sen-
return to sor plugged in and logics Replace
operation. plugged in, power up truck. logics.
Measure the voltage between
P3-6 (wire #85) and P3-7 (wire
#2). It should measure between
7.15 and 7.5 volts.
Voltage OK Voltage
Truck OK, Not ON
return to Replace
operation. logics.
75
SENB8604-02
PROBLEM 17
Display = “24”: (!) action light flashing: no lift truck operation. Line contactor opens and closes.
POSSIBLE CAUSES
Wiring defect: drive driver board defect: logics defect.
CHECKS
Check continuity between P2-5 and R312 (wire #31).
Check continuity between R312 and P12-15 (wire #32).
Check continuity between P12-16 and positive HS (wire #34).
Continuity OK Continuity Not OK

Check wires #31, #32, and #34 for burnt,. crushed, or shorted areas. Repair or replace open
wires.
Wires OK Wires Not Ok
Measure the resistance of R312. It should be: Repair or replace wire(s).
36/48V = 34.2-37.80 ohms
72/80V =71.25-78.75 ohms.
Resistance OK Resistance Not OK

Perform drive driver board tests. Replace
logics.
Test OK Test Not OK

drive driver
board.
76
SENB8604-02
PROBLEM 18
Display = “25”: (!) action light flashing: no lift truck operation.
POSSIBLE CAUSES
Accelerator control not adjusted or defective: dirt on optical switches: open wiring: logics defect.
CHECKS
Check accelerator control adjustment. See the Systems Operation section of this manual.
Adjustment OK Adjustment Not OK

Disconnect P9 connector. With keyswitch closed, check for battery voltage between P9-A (wire #1) and Adjust control to proper
P9-B (wire #4). (Be sure that the problem is not a defective keyswitch.) specifications.
OK If Low
Check voltage between P9-C and P9-A. Repair open wire between P9-A(wire #1) and
battery negative or P9-B (wire #4) and
15 Volts Not 15 Volts battery positive.
Check continuity Check continuity of wire #8 between logics P1-15
Plug accelerator back of wire #8 and P9-C.
into P-9 connector. between logics
Check voltages at logics P1-15 and P9-C.
P1-15 as follows:
Accelerator Voltage
Pedal Position Check for short to battery nega- Repair or replace
Fully UP 1.2 to tive (wire #1) in wire #8. broken wire.
12.5 volts
No Short Short
Fully depressed 1.6 to
2.0 volts Replace logics. Repair or
replace shorted
Voltage should decrease
wire.
from max to min as pedal is
depressed.
Voltage Voltage OK
readings OK but problem
Replace persists
accelerator Replace
control. logics.
77
SENB8604-02
PROBLEM 19
POSSIBLE CAUSES
CHECKS

Disconnect P9 connector. With keyswitch closed, check for battery voltage between P9-A Adjust control to proper
(wire #1) and P9-B (wire #4). (Be sure that the problem is not a defective keyswitch.) specifications.
OK If Low
Check voltage between P9-C and P9-A. Repair open wire between
P9-A(wire #1) and battery
negative or P9-B (wire #4) and
15 Volts Not 15 Volts
battery positive.
Plug accelerator back into Check continuity of wire #8 between
P-9 connector. Check logics P1-15 and P9-C.
voltages at logics P1-15
as follows: Continuity OK Continuity
Accelerator Voltage Not OK
Check for short to
Pedal Position
battery negative Repair or
Fully UP 1.2 to
(wire #1) in wire #8. replace broken
12.5 volts
wire.
Fully depressed 1.6 to
No Short
2.0 volts Short
Repair or
Voltage should decrease Replace replace
from max to min as pedal is logics. shorted
depressed.
wire.
Voltage Voltage OK
readings but problem
Not OK persists
Replace Replace
accelerator logics.
control.
78
SENB8604-02
PROBLEM 20
POSSIBLE CAUSES
Logics not programmed correctly: open circuit/short circuit in wire #115 and #116 connecting speed sensor to logic:
faulty speed sensor: faulty logics.
CHECKS
Measure the resistance of the speed sensor. It should be 2.3kΩ +/- 0.2 kΩ.
Resistance OK Resistance Not OK

Check wires #115 and #116 for opens or shorts between speed sensor Adjust control to proper
connector P52 and logics connector P1. specifications.
Wires OK Wires Not OK

Using the AC Volts setting on the volt-ohmmeter, measure the voltage Replace speed sensor.
between P1-18 and P1-19. This voltage should increase as the wheels turn
faster and decrease as the wheels turn slower.

Replace accelerator control. Replace speed sensor.
Field Notes
Other Checks:
1. If Code 29, 15 and/or 16 are found together in history, then check regen and line contactors.
7. Current sensor can check good and still code 29.
8. Replace current sensor, if all other tests are OK. Current sensor can still check good and still code 29.
9. Loose connection on directional contactors.
79
SENB8604-02
PROBLEM 21
POSSIBLE CAUSES
Shorted T1P or T2P: open wiring: failed pump driver board: failed logics: open circuit in pump motor PA1,
PS2 cables: welded pump contactor tips.
CHECKS
Disconnect the battery: check pump motor contactor for welded or shorted tips. Check contactor for free tip movement.
Tips Not Shorted Tips Shorted

Connect battery: close the seat key switches. Repair or replace
contact. Check
Line contactor closes then opens. Pump Line contactor closes then opens. Pump BDI adjustment.
motor does not turn. Display = “30”. motor turns a small amount. Display = “30”.
Disconnect battery: remove logics cover: check Check T1P, T2P for a short circuit.
continuity or wire #45 at emitter connector of
T2P to logics P2-10. No Shorts Shorts
No Continuity Continuity Test pump driver board. Replace failed

components.*
Replace logics. Check continuity from PA1 to
PS2 at panel.
Test Test
Continuity No OK Failed
Replace Continuity
logics. Replace logics. Replace pump
Check motor driver board.
and cables
and repair.
*NOTICE: Damage to the control panel could result.

To prevent further damage, before T1P, T2P, or the
drive driver board are replaced, complete the follow-
ing checks:
1. Check diode D4D for a failure.
2. Check diode D5D for a failure.
3. Check T1P, T2P for a failure.
4. Check pump driver board for a failure.
5. Check head capacitors for a failure.
6. Check for continuity from T2P emitter
(wire #45) to logics P2-10.
80
SENB8604-02
PROBLEM 22
POSSIBLE CAUSES
Faulty wire connections: D4P or T1P and T2P failed: failed pump driver board failed logics.
CHECKS
Disconnect the following wires. Visually inspect them for burnt or discolored terminals, loose connections, smashed or
compressed connectors, corrosion or foreign material. Also check:
Wire #45 from emitter of transistor T1P and T2P to P4-7 and P2-10.
Wire #34 from pump driver board to positive heatsink.
Wire #1 from pump driver board to negative heatsink.
Wire #229 from pump shunt (+) to P2-18.
Wire #29 from pump shunt (-) to P2-19.
Repair any defects then reconnect the wires.

Check diode D4P for a failure. Return truck to operation.
Not Failed Failed

Check transistors T1P, T2P for a failure. Replace failed diode*.
Not Failed Failed

Check pump driver board. Replace
transistor.*
Not Failed Failed

pump driver board.
*NOTICE: Damage to the control panel could result. To prevent further damage, before T1P, T2P, or the drive
driver board are replaced, complete the following checks:
1. Check diode D4P for a failure.
5. Check for continuity from emitter bus bar of power transistors (wire #45) to logics P2-10.
81
SENB8604-02
PROBLEM 23
POSSIBLE CAUSES
Faulty wire connections: D4P or T1P and T2P failed: failed pump driver board failed logics.
CHECKS
Disconnect the following wires. Visually inspect them for burnt or discolored terminals, loose connections, smashed or
compressed connectors, corrosion or foreign material. Also check:
Wire #45 from emitter of transistor T1P and T2P to P4-7 and P2-10.
Wire #34 from pump driver board to positive heatsink.
Wire #1 from pump driver board to negative heatsink.
Wire #119 from pump shunt (+) to P2-18.
Wire #29 from pump shunt (-) to P2-19.
Repair any defects then reconnect the wires.

Check diode D4P for a failure. Return truck to operation.
Not Failed Failed

Check transistors T1P, T2P for a failure. Replace failed diode.*
Not Failed Failed

Check pump driver board. Replace
transistor.*
Not Failed Failed

pump driver board.
*NOTICE: Damage to the control panel could result. To prevent further damage, before T1P, T2P, or the drive
driver board are replaced, complete the following checks:
1. Check diode D4P for a failure.
5. Check for continuity from emitter bus bar of power transistors (wire #45) to logics P2-10.
82
SENB8604-02
PROBLEM 24
Display = “33”: (!) action light flashing: no lift truck operation: line contactor closes and opens.
POSSIBLE CAUSES
Failure in pump circuit.
CHECKS
See problems 22 and 23, Display = “31” and “32”. Do both procedures.
83
SENB8604-02
PROBLEM 25
POSSIBLE CAUSES
Open wire #72: shorted diode D351: open transistor T351: shorted shunt field: failed logics.
CHECKS
Remove logics connector P2. Inspect P2-4 and P2-3 for corrosion, foreign material, poor crimp or loose contacts with logics pin.
Also check the following:
Wires OK Not OK
Check resistance of pump motor shunt field at wires #69 and #71. Measure the diameter of the pump Repair or replace defect.
motor, then see the table “Drive and Pump Motor Shunt Field Resistances” in the Specifications section
of this manual for the correct resistances.
Resistance OK Low Resistance

Check pump driver board. (Shunt field components only.) Repair or replace
pump motor.
Not Failed Failed

pump driver board.
84
SENB8604-02
PROBLEM 26
POSSIBLE CAUSES
Open shunt field fuse: poor wire connections: open shunt field: shorted transistor T351: failed logics.
CHECKS
connectors, corrosion or foreign material.
Repair any defects, then reconnect the wires.

Check drive shunt field fuse. Return truck to operation.
Not Failed Failed

Check continuity of wire #34 from positive Replace shunt field fuse. Verify pump shunt field resistance.
heatsink to logics P2-4, (wire #71). Measure the diameter of the pump motor, then see the table
“Drive and Pump Motor Shunt Field Resistances” in the
7 to 10 ohms No Specifications section for the correct resistance.
Continuity
Check pump driver board Display Still “39” Display Normal
(shunt field Repair or
components only.) replace open Check continuity of wire #34 from positive Return truck to
wire or heatsink to logics P2-4, (wire #71). operation.
connection.
7 to 10 ohms No
Not Failed Failed
Continuity
Replace Replace Check pump driver board
logics. pump driver (shunt field Repair or
board. components only.) replace open
wire or
connection.
Not Failed Failed
Replace Replace
logics. pump driver
board.
85
SENB8604-02
PROBLEM 27
Display = “40”: (!) action light flashing: no lift truck operation. Line contactor closes then opens.
POSSIBLE CAUSES
Excessive pump current: pump shunt defect: wiring defect: pump/pump motor defect: failed logics.
CHECKS
Check continuity between P2-18 and pump shunt. (Wire #119, side closest to negative heatsink.)
Check continuity between P2-19 and pump shunt. (Wire #29, side attached to standoff.)

Check wire #29 for burnt, smashed, cut or shorted areas. Repair or replace open
wires.
Check pump shunt connections to make sure they are tight and there is Repair or replace
no corrosion between the terminals for wire #29 or #119 and the shunt. defective wires.
Tight Not Tight

Attach clamp-on ammeter to PS2 cable. Power up truck and Tighten
check current. In steer idle, current should be less than 50A. bolts.
Current OK Current High
Replace logics. Correct pump/motor pump problem. Pump
could be binding. Cables running to pump
motor could be connected incorrectly.
Pump motor could be defective.
86
SENB8604-02
PROBLEM 28
POSSIBLE CAUSES
Pump shunt defect: wiring defect: pump/pump motor defect: failed logics.
CHECKS
Check continuity between P2-18 and pump shunt. (Wire #119, side closest to negative heatsink.)
Check continuity between P2-19 and pump shunt. (Wire #29, side attached to standoff.)
Wire #119 and #29 are reversed. (Wire #29 is on heat sink.)

Check wires #29 and #119 for burnt, smashed, cut or shorted areas. Repair or replace
open wires.
Check pump shunt connections to make sure they are tight and there is no Repair or replace
corrosion between the terminals for wire #29 or #119 and the shunt. defective wires.
87
SENB8604-02
PROBLEM 29
POSSIBLE CAUSES
Wiring defect: pump driver board defect: failed logics.
CHECKS
Check continuity between P2-7 and P4-1 (wire #79).
Check continuity between P4-5 and Positive HS (wire #34).

Check wires #79, #117, #118, and #34 for burnt, smashed, cut or shorted areas. Repair or replace
open wires.
Perform pump driver board tests. See the topic, “Pump Driver Board Tests” Repair or replace
in this section of the manual. defective wires.
Pump Driver Board OK Pump Driver Board Not OK

pump driver board.
* Typical Amps at steer idle 15 - 50 and 250 at steer lock.
88
SENB8604-02
PROBLEM 30
POSSIBLE CAUSES
Bypass contactor tips and pump contactor shorted. Shorted T1D, T2D, T1P, T2P, and T3D: poor connection at logics connector:
defective drive and/or pump driver boards.
CHECKS
See problems 9 and 21, Display = “10” and Display = “30”. Perform both procedures.
89
SENB8604-02
PROBLEM 31
POSSIBLE CAUSES
Blown line fuse: failed logics: faulty wiring.
CHECKS
See problems 10, 22, and 23 (Display = “11”, Display = “31”, Display = “32”, and Display = “33”). Perform all four procedures.
90
SENB8604-02
PROBLEM 32
POSSIBLE CAUSES
Serial communications fault between display and logics.
CHECKS
Check the following wires for continuity. Also visually inspect their connections for burnt or discolored terminals, loose connections,
smashed or compressed connectors, corrosion or foreign materials.
P3-4 to P6-4 (wire #12).
P3-5 to P6-3 (wire #16).
P6-2 to key switch (wire #4).
P6-1 to battery negative (wire #1).
P3-18 to key switch (wire #4).
P3-20, P3-21, P1-21 to battery negative (wire #1).
Checks OK Checks Not OK

Check for short to battery negative (wire #1) in the following wires: Repair or replace
Wire #12. open wires.
Wire #16.
Wire #4.

Connect a spare display unit to harness plug P6 and turn the key switch on. Fix shorts.
Spare Display Functions Properly Display = “60”

Replace display. Replace logics.
91
SENB8604-02
PROBLEM 33
POSSIBLE CAUSES
Internal EEPROM memory error in microprocessor or logics.
CHECKS
Replace logics.
92
SENB8604-02
PROBLEM 34
Display = “65”: (!) action light flashing: no lift truck operation. Line contactor never closes.
POSSIBLE CAUSES
Truck size not initialized.
CHECKS
Enter setup mode and access Option #30, Truck Size and Type (see the topic “Setup Options” in the Systems Operation section
of this manual).
Set the value of the option according to the size of your cushion truck.
All service replacement logics boards are shipped with Option #30 set to “0.00”. You must always enter setup mode and set the
value according to the size of your cushion truck.
Remember, Option #30 will not be programmed to new values until the DRS switch is moved to the RUN position while in the
SETUP mode. This will cause the “triple bar” display to show up, indicating successful programming of the new truck size and type.
Exit Setup mode and power up the truck in Run mode.
If the display still reads “65”, replace logics.
93
SENB8604-02
PROBLEM 35
POSSIBLE CAUSES
Internal microprocessor “Watchdog” timer failure.
CHECKS
Replace logics.
94
SENB8604-02
PROBLEM 36
Display = “68” or “69”: (!) action light flashing: no lift truck operation. Line contactor closes and opens.
POSSIBLE CAUSES
68: Battery volts too low for chosen jumper.
69: Battery volts too high for chosen jumper.
Short between connector P5-16 and P6-1
CHECKS
Check the following wires for continuity. Also visually inspect their connections for burnt or discolored terminals, loose connections,
smashed or compressed connectors, corrosion or foreign materials.
P3-4 to P6-4 (wire #12)
P3-5 to P6-3 (wire #16)
P6-2 to key switch (wire #4)
P6-1 to battery negative (wire #1)
P3-18 to key switch (wire #4)
P3-20, P3-21, P1-21 to battery negative (wire #1).

Check for short to battery negative (wire #1) in the following wires: Repair or replace
Wire #12. open wires.
Wire #16.
Wire #4.

Connect a spare display unit to harness plug P6 and turn the key switch on. Fix shorts.
Spare Display Functions Properly Display = “60”

Replace display. Replace logics.
Field Notes
Also Check:
1. Open line Contactor Coil.
95
SENB8604-02
PROBLEM 37
Seat switch or circuit defect.
POSSIBLE CAUSES
Seat switch defect: wiring to seat defect: logics defect.
CHECKS
Measure the voltage at logics P1-13 (wire #7, silver area) with weight on and off seat. Scrape coating off card pins if needed.
Voltage measured should be:
High with weight off the seat.
Low with weight on the seat.

Disconnect seat switch and check the continuity with weight on and off the seat. Resistance should be: Verify problem still exists.
If it does, replace logics.
Less than 50 ohms with weight on the seat.
OL (infinite) with weight off the seat.
OK Not OK
Check continuity from P1-13 to seat switch (wire #7). Replace
Check continuity from seat switch to battery negative (wire #1). seat switch.
OK Not OK
Check for short to battery negative Correct any open wires.
(wire #1) in wire #7. Correct short.
96
SENB8604-02
PROBLEM 38
Direction switch circuit defect.
POSSIBLE CAUSES
Direction switch defect: wiring to direction seat defect: logics defect.
CHECKS
Measure the voltage on logic card (silver area) at P1-10 (wire #14) and P1-9 (wire #15.) Scrape coating off pins if needed.
Use the following chart to determine proper voltages.
Logics Pin FWD REV Neutral

P1-10 Low High High
P1-9 High Low High
Voltage Not OK Voltage OK

Disconnect direction switch and check switch for proper continuity. Verify problem still exists.
Lever Position FWD (wire #14) REV (wire #15)

to BAT (wire#1) to BAT (wire #1)
FWD <50 ohms OL (infinite)
Neutral OL (infinite) OL (infinite)
REV OL (infinite) <50 ohms
Check OK Check Not OK

Check continuity from logics P1-10 (wire #14) and P1-9 (wire #15) Replace
to direction switch. seat switch.
OK Not OK
Check for short to battery negative (wire #1) Correct any open wires.
in wire #14 or #15. Correct short.
97
SENB8604-02
PROBLEM 39
Foot-operated direction switch circuit defect.
POSSIBLE CAUSES
Direction switch defect: wiring to direction seat defect: service brake interrupt switch defect: logics defect.
CHECKS
Measure the voltage on logic card (silver area) at P1-10 (Wire #14) and P1-9 (wire #15). Scrape coating off card pins if needed. Use
the following chart to determine proper voltages.
Logics Pin FWD REV Neutral

P1-10 Low High High
P1-9 High Low High

Disconnect direction switch and check switch for proper continuity. Verify problem still exists.
Lever Position FWD (wire #14) REV (wire #15)

to BAT (wire#1) to BAT (wire #1)
FWD <50 ohms OL (infinite)
Neutral OL (infinite) OL (infinite)
REV OL (infinite) <50 ohms
Check OK Check Not OK

Check continuity from P1-10 to P61-2 (wire #14). Replace
Check continuity from P1-9 to P61-3 (wire #15). direction switch.
Check continuity from P61-1 to battery negative (wire #1).
OK Not OK
Check for short to battery negative (wire #1) Correct any open wires.
in wire #14 or #15. Correct short.
98
SENB8604-02
PROBLEM 40
Park brake switch circuit defect.
POSSIBLE CAUSES
Park brake switch defect: wiring defect: logics defect.
CHECKS
Check park brake switch adjustment to make sure park brake switch is activated by park brake lever.

Measure the voltage at logics P1-11 (wire #91) with park brake applied and released. Adjust lever to make
Scrape coating off pin card if needed. Voltage should be: proper engagement
with switch.
High—Brake applied.
Low—Park brake released.
Disconnect park brake switch and check continuity with park brake Verify problem still exists.
applied and released. If it does, replace logics.
Resistance should be:
<50 ohms with park brake applied.
OL (infinite) with park brake released.
OK Not OK
Check for continuity from park brake switch to P1-11 Replace
(wire #91). park brake
Check for continuity from park brake switch to battery switch.
negative (wire #1).

Check for short to battery negative Correct open wire.
(wire #1) in wire #91. Repair short.
99
SENB8604-02
PROBLEM 41
Service brake switch circuit defect.
POSSIBLE CAUSES
Service brake switch defect: wiring defect: logics defect.
CHECKS
Check service brake switch adjustment to make sure service brake switch is activated by service brake lever.

Measure the voltage at logics P1-12 (wire #113) with service brake applied and released. Adjust pedal to make
Scrape coating off card pins if needed. Voltage should be: proper engagement
with switch.
High—Service brake applied.
Low—Service brake released.
Disconnect service brake switch and check continuity with service brake Verify problem still exists.
applied and released. If it does, replace logics.
Resistance should be:
<50 ohms—Service brake applied.
OL (infinite)—Service brake released.
OK Not OK
Check for continuity from service brake switch to P40-C to Replace
P1-12 (wire #113). service
brake
Check for continuity from service brake switch P40-A to switch.
battery negative (wire #1).

Check for short to battery negative Correct open wire.
(wire #1) in wire #113. Repair short.
100
SENB8604-02
PROBLEM 42
Accelerator switch circuit defect.
POSSIBLE CAUSES
CHECKS

Disconnect P9 connector. With keyswitch closed, check for battery voltage between P9-A (wire #1) Adjust control to the
and P9-B (wire #4). (Be sure that the problem is not a defective keyswitch.) proper specifications.
OK If Low
Check voltage between P9-C and P9-A. Repair open
wire between
P9-A (wire #1)
and battery
15 Volts Not 15 Volts negative or P9-
B (wire #4) and
Plug accelerator back into P9 connector. Check continuity of wire #8 between battery
Check voltages at logics P1-15 as follows: logics P1-15 and P9-C. positive.
Accelerator Control Pedal Voltage

Continuity OK Continuity
Position
Not OK
Check for short to battery
Fully UP 12 to 12.5 volts Repair or
negative (wire #1 in wire #8).
Fully depressed 1.6 to 2.0 volts replace
broken
Voltage should decrease from max to min wire.
as pedal is depressed.
No Short Short
Voltage Readings Voltage Ok But Replace Repair or
Not Ok Problem Persists logics. replace
Replace Replace logics. shorted
accelerator control. wire.
101
SENB8604-02
PROBLEM 43
Battery Discharge Indicator (BDI) display shows no bars. Drive may be slow: power steering is normal.
No hydraulics (lift or tilt). BDI circuit defect.
POSSIBLE CAUSES
Option #16 (BDI Reset value) set too high: battery discharged or defective: logics defect:
J1, J2, J3, or J4 jumper missing or in wrong position: BDI needs adjustment.
CHECKS
Verify that the value of Setup Option #16 is as expected. Typical value is 6.
Value OK Value Set Too High

Connect battery, turn on key switch, close seat switch, and measure voltage from line contactor to Reset Value.
negative heatsink. Voltage readings should be:
36V Battery—greater than 34.8V
48V Battery— greater than 46.4V
Voltage OK Voltage Low

Make sure jumper connector in the logics is in the correct position for the Verify problem still exists.
battery used. (J1=36V, J2=48V, J3=72V, J4=80V). If it does, replace logics.
Jumper Position Correct Not Correct

With key on, seat switch and line contact closed, Move
measure voltage at logics P3-18. jumper to
correct
Battery Voltage Less than Battery position and
Voltage recycle key
Adjust BDI to specifications. The switch.
key must be turned off between Repair shorted wire or
each adjustment of P5*. If BDI will high resistance
not adjust, replace logics. connection causing the
improper voltage.
*NOTE: Display will show no bars until BDI is adjusted far enough to change the display to a six-bar reading.
102
SENB8604-02
PROBLEM 44
Lift switch 1 and 2 circuit defects.
POSSIBLE CAUSES
Lift switch 1 and 2 not adjusted properly or defective: wiring defect: logics defect.
CHECKS
Check mechanical linkage for proper operation. Switch 1 should “click” in before switch 2.
Linkage OK Linkage Not OK

Measure the voltage on logics card (silver area) at P1-1 and P1-2. Scrape coating off card pins if Adjust linkage.
needed. Use the following chart to determine proper voltages:
Logics Pin Lift Lever Fully Lift Lever Fully Lift Lever 1/2 Lift Lever
FWD BACK BACK NEUTRAL
P1-1 High Low Low High
P1-2 High Low High High
Voltage NOT OK Voltages OK

Disconnect switches and check continuity with lever in neutral position Verify problem still
and pulled fully back. Resistance for these switches should be: exists. If it does,
replace logics.
Neutral—OL (infinite)
Fully Back—<50 ohms.
CHECK OK NOT OK
Check continuity between P13-5 to P1-1 (wire #13). Replace
defective
Check continuity between P13-6 to P1-2 (wire #81). switches.
Check continuity between P13-1 to battery negative
(wire #1).
Checks OK Checks
Check for short to battery negative Not OK
(wire #1) in wire #13. Repair or
Check for short to battery negative replace open
(wire #1) in wire #81. wire.
Repair shorts.
103
SENB8604-02
PROBLEM 45
Tilt switch circuit defects.
POSSIBLE CAUSES
Tilt switch not adjusted properly or defective: wiring defect: logics defect.
CHECKS
Check mechanical linkage for proper operation. Switch should “click” when depressed.

Measure the voltage on logics card (silver area) at P1-13. Scrape coating off card pins if needed. Adjust linkage.
Use the following chart to determine proper voltages:
Logics Pin Lift Lever Fully Lift Lever Fully Lift Lever
FWD BACK NEUTRAL
P1-3 Low Low High

Disconnect switches and check continuity with lever fully forward, in neutral Verify problem
position and pulled fully back. Resistance for these switches should be: still exists.
If it does,
Fully FWD—<50 ohms
replace logics.
CHECK OK NOT OK
Check continuity between P13-2 to battery negative (wire #1). defective
switches.
Checks OK Checks
(wire #1) in wire #89.
Repair or
Repair shorts. replace open
wire.
104
SENB8604-02
PROBLEM 46
Aux 1 switch circuit defect.
POSSIBLE CAUSES
Aux 1 switch not properly adjusted or defective: wiring defect: logics defect.
CHECKS

Measure the voltage on logics card (silver area) at P1-4. Scrape coating off card pins if needed. Adjust linkage.
Use the following chart to determine proper voltages:
Logics Pin Aux 1 Fully Aux 1 Lever Aux 1 Lever

FWD Fully BACK NEUTRAL
P1-4 Low Low High

Disconnect switches and check continuity with lever fully forward, in neutral Verify problem still
position and pulled fully back. Resistance should be: exists. If it does,
replace logics.
CHECK OK NOT OK
Check continuity between P13-3 to battery negative (wire #1). defective
switches.
Checks OK Checks
Repair shorts. replace open
wire.
105
SENB8604-02
PROBLEM 47
Aux 2 switch circuit defect.
POSSIBLE CAUSES
Aux 2 switch not properly adjusted or defective: wiring defect: logics defect.
CHECKS

Measure the voltage on logics card (silver area) at P1-5. Scrape coating off card pins if needed. Adjust lever to make
Use the following chart to determine proper voltages: proper engagement
with switch.
Logics Pin Aux 2 Fully Aux 2 Lever Aux 2 Lever
FWD Fully BACK NEUTRAL
P1-5 Low Low High

Disconnect switches and check continuity with lever fully forward, in neutral Verify problem still
position and pulled fully back. Resistance should be: exists. If it does,
replace logics.
CHECK OK NOT OK
Check continuity between P13-4 to battery negative (wire #1). park brake
switch.
Checks OK Checks
Repair short. replace open
wire.
106
SENB8604-02
PROBLEM 48
Hydraulic speed check. (Hydraulic Speed less than desired.)
POSSIBLE CAUSES
Speed options set to incorrect value for Lift, Tilt, or Aux in programmable Setup Options.
CHECKS
Enter Setup Mode and access Option #2 (First Group) Lift 1 Speed.
(See the topic “Setup Options” in the Systems Operation section of this manual).
Set the option to the correct value.
Exit Setup Mode and power up the truck in RUN mode. Check lift speed. Repeat procedure if lift speed still needs adjustment.
Remember, Option #2 will not be programmed to new values until the DRS switch is moved to the RUN position while in SETUP
mode. This will cause the “Triple Bar” display to show up, indicating successful programming of the new truck size and type.
Repeat the procedure if necessary for other hydraulic functions:
Option 3 – Lift 2
Option 4 – Tilt Speed
Option 5 – Aux 1 Speed
Option 6 – Aux 2 Speed.
107
SENB8604-02
PROBLEM 49
Incorrect contactor operation.
POSSIBLE CAUSES
Wiring defect: contactor defect: logics defect.
CHECKS
During the self-diagnostic test, which of the following occurs?
Contactor does not pull in or does not remain pulled in. Contactor remains
Disconnect the battery. Check for free mechanical movement of contactor bridge (tips). in whenever the key
switch is closed
Movement OK Movement Not Free through all tests.
Remove logics cover. Disconnect P3. Check continuity from P3-16 Repair or replace See OTHER PROBLEMS
(wire #38) to coil X terminal of the contactor with correct operation. contactor. list, “Any contactor closes
when key switch is
Continuity No closed.”
Measure continuity from the appropriate P3 socket to the Continuity

coil terminal Y of the contactor that has incorrect operation.
Determine the P3 socket with respect to the contactor that Replace
has incorrect operation as follows: display unit.
Line . . . . . . . . . . . . . . .P3-9, wire #26
Pump Bypass . . . . . . .P3-10, wire #30
Drive Bypass . . . . . . . .P3-11, wire #35
Reverse Direction . . . .P3-13, wire #19
Forward Direction . . . .P3-12, wire #20
Regen . . . . . . . . . . . . .P3-14, wire #75.
Perform contactor tests. Repair or
(Coil Resistance, Coil Suppression, Coil Pulsing). replace wire.
Tests OK Tests Not OK

Connect P3 and run Repair or
“Self” diagnostics again. replace
If contactor does not close, contactor.
replace logics.
108
SENB8604-02
PROBLEM 50
Any contactor closes when key switch is closed.
POSSIBLE CAUSES
Wiring defects: failed logics.
CHECKS
Connect the battery. Does the line contactor close when the key switch is closed?
Yes No
Check stored fault codes. Verify E1 is present.
No Yes
See the SELF DIAGNOSTICS Which contactor closed? Disconnect the battery.
PROBLEMS list; “Seat Switch Remove logics cover and disconnect logics P3 connector.
circuit defect.” Check for a short circuit from control panel battery negative
(negative heat sink) to P3 harness connector socket.
Determine the P3 socket with respect to the contactor that
closed as follows:
Line . . . . . . . . . . . . . . .P3-9
Pump Bypass . . . . . . .P3-10
Drive Bypass . . . . . . . .P3-11
Reverse Direction . . . .P3-13
Forward Direction . . . .P3-12
Regen . . . . . . . . . . . . .P3-14.
Repair or replace shorted wire. Replace logics.
109
SENB8604-02
PROBLEM 51
Drive motor does not operate or operates with low power or is erratic. Pump and power steering systems operation normal.
POSSIBLE CAUSES
Accelerator control defective: drive driver board defective: current limit set too low: wiring defect: failed logics.
CHECKS
Perform self-diagnostics.
Passed Failed
Turn current limit potentiometer P1 clockwise and check operation. See respective PROBLEM
for defective circuit.
Wheels Don’t Spin Wheels Spin
Check R312 for correct resistance. Adjust current
limit to
36/48V = 34.20 - 37.80 ohms
specification.
72/80V = 71.25 - 78.75 ohms
In Specification Not in
Check wires #31 and #32 for a good connection on Specification
R312. Check wires #36 to base of transistors T1D and
T2D. Check continuity of wire #37 from emitter T2D to Replace resistor
logics P2-6. R312.
All OK Defective
Check diodes D5D and D4D for shorts Repair or
or open circuits. replace.
Diodes OK Defective
Check drive motor for Replace
open circuit. Check cur- defective
rent shunt and wiring for diode.
continuity. Check drive
driver board for defects.
Checks OK Defective
drive driver
board.
*NOTE: Reset current limit to specifications after repairs are complete.
110
SENB8604-02
PROBLEM 52
Poor acceleration: loss of power on ramps.
POSSIBLE CAUSES
Current limit out of adjustment: cables or connections to motor defective: T1D and T2D degenerative or defective:
motor defective: failed logics.
CHECKS
Verify the value of Setup Option #8 (Variable Acceleration) is set high enough.
Value OK Value Too

Verify value of Setup Option #15 (80% Bypass). Low
Reset to
Value = 1 (ON) Value = 0 (OFF) higher value.
Reset to 0 (off). By setting this option to 0, you are removing a feature Make sure the truck passes all
that helps protect the drive motor from abuse. This may be necessary self-diagnostic tests.
in some applications that have steep ramps. However, use caution
Passes Self- Fails Self-Diagnostics
when turning off this option, as increased motor drive failures may
Diagnostics Replace failed circuit.
occur.
Check the current limit setting of the drive motor.
If Correct If Not Correct

Check motor and cables for poor connections. Adjust current limit to
specifications.
Connections Good Connections Cannot

Loose Adjust
Check drive motor
for defect or Repair or See
mechanical tighten loose Problem 54.
drag of drive train. connections.
111
SENB8604-02
PROBLEM 53
Lift truck has long electrical braking distance or sudden (jerk) stop at end of electrical braking cycle. Pump system operation normal.
POSSIBLE CAUSES
Wire #51 defective: current limit set too low: electrical braking diode D5D defective: current sensor defective:
electrical braking current not adjusted properly.
CHECKS

Set current limit. Adjust potentiometer P3 to electrical braking specifications if needed. Repair or replace open wires.
Cannot Adjust Adjustment

Check continuity from FWD contactor (wire #51) to logics connection P2-17. corrected
Return truck
to service.
Check diode D5D for defect. Repair or
replace wire.
OK Defective
Replace logics. Replace diode D5D.
112
SENB8604-02
PROBLEM 54
Current limit and/or electrical braking limit adjustment cannot be made.
POSSIBLE CAUSES
Current sensor defect: motor cables incorrect: logics failure.
CHECKS

Check motor cables for proper connections. If not OK, repair. If connections are OK, replace T1D and T2D. Repair or replace open wires.
If replacing T1D and T2D doesn’t fix the problem, replace logics.
113
SENB8604-02
PROBLEM 55
Auxiliary lighting and/or alarm does not function correctly. Lift and drive operations normal.
POSSIBLE CAUSES
Open fuse: faulty wiring: defective switch: shorted load: open load: loss of input voltage to DC-DC converter: defective DC-DC converter.
CHECKS
Is lift truck equipped with a DC-DC converter?
Yes No
Connect the battery and close the key switch. Measure from the
DC-DC converter 12V positive terminal to the 12V negative terminal.
No Voltage Voltage Voltage 11

Voltage above 13V below 11V to 13V
See Chart 55A. See Chart 55B. See Chart 55C. With the faulty auxiliary circuit activated, check for
voltage on the load side of the auxiliary fuse.
Battery Voltage No
Voltage
Check for voltage on the low side of the
Check for
auxiliary switch. short circuits.
Battery Volts 0 Volts Replace
auxiliary fuse.
Check for voltage at the nega- Repair or
tive connection of the load. replace
0 Volts Battery Volts open wire
from fuse
Repair or Repair or or replace
replace open wire replace open defective
from the auxiliary wire from switch.
switch or replace fuse or
the defective replace
auxiliary defective
component. switch.
114
SENB8604-02
PROBLEM 55A
No Voltage Output (See problem 55).
CHECKS
Measure the voltage from (POS INPUT) to (NEG INPUT).
Battery Voltage 0 Volts

Measure the voltage from (12V POS) terminal of the DC-DC converter to Measure the voltage from the battery positive
battery negative. cable at the line contactor to the (NEG INPUT)
terminal of the DC-DC converter.
Measure the voltage from (ENABLE) terminal of the Replace
the DC-DC Check for open fuse or Repair open
DC-DC converter to battery negative. converter. wiring between the line negative connec-
Battery Voltage 0 Volts contactor and the (POS tion from convert-
INPUT) terminal of the er (NEG INPUT)
Test the fuse at the DC-DC converter for continuity. Repair or
replace open DC-DC converter. to battery
wiring from negative.
Fuse Good Fuse Open the key Open Fuse Open
switch to the
Remove the load connections at the Replace fuse. If (ENABLE) Replace fuse and Wiring
(12VPOS) and (12VNEG) terminals fuse continues terminal of
of the DC-DC converter. to fail, replace check wiring for Repair or
the DC-DC
the DC-DC converter. shorts. If no replace
converter. shorts are found faulty
and the fuse con- wiring.
11 to 13 Volts <11V or tinues to fail,
>13V replace the DC-
Check for a short
circuit in each auxiliary Replace DC converter.
circuit. the DC-DC
converter.
No Shorts Short
Found Found
Replace the Repair or
DC-DC replace
converter. faulty
wiring or
compo-
nents.
115
SENB8604-02
PROBLEM 55B
Voltage Below 11 Volts (See problem 55).
CHECKS
Measure the (POS INPUT) or (+IN) terminal to the (NEG INPUT) or (- IN) terminal of the DC-DC converter.
35 Volts or Above Below 35 Volts

Remove all connections at the (12V POS) and the (12V NEG) or the Perform “Battery Load Tests”.
(+OUT) and the (-OUT) terminals of the DC-DC converter. Measure
the voltage from the (12V POS) to (12V NEG) or (+OUT) to (-OUT). Battery Low Battery Good
Below 11 Volts Charge or replace Check all DC-DC converter input connections
11 to 13 Volts battery.
from the battery, fuse, and key switch or relay.
Check for a short or low resistance in DC-DC converter faulty.
the auxiliary circuits and loads. NOTE: Replace converter.
Excessive loading places the converter All Connections Poor
into current limit. (12A maximum) Good Connections
Replace plug-in relay Repair or replace
at the relay printed faulty wiring or
circuit board (if connections.
equipped with a relay).
116
SENB8604-02
PROBLEM 55C
Voltage above 15 volts (see problem 55).
CHECKS
Remove all connections at the (12V POS) and (12V NEG) or the (+OUT) and the (-OUT) terminals of the DC-DC converter.
Measure the voltage from the (12V POS) to (12V NEG) or (+OUT) to (-OUT).
11 to 13 Volts Above 11 Volts

Check the output load circuits for incorrect wiring or shorts to battery negative. DC-DC converter faulty. Replace converter.
117
SENB8604-02
PROBLEM 56
Slow steering, but pump motor does turn. Drive and lift systems operation normal.
POSSIBLE CAUSES
Steering pressure switch defect: wiring defect: failed logics.
CHECKS
Check the battery, close the seat switch and key switch. Put the direction lever in forward. Disconnect pressure switch connector P24.
Pump Motor Speed Remains The Same. Pump Motor Speed

With P24 disconnected, check for a short circuit between P1-6 (silver area) and battery negative. Increases
Replace the steering
Not Shorted Shorted pressure switch.
Test the head capacitors. Inspect the capacitor wiring to positive and negative Repair or replace
heatsinks. Verify correct torque for capacitor hardware. faulty wiring.
Test OK Test Failed

Replace logics. Replace failed capacitors or repair
connections and wiring.
118
SENB8604-02
PROBLEM 57
Steering idle speed runs fast. Pump motor turns at high power steering speed continuously.
Pump motor runs continuously when neutral is selected (no chat mode).
POSSIBLE CAUSES
Steering pressure switch defect: pressure switch connector disconnected: wiring defect: failed logics.
CHECKS
Check steering pressure switch connector P24 for proper connection.
Connected Disconnected
Disconnect the pressure switch connector P24. Place a jumper wire from P24-1 to P24-2. With the key Connect P24.
switch ON, seat switch closed, and a direction selected, the pump motor should run at slow speed.
Remains at High Speed Runs at Slow Speed
Disconnect the battery and discharge the head capacitors. Check continuity Replace the pressure
from P24-1 to the control panel battery negative. Also check continuity from switch.
P24-2 to logics P1-6 (wire #78).
Replace logics. Repair or replace open wire.
119
SENB8604-02
PROBLEM 58
Travel Speed reduced to 2.0 mph (no code).
POSSIBLE CAUSES
Speed set at 2.0 mph: service or park brake switch out of adjustment or broken: wiring defect.
CHECKS
Run Self Diagnostic.
Failed Passed
Check failed circuit and repair. Check Lift Setup.
Brake Switch Failed

Check adjustment & operation of switch.
OK Not OK
Check wiring to switch. Repair switch and adjust.
Not OK
Check logics.
120
SENB8604-02
PROBLEM 59
Display = “FFFF.O” .
POSSIBLE CAUSES
Display is defective.
CHECKS
Replace Display.
121
SENB8604-02
PROBLEM 60
Display = Code “H” .
POSSIBLE CAUSES
Hydraulic switch closes before turning key switch on.
CHECKS
Adjustment of hydraulic switches.
Adjust or repair as needed.
122
SENB8604-02
PROBLEM 61A
Display = Code “E” (Not Flashing).
POSSIBLE CAUSES
Accelerator depressed before turning key switch on.
CHECKS
Adjust accelerator linkage as needed.
PROBLEM 61B
Display = Code “E” (Flashing) .
POSSIBLE CAUSES
Seat Switch open when it should be closed.
CHECKS
1. Seat Switch.
2. Open in Seat Switch Harness.
CORRECTION
1. Replace Switch.
2. Repair Wires.
123
SENB8604-02
NOTES
124
SENB8604-02
Systems Operation Discharging Head Capacitor

(HEAD CAP)
and Test Equipment
6V7070 Heavy Duty Digital Multimeter (1) can be used
to measure voltage, resistance or current. When used
! WARNING
to troubleshoot MicroCommand II control panels, Battery voltage and high amperage are present.
8T3224 Needle Tips (5) should be attached to the Injury to personnel is possible. Disconnect the bat-
meter leads. These needle tips have a smaller diameter tery and discharge the head capacitor (HEAD CAP)
and are less likely to cause damage to connectors. See before any contact is made with the control panel.
the enclosed Instructions for the correct operation of
Before servicing truck, always discharge the head
6V7070.
capacitors. The voltage measured across the
8T0900 Clamp-On Ammeter (2) may be used to mea- capacitors should be less than 5 volts. If the capac-
sure current. When using ammeter (2) with 6V7070 itors are not discharged, use the following proce-
Digital Multimeter (1) as a remote readout, 6V6014 dure to discharge them.
Cable (4) should be used to connect ammeter (2) to
multimeter (1). See Special Instructions SEHS8420 for
the correct operation of 8T0900.
Resistor (3) is a 150 ohm, 25 watt resistor used to dis-
charge the head capacitor before contact is made with
the control panel.
4C4029 Trimmer Adjust Tool (6) allows easier adjust-
ment of the adjusting screw found on potentiometers.
The insulated body has a blade on each end. One
blade is recessed to provide a captive screwdriver for
adjustments that are difficult to see. The other end has
an exposed blade to reach adjustment screws that are
behind panels which have small access holes.
2 30703P1
1
1. Disconnect the battery and discharge the head
capacitor.
4
2. Put a 150 Ohm, 25 watt resistor (1), Part No.
3 0358280, in position between the terminals of
head capacitor (2). Hold the resistor in position
for 20 seconds. This will discharge the capacitor
below 5 volts.
Tools.eps
(1)6V7070 Heavy Duty Digital Multimeter
(2) 8TO900 Clamp-On Ammeter (3) 0358280 Resistor
(4) Ammeter 6V6014 Cable (5) 8T3224 Needle Tips
(6) 4C4029 Trimmer Adjust Tool
125
SENB8604-02
Logics Removal Component Tests
! WARNING ! WARNING
Battery voltage and high amperage are present. Battery voltage and high amperage are present.
Injury to personnel is possible. Disconnect the bat- Injury to personnel is possible. Disconnect the bat-
tery and discharge the head capacitor (HEAD CAP) tery and discharge the head capacitor (HEAD CAP)
before any contact is made with the control panel. before any contact is made with the control panel.
1. Disconnect the battery and discharge the head To clean the control panel, use air pressure to blow
capacitor. off dust and dirt. Do not use steam or solvent.
NOTICE: Do not use steam or solvent to clean the
controls. Damage can be caused to the control
panel. Use pressure from an air hose with a maxi
mum pressure of 205 kPa (30 psi) to clean the
control panel when necessary. The air supply must
be equipped with a water filter.
NOTE: When control wires and power cables or
bus bars are to be connected to the same bolt or
stud, place all control wires together on the top of
the bus bar or power cable.
Use the wiring diagram and electrical schematic (locat-
ed inside rear panel cover) to locate components
referred to by name and number in the procedures that
follow. All wires must be located as shown on the
wiring diagram and schematic.
97C54-00301
Component Location 2) Logics cover. (3) Screws.
2. Loosen screws (1) that hold logics cover (2).

3. Remove the logics cover.
4. Disconnect connectors P1, P2 and P3. When
disconnecting connectors, pull on the plastic
connector housing, not on the wires.
5. Loosen screws (3) which hold the logics to
control panel.
6. Remove logics and replace logics cover to
prevent damage.(1)Screws.
Wiring Diagram And Schematic Inside Rear Panel Cover (Example Only)
Logics Connector Removal
126
SENB8604-02
Logic Unit Quick Reference Voltage Check

The chart that follows is a quick reference of the
expected voltages at the logics card pin connectors.
All voltage measurements are made with respect to
battery negatives.
! WARNING
The lift truck can move suddenly. Injury to personnel
or damage to the lift truck is possible. Safely lift the
drive wheels off the floor. Put blocks of wood under
the frame so both drive wheels are free to turn.
Keep away from drive wheels.
1. Put blocks of wood under the frame so both
drive wheels are free to turn.
capacitor.
4. Connect the multimeter negative lead to control
panel battery negative.
5. Set the multimeter to the 200 volt DC range.
6. Use the multimeter positive lead with an 8T3224
Needle Tip to measure the voltages under normal
and activated conditions as shown in the Logic
Voltage Checks chart.
Logic Board Layout
127
SENB8604-02
LOGIC VOLTAGE CHECKS

Logic Wire Function *Normal Activated Test Procedure.
Terminal No. Voltage Voltage
P1-1 13 Lift_1 High Low Activated by moving lift lever OFF to full ON.
P1-2 81 Lift_2 High Low Activated by moving lift lever OFF to full ON.
P1-3 89 Tilt High Low Activated by moving tilt lever.
P1-4 88 Aux 1 High Low Activated by moving Aux 1 lever.
P1-5 87 Aux 2 High Low Activated by moving Aux 2 lever.
P1-6 78 Pressure Switch Low High Activated by turning steering wheel.
P1-7 82 Drive BWI High Low Activated by brush wear.
P1-8 83 Pump BWI High Low Activated by brush wear.
P1-9 15 Reverse (without backup alarm) High Low Activate direction lever from NEU to REV.
P1-10 14 Forward High Low Activate direction lever from NEU to FWD.
P1-11 91 Park Brake Switch Low High Activate park brake lever then release.
P1-12 113 Service Brake Switch Low High Activate service brake then release it.
P1-13 7 Seat Switch High Low Activated = switch closed.
P1-14 105 Lift Limit Switch High Low See Note 1.
P1-15 8 Accel PWM 12 to 12.75 1.6 to 2.0 Depress accelerator fully then release.
P1-16 - Not used
P1-17 - Not used
P1-18 115 Drive Motor Speed 1 2.5
P1-19 116 Drive Motor Speed 2 2.5
P1-20 Polarizing Plug
P1-21 1 GND 0 0 Battery / logic card negative.
P2-1 96 Drive SF Control 0 to 1 11 to 12 Activate drive system.
P2-2 92 Drive SF Collector B+ 0 to 1 Activate drive system.
P2-3 72 Pump SF Control 11 to 12 0 to 1 0 - 8 = 11 to 12 9 = 5.5 to 6.25 10 = 0 to 1
P2-4 71 Pump SF Collector 0 to 1 B+ 0 - 8 = 0 to 1 9 = 1/2 B+ 10 = B+
P2-5 31 Drive Armature Control B+ B+ to 0 Volts Activated as drive system runs faster.
B+ to B+
P2-6 37 Drive Emitter 0 to 1 0 to 1 - Activated as drive system runs faster. See Systems
Increasing Operation section, “Drive System Shunt Field Operation.”
to B+
P2-7 79 Pump B Control B+ Activate Pump.
P2-8 117 Pump B0 Control B+ Activate Pump.
P2-9 118 Pump B0 Turn Off Control
P2-10 45 Pump Emitter See Systems Operation section, “Pump System Shunt Field
Operation.”
P2-11 97 D6D (Regen) Anode
P2-12 34 Heatsink
128
SENB8604-02
Logic Wire Function *Normal Activated Test Procedure.

Terminal No. Voltage Voltage
P2-13 100 Frame
P2-14 101 A1
P2-15 102 A2
P2-16 Polarizing Plug
P2-17 51 Plug
P2-18 119 Pump Shunt +
P2-19 29 Pump Shunt - 0 0
P2-20 106 Brake Fluid Level High Low Activated by low brake fluid level.
P2-21 1 GND
P3-1 76 Drive Thermal Low High Activated by hot drive motor.
P3-2 77 Pump Thermal Low High Activated by hot pump motor.
P3-3 46 Control Thermal Low High Activated by hot control panel. See *
P3-4 12 Display (+) 10.9 to 13.75 10.9 to 13.75 Test with truck in normal state.
P3-5 16 Display (-) 0 to 2.75 0 to 2.75 Test with truck in normal state.
P3-6 85 Current Sensor Supply 7.15 to 7.5 7.15 to 7.5 Test with truck in normal state.
P3-7 2 Current Sensor GND 0 0 Test with truck in normal state.
P3-8 42 Current Sensor Input 3.6 to 4.0 Increasing Activated by current flow in drive circuit.
Output
P3-9 26 Line Contactor B+ See Note 2. B+ = coil open. Pulsed voltage = coil closed.
P3-10 30 Pump Bypass Contactor B+ See Note 2. B+ = coil open. Pulsed voltage = coil closed.
P3-11 35 Drive Bypass Contactor B+ See Note 2. B+ = coil open. Pulsed voltage = coil closed.
P3-12 20 Forward Contactor B+ See Note 2. B+ = coil open. Pulsed voltage = coil closed.
P3-13 19 Reverse Contactor B+ See Note 2. B+ = coil open. Pulsed voltage = coil closed.
P3-14 75 Regen Contactor B+ See Note 2. B+ = coil open. Pulsed voltage = coil closed.
P3-15 Polarizing Plug - -
P3-16 38 Contactor Supply B+ B+
P3-17 38 Contactor Supply B+ B+
P3-18 4 Switched Positive B+ B+
P3-19 - Not Used
P3-20 1 GND 0 0
P3-21 1 GND 0 0
NOTES:
* “Normal” = Battery connected, key switch, seat Low voltage should be 0 to 1 volt.
switch, park brake switch and line contactor closed. 1. Depending upon Option #10, voltages could be
reversed.
High voltage should be 14 to 16 volts. *Hi voltage
2. Battery voltage minus the voltage drop across
is 14v without line contactor and 22v with Line
the contactor (18 to 28 volts).
contactor in.
129
SENB8604-02
Conductor And Switch Capacitor Test, then each capacitor must be discon-
nected and tested separately. The failed individual
Continuity Tests capacitors must be replaced.
1. Set the multimeter to the 200 Ω range. 1. Disconnect the battery and discharge the head
2. Use the multimeter to perform the continuity test. capacitor.
If continuity exists, the measurement will be less 2. Visually inspect the capacitor for bulges at the
than 1 ohm. If the measurement is more than terminals.
this, continuity does not exist and the problem
will have to be repaired. 3. Verify the plastic top is not melted around the
terminals and that the blow plug is not leaking.
Accelerator Control
! WARNING
! WARNING Head Capacitor “blow plug” will rupture with
Battery voltage and high amperage are present. reverse polarity. Vapors and contents of Head
Injury to personnel is possible. Disconnect the bat- Capacitors are toxic, flammable and corrosive.
tery and discharge the head capacitor (HEAD CAP) Personal injury can be caused from breathing the
before any contact is made with the control panel. fumes or if its contents make contact with the skin.
Be sure to always connect the positive wire from
the positive heatsink to the positive terminal of the
Head Capacitor.
4. Disconnect positive cable (2) from the positive
heatsink connection point (1).
5. Set the multimeter to the 20KΩ range. Connect
the multimeter positive lead to positive side (5) of
head capacitor (3). Connect the multimeter
negative lead to negative side (4) of head
capacitor (3).
6. The meter must increment to above 10,000
ohms. Replace the capacitor if the indication is
not correct.
See Head Capacitor in Specifications Section for proper
P9 Connector Location (Under Floor Plate (1)P9 connector
(2) Accelerator control assembly order of the head capacitor connections and
bolt torque specifications.
Refer to “Self Diagnostics” Accelerator Control in
Troubleshooting section. 1
Capacitor (HEAD)
! WARNING 3
Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the bat-
tery and discharge the head capacitor (HEAD CAP) - +
2
before any contact is made with the control panel.
NOTICE: Damage can be caused to the head
capacitor. Do not remove bolts from capacitors to
4
perform tests. Remove capacitor connecting cables
at heatsink connections.
Location Of Components (1) Positive heatsink connection point (2)Head
On these trucks, head capacitor refers to all the head Capacitor (3) Negative side of capacitor (4) Positive side of Capacitor
capacitors hooked together as installed in the control
panel. If the capacitors hooked together fail the Head
130
SENB8604-02
Contactor Coil Suppression For Line, Bypass, and

Pump Contactors
Bypass Activation
! WARNING
! WARNING Battery voltage and high amperage are present.
The lift truck can move suddenly. Injury to person- Injury to personnel is possible. Disconnect the
nel or damage to lift truck is possible. Safely lift the battery and discharge the head capacitor (HEAD
drive wheels off the floor. Put blocks of wood under CAP) before any contact is made with the control
the frame so both drive wheels are free to turn. panel.
Keep away from drive wheels that turn. The coil suppression diode for the line, bypass, pump,
NOTE: Damage can be caused to the control panel. and regen contactors is built into the logics. To check
Do not switch the direction lever from one direction the suppression diode, use the following procedure:
to the other (plug the lift truck) when the drive 1. Disconnect the battery and discharge the Head
wheels are off the ground and in rotation at full Capacitor.
speed.
1. Connect the battery and close the seat switch.
3. Remove connector P3 from the logics board.
2. Turn the key to ON and release the parking
brake. 4. Set the multimeter to the diode test position.
3. Select a direction and rapidly depress the 5. Connect the negative multimeter lead to logics
accelerator pedal all the way to the floor. board P3-17.
4. Measure and record the time it takes the bypass 6. Connect the positive multimeter lead to logics
contactor to close. This should be.5 to 4.5 board:
seconds after the accelerator is fully depressed.
P3-9 for line contactor
5. If the recorded value from step 4 is less than.5 P3-11 for bypass contactor
seconds, the logics may need to be replaced. P3-10 for pump contactor
(During normal operation this time will vary with P3-14 for regen contactor
the load on the truck and width the value set in
7. The multimeter must indicate .3 to .9 volts.
option #8 of the programmable features. See the
topic “Programmable Features” in the Systems 8. Reverse the leads. The meter must indicate OL.
Operation section.)
9. If either test fails, replace the logics.
6. If the recorded value from step 4 is more than
4.5 seconds, check the bypass contactor tips for
free movement. Check wiring for bad connec
tions. Also check for drive train drag and the
current limit setting (potentiometer P1).
NOTE: The bypass contactor will not close if the
accelerator linkage is not adjusted correctly.
C0000 Logics Board
131
SENB8604-02
Coil Suppression For Direction Contactors Coil Pulsing

The coil suppression diode for the direction contactors 1. Disconnect the battery and discharge the head
is built into the logics, but is different from the other capacitor.
contactors. To check the suppression diode, use the
2. With the contactor coil leads and suppression
following procedure:
assembly leads connected, set the multimeter to
1. Disconnect the battery and discharge the head the 200 volt DC range.
capacitor.
3. Connect the multimeter negative lead to the
2. Remove the logics cover. negative coil terminal Y and the meter positive
lead to the coil positive terminal X wire #38.
3. Remove connector P3 from the logics board.
4. Connect the battery and activate the controls
4. Set the multimeter to the diode test position.
necessary for the contactor to be activated.
5. Connect the negative multimeter lead to logics
5. After the contactor activates the multimeter
board P3-17.
must indicate 15 to 30 volts. If the voltage is
6. Connect the positive multimeter lead to logics not correct and the contactor passed the Coil
board: Suppression test and the Coil Resistance test,
the logics must be replaced.
P3-12 for forward contactor
P3-13 for reverse contactor Contactor Tips
7. The multimeter must indicate OL. 1. Disconnect the battery and discharge the head
capacitor.
8. Reverse the leads. The meter must indicate OL.
2. Visually inspect the tips to verify they are not
9. If either test fails, replace the logics.
welded, melted, burned or pitted.
3. Press and release the tips quickly to verify there
is not binding.
4. Visually inspect the contactor assembly. Verify
foreign objects don’t interfere with normal
contactor operation.
NOTE: Perform a contactor tip gap check on
direction contactors only.
5. Check contactor tip gap with a feeler gauge as
shown. Refer to Specifications section for correct
settings.
C0000 Logic Board Layout
Coil Resistance
capacitor.
2. Disconnect all leads to the X and Y terminals of
the coil.
3. Set the multimeter to the 200 KΩ range.
4. Measure the resistance of the coil at the X and Y
terminals. It must be within specifications. See Checking Contactor Tip Gap
Component Measurements in the Specifications
section.
5. If the coil is not within specifications, the
contactor assembly will have to be replaced.
132
SENB8604-02
DC /DC Converter 1. Disconnect the battery and discharge the head

capacitor.
Refer to Problem 55 in the Troubleshooting section.
2. Remove the logics.
Diodes
3. Disconnect the cathode and remove the diode.
! WARNING 4. Wipe contact surface of the diode (1) clean. Put
Battery voltage and high amperage are present. a small amount of 5P8937 or 5P9810 Thermal
Injury to personnel is possible. Disconnect the bat- Joint Compound on contact surfaces (1), but not
tery and discharge the head capacitor (HEAD CAP) on the threads.
before any contact is made with the control panel. 5. Install the diode and tighten to the specification
NOTE: The following test procedure can be applied listed in the following chart:
to diode D4P, D4D and D5D. Diode D5D will be used
in the following examples. Diode Torque
1. Disconnect the battery and discharge the head D4D, D5D 36 N•m (320 lb in)
capacitor.
D4P 13 N•m (16 lb in)
2. Disconnect the D5D cathode lead wire (5).
6. Connect all wires that were removed.
3. Set the multimeter to the diode test position.
4. Connect the negative multimeter lead on D5D
cathode lead wire (5). Connect the positive
multimeter lead to battery negative (7). The
multimeter should indicate .3 to .9 volts.
5. Reverse the multimeter leads. The multimeter
should indicate OL. If any of the measurements
are not correct, replace the diode.
C25486P1
Diode Installation (Typical example)
(1) Contact surfaces
Vehicle Monitoring System

The display panel performs a lamp test during power
up. All segments and LEDs should light for three
seconds.
97C54-00300
1)D4P Cathode lead wire 2) D4P 3)D4D cathode lead wire
4)D4D 5)D5D Cathode lead wire 6)D5D 7) Battery Negative
Diode Replacement
! WARNING P6 Harness Connector Contact Layout (end view)

tery and discharge the head capacitor (HEAD CAP)
133
SENB8604-02
Driver Board Tests

Drive Driver Board
B
A
Driver Board Terminal Connections(A) P12 Connector(B) B Terminals(C) BO Terminals
Pump Driver Board
B
A
(A)P4 Connector (B)B Terminals (C)BO Terminals
134
SENB8604-02
Driver Board Testing

Use the following charts for testing the driver boards (36/48/72/80V):
Drive Driver Board Tests
Component Multimeter Range + Lead - Lead Results
T314/T315 (B to E) 200Ω P12-15 P12-16 3.7 to 4.1Ω
R311 P12-16 P12-15 3.7 to 4.1 Ω
T314/T315 (B to C) Diode B P12-15 OL
P12-15 B 0.3 to 0.9
T314/T315 (C to E) Diode B P12-16 0.3 to 0.9
Z313 P12-16 B OL
BO Balance 200Ω BO BO 0 to 0.5 Ω
D311, R313 200Ω P12-14 B 4.5 to 7.5 Ω
B P12-14 4.5 to 7.5 Ω
R315, R316, R317 2 KΩ P12-14 P12-5 .315 to .350 kΩ
P12-5 P12-14 .315 to .350 kΩ
Pump Shunt Field Components
Pump SF Fuse 200Ω P12-1 P12-2 0 to 0.5
D351 Diode P12-2 P12-6 OL
P12-6 P12-2 0.3 to 0.9
T351 (D to S) Diode P12-6 P12-10 OL
P12-10 P12-6 0.3 to 0.9
T351 (G to S) 2 KΩ P12-8 P12-10 1.71 kΩ to 1.89
R351, C351, Z351 P12-10 P12-8 kΩ1.71 kΩ to 1.89 kΩ
T 351 (G to S) Diode P12-8 P12-10 First reading should be OL. First reading should be greater
R351, C351, Z351 P12-10 P12-8 than second reading. Neither reading should be less than 0.5
Drive Shunt Field Components

Drive SF Fuse 200Ω P12-3 P12-4 0 to 0.5
D371 Diode P12-4P12-7 P12-7P12-4 OL
0.3 to 0.9
T371 (D to S) Diode P12-7 P12-10 OL
P12-10 P12-7 0.3 to 0.9
T371 (G to S) 2 KΩ P12-9 P12-10 1.71 kΩ to 1.89 kΩ
R371, C371, Z371 P12-10 P12-9 1.71 kΩ to 1.89 kΩ
T371 (G to S) Diode P12-9 P12-10 First reading should be OL. First reading should be greater
R371, C371, Z371 P12-10 P12-9 than second reading. Neither reading should be less than 0.5.
135
SENB8604-02
Pump Driver Board Tests

Component Multimeter Range + Lead - Lead Results
R329, R330 2 KΩ P4-1 P4-5 1.375 to 1.525 kΩ
R328, C322 P4-5 P4-1 1.375 to 1.525 kΩ
Z324, T327 (G to S)
R339, R340 2 KΩ P4-2 P4-5 .798 to .882 kΩ
R338, C332 P4-5 P4-2 .798 to .882 kΩ
Z334, T337 (G to S)
T337 (G to D) Diode P4-2 P4-7 OL
P4-7 P4-2 0.5 to OL
T327 (G to D) Diode P4-1 P4-7 OL
P4-7 P4-1 0.5 to OL
T337 (D to S) Diode P4-7 P4-10 0.5 to 1.1
R332 P4-10 P4-7 OL
T327 (D to S) Diode P4-7 P4-3 0.5 to 1.1
R332 P4-3 P4-7 OL
T341 (B to C) Diode P4-7 P4-4 0.3 to 0.9
R343, R342 P4-4 P4-7 OL
T341 (B to E) 200 Ω P4-4 BO 37.9 to 41.9Ω For 72/80V 79.9 to 83.9 Ω
*
R343, R342, R341 BO P4-4 37.9 to 41.9 Ω 79.9 to 83.9 Ω
*
T341 (C to E) Diode P4-7 BO 0.3 to 0.9
*
BO P4-7 OL
*
T331/ T332 (B to E) 200 Ω P4-5 P4-10 2.84 to 3.29 Ω
R331 P4-10 P4-5 2.84 to 3.29 Ω
T331 / T322 (B to C) Diode P4-10 BO OL
*
BO* P4-10 0.3 to 0.9
T 331 / T332 (C to E) Diode P4-5 BO OL

*
BO* P4-5 0.3 to 0.9
T324 (B to E), R321 200 Ω P4-5 P4-3 2.84 to 3.29 Ω
P4-3 P4-5 2.84 to 3.29 Ω
T324 (B to C) Diode P4-3 B OL
**
B** P4-3 0.3 to 0.9
T324 (C to E) Diode P4-5 B OL

**
Z 323 B** P4-5 0.3 to 0.9
D321 Diode P4-7 B 0.3 to 0.9

**
B** P4-7 OL
R327 200 Ω B BO* 0.5 to 2 Ω

**
BO B 0.5 to 2 Ω
* **
*Test BO terminals on both transistors.
**Test B terminals on both transistors.
136
SENB8604-02
Traction Motor Current Sensor Test 9. Move the direction selection lever to forward and
depress the accelerator. The voltage being
measured should increase. If the voltage
! WARNING decreases, the current sensor is mounted
backward. If there is no voltage measured or the
Battery voltage and high amperage are present. voltage being measured does not change, the
Injury to personnel is possible. Disconnect the bat- current sensor must be replaced.
tery. The head capacitor (HEAD CAP) must be dis-
charged before any contact with the control panel
is made. Disconnect the battery and discharge the
HEAD CAP.
1. Disconnect the battery, discharge the head
capacitors, and remove the logic cover.
2. Disconnect current sensor connector P16.
3. Check continuity from harness connector P16-3
(wire #85) to logics P3-6 and connector P16-2
(wire #42) to logics P3-7. Check for short
between harness the connector P16-3 wire #85
and the control panel battery negative. Check for
short between the harness connector P16-2 (wire
#42) and the control panel battery negative.
Repair or replace any defective wires.
! WARNING
The lift truck can move suddenly. Injury to person-
nel or damage to the lift truck is possible. Safely lift
the drive wheels off the floor. Put blocks of wood
under the frame so both drive wheels are elevated
and free to turn. Keep your person away from the
drive wheels that turn.
4. Set the multimeter to the 20V DC range. With the
connector P16 reconnected, connect the multi-
meter positive lead to logics P3-6. Connect the
multimeter negative lead to the control panel bat-
tery negative.
5. Connect the battery and turn the key ON. The
measurement must be 7.15 to 7.50 volts.
Connect the multimeter positive lead to logics
P3-8. The measurement must be 3.6 to 4.0 volts.
If both measurements are not correct, replace
the logics.
capacitors.
7. Set the multimeter to the 20V DC range and
connect the multimeter positive lead to logics
P3-8. Connect multimeter negative lead to the
control panel battery negative.
8. Connect the battery and turn the key ON. The
measurement must be 3.6 to 4.0 volts.
137
SENB8604-02
Hydraulics
The instrument panel is also powered at this time.
NOTE: On these circuit diagrams shaded lines Current will flow through the key fuse, P5-3, key
illustrate current flow. switch, wire #4,
Actuation Circuit P6-2, and P6-1 back to battery negative. The display
This circuit supplies power to the MicroCommand II first does a “lamp test” which will light all the LED sym-
and the monitoring system instrument panel. It must be bols and LCD segments for 5 seconds. The hour meter
activated before power steering, hydraulics, or drive will readings are then indicated.
operate. The logics will start to perform a set of “Run-Time” diag-
When the battery is connected and the key switch is nostics checks. The letter “E” will flash on the display
closed, current flows from battery positive through the indicating the key is ON with no operator in the seat.
key fuse, key switch, wire #4, P5-4 to the logics con- When the seat switch is closed, current will flow from
nection P3-18. The logics connection to battery nega- the logics to P1-13 through P5-7 (the seat switch) to
tive is at P1-21, P2-21, P3-20 and P3-21. The logics battery negative. The logics then activates the line
circuits are powered up to accept voltage inputs and contactor coil and P3-9 back to battery negative.
create voltage outputs whenever the battery is
connected and the key is ON.
3
3
LIGHTS FUSE 15A
34
P12-13
KEY FUSE 10A 3 HORN BUTTON
P12-11 P12-12 3 P5-3 P46-2 4 P46-1
R319 R320 KEY SWITCH
P3-18 P5-4 4
P3-4 P5-12 12 P6-4 P6-2 4

DISPLAY
46
34 P3-5 P5-16 16 P6-3 P6-1 1

P2-12 LIFT LIMIT SW
P3-3 SEAT OPERATED BRAKE SW
P1-14 127 P5-21 P60-C P60-A
100 1 +
P2-13
SEAT SWITCH 1
P1-13 P5-7 7 1 HORN
2
PUMP MOTOR THERMOSTAT -
P3-2 77 P5-25 1
P3-1 76 P5-24 1
DRIVE MOTOR THERMOSTAT SERVICE BRAKE SWITCH 3
P1-12 P5-23 113 P40-C P40-B 1
P1-11 P5-19 91 1
PARK BRAKE SW BRAKE FLUID SWITCH
P2-20 P5-22 106 P33-2 P33-1
FWD
P1-10 P5-14 14 P7-B 4
DIR SW P7-A 1
34 REV
P1-9 P5-15 15 P7-C
39 P3-17
LINE COIL
XY 26 P3-9 FWD
P61-2
LIFT COIL P61-1 1
X Y 30 P3-10 FOOT DIR SW
REV
BYPASS COIL P38-8 P61-3
LOGICS
XY 35 P3-11
FWD COIL
P1-1 P5-13 13 P13-5 1
XY 20 P3-12
REV COIL LIFT 1 SW
XY 19 P3-13 P1-2 P5-27 81 P13-6 1 4
REGEN COIL LIFT 2 SW
XY 75 P3-14
3 P1-3 P5-34 89 P13-2 1 P32-3 1
38 P3-16 TILT SW
P32-4 3
LINE FUSE P1-4 P5-33 88 P13-3 1
2 TO 3 TON AUX 1 SW 4
36/48 VOLT
675 AMP P1-5 P5-32 87 P13-4 1 P13-1
600 AMP
1TON AUX 2 SW
P1-6 P5-26 78 P24-2 P24-1 1 1
LINE TWISTED PAIR TWISTED PAIR
CTR PRESSURE SWITCH
P1-19 116 P5-31 P52-2
SPEED
SENSOR
P1-18 115 P5-30 P52-1 SWITCH 1 1 4 1
BATTERY
36/48 VOLT P1-15 8 P5-8 P9-C P9-A
OR P9-B
72/80 VOLT ACCEL
CONTROL
P3-21
P1-21
P3-20
P2-21
P5-36
P5-37
P5-2
P5-1
2EC1513
138
SENB8604-02
Capacitor Charging Circuit 3

34
With the line contactor tips closed, the logics continues
its checks for any “Run Time” faults. If no faults are P12-13
KEY FUSE 10A
detected, the display will indicate the battery charge P12-11
R319 R320
level, the power steering system operates, the pump
and drive power circuits receive battery voltage and the
34
logics receives battery voltage on wire #34 at P2-12. P2-12
A charging resistor is used to maintain voltage on the 34

head capacitor whenever the battery is connected and
the line contactor is open. This voltage reduces arcing
3
of the line contactor tips during line contactor activa-
39 P3-17
tion. The charging resistor is installed parallel with the LINE FUSE LINE COIL
2 TO3 TON XY 26 P3-9
line contactor tips. Current flows from battery positive 36/48 VOLT LIFT COIL
675 AMP
through the key fuse, charging resistor, line fuse and 600 AMP
1 TON
X Y 30
BYPASS COIL
P3-10
the positive heat sink into battery negative. This circuit XY 35 P3-11
LOGICS
LINE FWD COIL
will maintain a voltage across the head capacitor above CTR XY 20 P3-12
REV COIL
approximately 20 volts. XY 19 P3-13
REGEN COIL
XY 75 P3-14
BATTERY
36/48 VOLT HEAD
OR CAP 38 P3-16
72/80 VOLT
P3-21
1
Capacitor Charging Circuit (Typical Example)
139
SENB8604-02
Hydraulic Pump Motor Circuit

Only one hydraulic pump motor is used for all power
steering, lift, tilt, and auxiliary hydraulic functions. To
activate the pump circuit, the seat switch, key switch
and line contactor must be closed first as explained in
the topic, Actuation Circuit. The power steering, lift, tilt,
and auxiliary circuits are explained as follows:
140
SENB8604-02
Power Steering Circuit with an oscilloscope. During steering, when this signal
is high, it indicates that the transistors should be off.
The power steering (PS) circuit has two speeds: PS Idle When this signal is low, it indicates that the transistors
and PS Boost-up. should be on. When this signal goes low, current flows
NOTE: Shaded lines on the circuit diagrams indicate down through R338, R339, and R340. These resistors
current flow. Other circuits can be activated at the form a voltage divider that starts to reduce the voltage
same time, but each one is shown separately to on the gate of T337. It does not reduce immediately,
illustrate current flow in each individual circuit. due to capacitor C332. Also, it will not drop further
than about 7V below battery positive because of Z334.
Power Steering Idle Since no current is flowing in T337, its source is held at
battery positive by R331 and R332. T337 is a P-chan-
After the line contactor closes, the logics generates a
nel mosfet. A P-channel mosfet is a voltage controlled
pulsing signal on P2-8 (Wire #117). This signal oscil-
device that will turn on when the gate voltage is 5V less
lates (moves) between battery negative and battery
than the source voltage. When voltage on the gate of
positive at 15,000 times each second. This is faster
T337 becomes 5V less then its source, T337 turns on.
than can be seen on a voltmeter and must be viewed
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T331
T332
T2P P3-3
T1P
P8-1
R327
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
SHUNT FIELD 83 P5-29 83 P1-8
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT LIFT COIL
675 AMP
600 AMP
X Y 30 P3-10
1 TON 109 BYPASS COIL
E1 PA1 DRIVE XY 35 P3-11
(F1) FWD COIL
LINE POWER
CTR ARM 110 CIRCUIT XY 20 P3-12
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P
OR PUMP CAP 38 P3-16

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1515
141
SENB8604-02
When T337 turns on current flows from BAT+ through When T331 and T332 turn on, current flows through
the emitter/base junction of T331 and T332 through T331 and T332, through the B0/emitter junction of the
R332 through T337 to the emitter of T1P and T2P. power transistors T1 P and T2P through the pump
Because T331 and T332 are PNP transistors, the cur- armature/series field to BAT-. Since T1 P and T2P are
rent flow through the emitter/base junction causes NPN transistors, the current flow through the B0/emit-
them to turn on. ter junction causes the second stage transistor in T1 P
and T2P to turn on. Now when T337 is on, T331, T332,
When T337 is on, T331 and T332 are on. When T337 is
T1P (second stage), and T2P(second stage) are on.
off, T331 and T332 are off.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T331
T332
T2P P3-3
T1P
P8-1
R327
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1516
142
SENB8604-02
When the second stage transistor of T1 P and T2P turn during steer idle. During steer idle P2-8 is low about
on, current flows from BAT+ through the second stage 6% of the time, which means T1P and T2P are on 6%
of T1 P and T2P, through the pump armature/series of the time. This results in about 6% of battery voltage
field to BAT-. This causes the pump to turn. So when being applied to the armature during steer idle. This
P2-8 (Wire #1 17) is low, the second stage of the number will not be exactly 6% because the T1 P and
power transistors T1 P and T2P is also on. The logic T2P “ON” time is adjusted by the logics (via P2-8) to
controls this ‘low” time on P2-8 to control the pump help offset changes in battery voltage.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T331
T332
T2P P3-3
T1P
P8-1
R327
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1517
143
SENB8604-02
Additional Information:
Only the second stage transistor of T1P and T2P is These transistors are slow in switching and also suffer
used during steer idle and steer boost-up because of from a problem called “storage time,” which causes
the speed at which these transistors are pulsed. The them to stay on for a short period of time even after
transistors are pulsed at 15,000 Hz (cycles per second) the base/emitter drive is removed. Using only the sec-
to help reduce audible whine that used to exist on ond stage of the power transistors reduces both the
older style trucks during steer idle and boost up. On switching time and the ‘storage time” to acceptable
these systems the transistors were pulsed at 187.5 Hz, values for use at 15,000 Hz pulsing. When only the
which was audible and bothersome to some operators. second stage of the transistors is used, the power tran-
Moving this pulsing frequency to 15,000 Hz has made sistors cannot carry as much current. But this is
the noise both quieter and much more difficult to hear acceptable because the transistors are driven this way
because it is outside the range of human hearing. To only in steer idle and boost up, where the current
accomplish this, it was necessary to speed up the required is not too high.
switching of pump power transistors T1P and T2P.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T331
T332
T2P P3-3
T1P
P8-1
R327
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1518
144
SENB8604-02
Hydraulic Pump Shunt Field Circuit

At the same time the logics is pulsing the pump arma- through the pump shunt field fuse, through the pump
ture circuit, a constant voltage (about 12V) is being shunt field, through T351, to BAT-. When the pump
supplied from the logics P2-3 to the gate of T351. shunt field is on 100%, it is at maximum strength.
T351 is an N-channel mosfet, which will turn on when During the power steering speeds, the pump shunt
the gate is 5V greater than the source. Since we have field adds to the motor torque, making it a very power-
applied 12V (which helps insure that T351 is fully on), ful motor at low rpm. The motor during power steering
T351 is on. With T351 on current can flow from BAT+, idle is turning at about 200 rpm.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T331
T332
T2P P3-3
T1P
P8-1
R327
B0 B0 100 P2-13
T R341 R340 R339
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1519
145
SENB8604-02
Power Steering In Use

If the steering wheel is turned, hydraulic pressure increase the duty cycle applied to T1P and T2P with
increases, and a pressure switch located in the steering the signal on P2-8. Increasing the duty cycle on T1P
gear load sensing line will open. This causes the volt- and T2P increases the voltage applied to the arma-
age at logics connector P 1 -6 to change from a LOW ture/series field, which increases the speed of the
to a HIGH signal. When a HIGH signal is present, the motor and therefore the flow provided to the steer gear.
logics knows that more hydraulic flow is required When the pressure switch is open, the pump motor
because the operator is steering the truck. It will speed will be about 500 rpm.
3
3
LIGHTS FUSE 15A
34
P12-13
P12-11 P12-12 3 P5-3 P46-2 4 P46-1
P3-18 P5-4 4
P3-4 P5-12 12 P6-4 P6-2 4
DISPLAY
46
34 P3-5 P5-16 16 P6-3 P6-1 1

P2-12 LIFT LIMIT SW
P1-14 127 P5-21 P60-C P60-A
100 1 +
P2-13
SEAT SWITCH 1
P1-13 P5-7 7 1 HORN
2
P3-2 77 P5-25 1
P3-1 76 P5-24 1
P1-12 P5-23 113 P40-C P40-B 1
P1-11 P5-19 91 1
P2-20 P5-22 106 P33-2 P33-1
FWD
P1-10 P5-14 14 P7-B 4
DIR SW P7-A 1
34 P1-9 15 REV
P5-15 P7-C
39 P3-17
LINE COIL
XY 26 P3-9 FWD
P61-2
LIFT COIL P61-1 1
REV
LOGICS
XY 35 P3-11
FWD COIL
P1-1 P5-13 13 P13-5 1
XY 20 P3-12
REV COIL LIFT 1 SW
XY 19 P3-13 P1-2 P5-27 81 P13-6 1 4
XY 75 P3-14
3 P1-3 P5-34 89 P13-2 1 P32-3 1
38 P3-16 TILT SW
P32-4 3
LINE FUSE P1-4 P5-33 88 P13-3 1
36/48 VOLT
675 AMP P1-5 P5-32 87 P13-4 1 P13-1
600 AMP
1 TON AUX 2 SW
P1-6 P5-26 78 P24-2 P24-1 1 1
CTR PRESSURE SWITCH
P1-19 116 P5-31 P52-2
SPEED
SENSOR
P1-18 115 P5-30 P52-1 SWITCH 1 1 4 1
BATTERY
36/48 VOLT P1-15 8 P5-8 P9-C P9-A
OR P9-B
72/80 VOLT ACCEL
CONTROL
P3-21
P1-21
P3-20
P2-21
P5-36
P5-37
P5-2
P5-1
2EC1520
146
SENB8604-02
Flyback Circuit
D4P is a flyback diode for the hydraulic pump motor field/armature goes through PS2, Pump Shunt, D4P,
circuit. Because the series field/armatures on the pump PA1, and back to the series field/armature. When T1P
motor are inductors they need a path for the current to and T2P are pulsing, the flyback circuit causes the
flow when T1P and T2P are turned off. When T1P and average pump motor current to be greater than the
T2P are turned OFF, all the current flowing in the series average battery current flowing through T1P and T2P.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T331
T332
T2P P3-3
T1P
P8-1
R327
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1521
147
SENB8604-02
Lift Circuit HYDRAULIC PUMP MOTOR SPEED CHART

PUMP ARMATURE SHUNT FIELD PUMP
Lift Control Circuit SPEED DUTY CYCLE DUTY CYCLE CONTACTOR
The 2EC15 family of lift trucks is equipped with a two- 0 0% 100% Off
speed lift system. The system is controlled by two
microswitches that work off of the lift spool on the 1 15 100% Off
main hydraulic valve. As the lift lever is pulled back, Lift 2 20 100% Off
Switch 1 is depressed, which causes the signal on
Logic Connector P1-1 to go from HIGH to LOW. This 3 25 100% Off
signals the logics to run the pump motor at the speed 4 35 100% Off
set for LIFT1 SPEED. As the lift lever is pulled back
further, Lift Switch 2 is depressed, which causes the 5 45 100% Off
signal on Logic Connector P1-2 to go from HIGH to
6 55 100% Off
LOW. This signals the logics to run the pump motor at
the speed set for LIFT2 SPEED. When the operator 7 70 100% Off
releases the lever or pushes the lever forward to lower
8 0 (Bypass) 100% On
a load, both Lift Switches are released. Options 2 and
3 in the setup mode determine at what speed the 9 0 (Bypass) 50% On
pump will run when the lift switches are depressed.
10 0 (Bypass) 0% On
The chart to the right shows the possible speeds:
If the operator pulls back on the lift lever rapidly, the
logics will smoothly ramp up to LIFT2 SPEED in about
1/2 second.
148
SENB8604-02
Lift Power Circuit

When any hydraulic lever is activated (Lift, Tilt, Aux1, or system described in the power steering system opera-
Aux2), the logics stop using the control output P2-8 tion, we cannot use this system during the heavy cur-
(Wire #117) to control the pump. Because of the rents involved with the lift system. The lift system is
current limitation of the 15,000 Hz pump control operated at 187.5 Hz and controls the B terminal of the
power transistor.
3
3
LIGHTS FUSE 15A
34
P12-13
P12-11 P12-12 3 P5-3 P46-2 4 P46-1
P3-18 P5-4 4
P3-4 P5-12 12 P6-4 P6-2 4
DISPLAY
46
34 P3-5 P5-16 16 P6-3 P6-1 1

P2-12 LIFT LIMIT SW
P1-14 127 P5-21 P60-C P60-A
100 1 +
P2-13
SEAT SWITCH 1
P1-13 P5-7 7 1 HORN
2
P3-2 77 P5-25 1
P3-1 76 P5-24 1
P1-12 P5-23 113 P40-C P40-B 1
P1-11 P5-19 91 1
P2-20 P5-22 106 P33-2 P33-1
FWD
P1-10 P5-14 14 P7-B 4
DIR SW P7-A 1
34 P1-9 15 REV
P5-15 P7-C
39 P3-17
LINE COIL
XY 26 P3-9 FWD
P61-2
LIFT COIL P61-1 1
REV
LOGICS
XY 35 P3-11
FWD COIL
P1-1 P5-13 13 P13-5 1
XY 20 P3-12
REV COIL LIFT 1 SW
XY 19 P3-13 P1-2 P5-27 81 P13-6 1 4
XY 75 P3-14
3 P1-3 P5-34 89 P13-2 1 P32-3 1
38 P3-16 TILT SW
P32-4 3
LINE FUSE P1-4 P5-33 88 P13-3 1
36/48 VOLT
675 AMP P1-5 P5-32 87 P13-4 1 P13-1
600 AMP
1 TON AUX 2 SW
P1-6 P5-26 78 P24-2 P24-1 1 1
CTR PRESSURE SWITCH
P1-19 116 P5-31 P52-2
SPEED
SENSOR
P1-18 115 P5-30 P52-1 SWITCH 1 1 4 1
BATTERY
36/48 VOLT P1-15 8 P5-8 P9-C P9-A
OR P9-B
72/80 VOLT ACCEL
CONTROL
P3-21
P1-21
P3-20
P2-21
P5-36
P5-37
P5-2
P5-1
2EC1522
149
SENB8604-02
When a hydraulic lever is activated, the logics senses down through R328, R329, and R330. These resistors
this through the hydraulic switches and stops using form a voltage divider that starts to reduce the voltage
control output P2-8 (Wire #117) to control the pump. It on the gate of T327. It will not drop further than about
begins to use control output P2-7 (Wire #79). The log- 7V below battery positive because of Z324. Since no
ics generates a 187.5 Hz pulsing signal on P2-7. This is current is flowing in T327, its source is held at battery
faster than ran be seen on a voltmeter and must be positive by R321 and R322. T327 is a P-channel mos-
viewed with an oscilloscope. During hydraulic func- fet. A P-channel mosfet is a voltage controlled device
tions, when this signal is low, it indicates the power that will turn on when the gate voltage is 5V less than
transistors T1P and T2P should be on. When this signal the source voltage. When the voltage on the gate of
is high, it indicates the power transistors T1P and T2P T327 becomes 5V less than its source, T327 turns on.
should be off. When this signal goes low, current flows
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T332
T2P P3-3
T1P
P8-1
R327
T331
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1523
150
SENB8604-02
When T327 turns on, current flows from BAT+ through T324 is a PNP transistor, the current flow through the
the emitter 1 base junction of T324, through R322, emitter/base junction causes it to turn on. When T327
through T327 to the emitter of T1 P and T2P. Because is on, T324 is on. When T327 is off, T324 is off.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
D321 R330 34
P2-12
T337
B B
T332
T2P P3-3
T1P
P8-1
R327
T331
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1524
151
SENB8604-02
When T324 turns on, current flows through T324, current flow through the B/emitter junction causes the
through the B/emitter junction of the power transistors entire power transistor to turn on. Now when T327 is
T1P and T2P, through the pump armature/series field to on, T324, T1P (entire) transistor), and T2P (entire
BAT-. Since T1P and T2P are NPN transistors the transistor) are on.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T1P T2P T332 P3-3
P8-1
R327
T331
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1525
152
SENB8604-02
When the power transistors T1P and T2P turn on, cur- (Wire #79) is low, the power transistors T1P and T2P
rent flows from BAT+ through the power transistors are on. The logics controls this ‘loW’ time on P2-7 to
T1P and T2P, through the pump armature/series field to control the pump during hydraulic functions.
BAT-. This causes the pump to turn. So when P2-7
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T332
T1P T2P P3-3
P8-1
R327
T331
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1526
153
SENB8604-02
As shown in the chart under Lift Control Circuit, lift results in faster hydraulic operation. Just as the pump
speeds 0-8 keep the shunt field on at 100%. For speed armature/shunt field needs a flyback diode, the shunt
9 the shunt field is pulsed at 50%, and for speed 10 field also needs a path for the current to flow when
the shunt field is turned off. Reducing the shunt field in T351 turns off. D351 serves this function. When T351 is
the pump motor serves the same function as turning turned OFF, all the current flowing in the shunt field
off the shunt field in the drive motor. It changes the goes through E2, through D351, through E1, and back
motor characteristics so that it will spin faster. This to the shunt field.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
B B T337
T331
T332
T2P P3-3
T1P
P8-1
R327
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1527
154
SENB8604-02
Pump Contactor Operation

If lift speed 8, 9, or 10 is set for Option 2 (LIFT1 Speed) current to flow out of P3-17, through the pump contac-
or Option 3 (LIFT2 Speed), and it is necessary to pro- tor coil, through P3-10 to BAT-. While the pump con-
vide one of these speeds because the lift lever has tactor is pulling in the pump, transistors T1P and T2P
been pulled back, then the lift contactor will be used to are driven at 99% to reduce the arc when the contact
provide 100% voltage to the pump armature/series tips touch. After this the transistors are turned off. The
field. The logic activates the pump contactor by allowing pump armature/series field is now connected directly to
the battery.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
B B T337
T331
T332
T2P P3-3
T1P
P8-1
R327
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1528
155
SENB8604-02
Tilt And Auxiliary Control Tilt

Aux1
The Tilt, Aux1, and Aux2 hydraulic levers each have Aux2
their own microswitch. This allows the speed for Lift1, Lift 2
each function to be set separately using Setup
Options 4, 5, and 6. The same control of pump This means that if you pull back on Tilt and Aux2, the
motor that was explained earlier for the lift lever also speed associated with Tilt will be used.
applies to these three levers.To handle the situation
when more than one lever is pulled, the following
priority is given to the levers
3
3
LIGHTS FUSE 15A
34
P12-13
P12-11 P12-12 3 P5-3 P46-2 4 P46-1
P3-18 P5-4 4
P3-4 P5-12 12 P6-4 P6-2 4
DISPLAY
46
34 P3-5 P5-16 16 P6-3 P6-1 1

P2-12 LIFT LIMIT SW
P1-14 127 P5-21 P60-C P60-A
100 1 +
P2-13
SEAT SWITCH 1
P1-13 P5-7 7 1 HORN
2
P3-2 77 P5-25 1
P3-1 76 P5-24 1
P1-12 P5-23 113 P40-C P40-B 1
P1-11 P5-19 91 1
P2-20 P5-22 106 P33-2 P33-1
FWD
P1-10 P5-14 14 P7-B 4
DIR SW P7-A 1
34 REV
P1-9 P5-15 15 P7-C
39 P3-17
LINE COIL
XY 26 P3-9 FWD
P61-2
LIFT COIL P61-1 1
REV
LOGICS
XY 35 P3-11
FWD COIL
P1-1 P5-13 13 P13-5 1
XY 20 P3-12
REV COIL LIFT 1 SW
XY 19 P3-13 P1-2 P5-27 81 P13-6 1 4
XY 75 P3-14
3 P1-3 P5-34 89 P13-2 1 P32-3 1
38 P3-16 TILT SW
P32-4 3
LINE FUSE P1-4 P5-33 88 P13-3 1
36/48 VOLT
675 AMP P1-5 P5-32 87 P13-4 1 P13-1
600 AMP
1TON AUX 2 SW
P1-6 P5-26 78 P24-2 P24-1 1 1
CTR PRESSURE SWITCH
P1-19 116 P5-31 P52-2
SPEED
SENSOR
P1-18 115 P5-30 P52-1 SWITCH 1 1 4 1
BATTERY
36/48 VOLT P1-15 8 P5-8 P9-C P9-A
OR P9-B
72/80 VOLT ACCEL
CONTROL
P3-21
P1-21
P3-20
P2-21
P5-36
P5-37
P5-2
P5-1
2EC1513
156
SENB8604-02
Additional Lift System Information:

Two additional systems exist on the EP16 family The shunt is also used to current limit the pump tran-
system that are new to MicroCommand II. The first sys- sistors. Just as the drive transistors are current limited
tem is the pump shunt. This shunt is a precision, very to help protect them, so are the pump transistors. This
low value resistor that measures the current flowing in current limit will not be reached during normal opera-
the pump. The logics uses this information for various tion, but during a pump failure when the pump locks
reasons: Because of the current limitation of the 15,000 up, the transistors are protected from overcurrent.
Hz steering system (-150A), the system must not be
Finally, the shunt is used to prevent a stalled pump
overloaded. During steering idle or steering boost-up,
motor from blowing the main fuse when the pump
the 15,000 Hz system is used, but if the any hydraulic
bypass contactor i-s pulled in. Again, if the pump locks
lever is activated (Lift, Tilt, Aux1, or Aux2) or the current
up and the pump bypass contactor is pulled in, the
in the pump rises above an acceptable limit, the logics
logics will sense the high stalled motor current and
will automatically switch to 187.5 Hz pulsing. The
shut down the truck before the fuse blows.
hydraulic levers are monitored by the microswitches
attached to each spool. The current is monitored with
the pump shunt.
157
SENB8604-02
Pump Power Transistor

Turn-Off Circuit
The second system is the pump power transistor turn- off; and P2-9 will be off when either P2-7 or P2-8 are
off circuit. This circuit helps to turn off the main power on. Because these signals change rapidly, this cannot
transistors T1P and T2P as quickly as possible. This be seen on a voltmeter, but must be viewed with an
helps the 15,000 Hz steering system work more con- oscilloscope. When P2-9 is low, current flows from the
sistently. The turn-off circuit is controlled by the logics BO terminal of T1P and T2P, through the emitter/base
control output P2-9 (Wire #118). When P2-9 is low, the junction of T341, through R342 and R343 to P2-9.
turn-off circuit is active; and when P2-9 is high, the Because T341 is a PNP transistor, the flow of current
turn-off circuit is inactive. Because P2-9 controls the through the emitter/base junction of T341 turns it on.
turn-off circuit, it will be on when P2-7 and P2-8 are So when P2-9 is low, T341 is on.
P4-5
C332
T327 R322
R321
C322
Z324
R328
R338
Z334
THERMOSTAT
P8-2
Z323
T324
CONTROL
R329 46
R331
R332
R330 34
D321
P2-12
T337
B B
T332
T1P T2P P3-3
P8-1
R327
T331
B0 B0 100 P2-13
R340 R339
T R341
T341 1
P4-7
P4-2
R343 R342
45 1
P4-1
P4-4
PUMP
CTR 117 117 P2-8
118 118 P2-9
P12-3 79 79 P2-7
DRIVE 45 P2-10
FUSE 15 AMP 1
P12-1 68
83
PUMP
P12-2
SHUNT FIELD
FUSE 15 AMP
69 39 P3-17
LINE FUSE LINE COIL
P32-5
DU1
LOGICS
2 TO 3 TON XY 26 P3-9
675 AMP
600 AMP
X Y 30 P3-10
(F1) FWD COIL
LINE POWER
REV COIL
XY 19 P3-13
REGEN COIL
E2 (PS2)
(F2) XY 75 P3-14
BATTERY PD2
36/48 VOLT 1 HEAD
D4P

72/80 VOLT MOTOR
P32-2
D351
P12-6
71 119
P2-18
SHUNT P2-19
T351
P2-4
29
C351
Z351
TWISTED 119
R351
P2-3
PAIR 29
72
P3-21
P3-20
P2-21
P1-21
71
72
P12-10
P12-8
119 119
29 29
71 71
72 72
2EC1530
158
SENB8604-02
When T341 turns on, current flows from the B0 terminal quickly, and at 15,000 Hz pulsing this would result in
of T1P and T2P, through T341 to the emitter of T1P and the pump running faster than necessary. Although this
T2P. This flow of current is a good way to quickly turn does affect the steering, it means the pump transistors
off the pump power transistors by removing excess are on more than necessary, which results in lower sys-
base charge from the second stage transistor. Without tem efficiency.
this circuit the pump transistors would not turn off
2EC1531
159
SENB8604-02
Electrical Testing If pump circuit failed:

2. Check D4P for a failure.
Testing Transistors 3. Check T1P and T2P for a failure.
Use the following chart to test transistors. If any
measurements are incorrect, replace the transistor. 4. Check pump driver board for a failure.
NOTE: If a transistor is found to be failed and it is 5. Check continuity from T1P, T2P emitter bus bar
part of a pump or drive system pair, replace both (wire #45) to logics P2-10.
transistors of the pair. 6. Check continuity of pump shunt wires (wires #29
and #119).
TRANSISTOR SPECIFICATIONS
1 2
MULTIMETER (+) TEST (-) TEST 927566 974222
SETTING LEAD LEAD RESULTS RESULTS
Resistance Emitter Base 45 to 135 Ω 60 to 180 Ω 3
Diode Base Collector .3 to.9V .3 to.9V
Diode Collector Base OL OL
Diode Emitter Collector .3 to.9V .3 to.9V
Diode Collector Emitter OL OL 3 4
NOTICE: Damage to the control panel could result. C30706P2

927566 and 974222 Transistor
To prevent further damage before a power transistor (1)Emitter (2)Base (3)Collector (4)B0
is replaced, complete the check list that follows.
1. Check head capacitor for a failure.
If drive circuit failed:
2. Check D4D for a failure.
5. Check T1D and T2D for a failure.
6. Check drive driver board for a failure.
7. Check continuity from T1D, T2D emitter bus bar
(wire #37) to logics P2-6.
8. Check for continuity of drive current sensor wires
(wires #2, #42, #85).
160
SENB8604-02
Transistor Replacement 3. Remove the transistor mounting bolts (3).

(T1P, T2P, T1D and T2D)
! WARNING
tery and discharge the head capacitors (HEAD CAP)
T1P is described in the procedure that follows. All C63562P1: Transistor Removal (Typical)
transistors are replaced in the same way. (4) Contact Surface
1. Disconnect the battery discharge the head 4. Contact surface (4) of transistor (2) is coated with
capacitors, and remove the logics board. 5P8937 Thermal Joint Compound. Carefully
remove the transistor (2).
2 2 5. To replace the transistor, wipe the contact
surface (4) and the heatsink clean. Put a small
1 amount of 5P8937 Thermal Joint Compound on
contact surface (4). Coat heatsink and transistor
so that compound covers only contact area.
6. Install transistor (2) with mounting bolts (3).
Tighten bolts (3) to a torque of 4 to 6 N•m (35 to
53 lb in.).
7. Reinstall driver boards (1).
3 2
Location of Components
(1)Driver Board (2)Transistor (3)Mounting Bolts
2. Remove drive and pump driver boards (1).
161
SENB8604-02
Resistor R312
! WARNING ! WARNING
Resistor R312
tery and discharge the head capacitors (HEAD CAP) Battery voltage and high amperage are present.
before any contact is made with the control panel. Injury to personnel is possible. Disconnect the bat-
tery and discharge the head capacitors (HEAD CAP)
NOTE: Look for visual beaks or cracks on resistors.
1. Disconnect the battery, discharge the head
capacitor, and remove the logics board. NOTICE: Damage to the thermal switch will occur.
Do not heat the thermal switch over an open flame.
1 Control Panel
NOTE: If the thermal switch is removed from the
heatsink, it can be tested in an oven. Switch (1) will
open circuit if the temperature is 81°-89°C (178°-
Location of Components: (1) R312
2. Disconnect wire #32 from resistor R312 (1). 192°F) and close (short circuit) at 69°-77°C (156°-171°F).
3. Set the multimeter to the 200 ohm range. Refer to the topic “Run-Time Diagnostics”, Overtem-
Connect the multimeter leads to the terminals on perature Indicator ON, in the troubleshooting section.
resistor R312 (1) to check the resistance. 97C54-11300
Location of Components: (1) Thermal switch
4. The measurement from the resistor must be 34 to
38 ohms (36/48V trucks) or 71 to 79 ohms Pump and Drive Motor
(72/80V trucks). NOTE: If the pump or drive thermal switch is
5. If the measurement is not correct, the resistor removed from the motor, it can be tested in an oven.
must be replaced. Switches 3 and 4 will open circuit if the temperature
is 144°-156°C (291°-312°F) and close (short circuit) at
124°-136°C (255°-276°F).
Refer to the related problems under “Run-Time
Diagnostics”, Overtemperature Indicator ON, in the
Troubleshooting Section.
Location of Components: (1) Drive Motor (2) Pump Motor

(3) Pump Motor Thermal Switch (4) Drive Motor Thermal Switch
162
SENB8604-02
Electrical System Accelerator Control Linkage

Adjustments
Method A (Mechanical)
1. Disconnect the battery.
2. Fully depress the accelerator pedal (1) until pedal
is stopped on bolt (3). Adjust bolt so that groove
(4) on accelerator control shaft (2) is even with
face (5) of accelerator control (6). The groove
should not reach the shaft wiper.
3. Release accelerator pedal (1).
Method B (Electrical)
1. Place the truck in the “Self” Diagnostic mode and
proceed to test 5.
2. Cycle the RUN/DIAG/SETUP switch so that the
accelerator speed is flashed on the display. Accelerator Control Linkage: (1) Accelerator Pedal
(2) Accelerator Control Shaft (3) Bolt (4) Groove (5) Face
3. Depress the accelerator pedal until the floor plate (6) Accelerator Control
bolts stops the pedal motion.
4. Adjust the floor plate bolt until a “14” is flashed
on the display. If the speed flashed is less team
“14”, adjust the bolt to allow more pedal travel. If
the speed flashed is more than “14”, adjust the
bolt to allow less pedal travel.
5. Adjust the floor plate bolt just enough to get the
display to change from a flashing “14” to a
flashing “15”. Ensure that the groove on the
accelerator control shaft does not reach the shaft
wiper when the accelerator is fully depressed.
163
SENB8604-02
Parking Brake Switch Lift, Tilt, and Auxiliary Switches

Each function has its own independent microswitch for
! WARNING activating the hydraulic pump motor. Refer to the topic
“Programmable Features” in the System Operation
The lift truck can move suddenly. Injury to section of this manual for information on adjusting lift
personnel or damage to the lift truck is possible. tilt, and auxiliary speeds.
Safely lift the drive wheels off the floor. Put blocks
of wood under the frame so that both drive wheels
are free to turn.
1
1. Close the seat switch and turn the key ON. 4
2. Release the parking brake and put the truck in
forward.
3. Depress the accelerator. With the tires in rotation, 2
3
apply the parking brake.
4. Tire rotation should slow and/or stop and the
parking brake action light should turn ON.
5. If the parking brake action light did not turn ON,
check the parking brake switch and wiring to the
logics. Refer to problem 40, “Park Brake Circuit
Defect” in the Troubleshooting Section.
Location of Components: (1) Lift 1 Switch (2)Lift 2 Switch

(3) Tilt Switch (4) Aux 1 Switch
Location of Components: (1) Switch
164
SENB8604-02
Rapid Tune-Up Procedure

The rapid tune-up procedure establishes a starting
! WARNING
point for logic card adjustments. The following proce- The lift truck can move suddenly. Injury to
dure allows the truck to be operated for test purposes personnel or damage to the lift truck is possible.
without damage to the truck or its components. Safely lift the drive wheels off the floor. Put blocks
of wood under the frame so that both drive wheels
Always verify that the jumper on the logic board is in its
are free to turn.
proper position for the voltage of the lift truck being
tuned. NOTE: All programmable features should be set to
their default values before making any adjustments.
J1 = 36V J2 = 48V J3 = 72V J4 = 80V
See the topic “Activating Default Settings” in the
Service exchange logic boards do not need a rapid Systems Operation section of this manual.
tune-up procedure. These boards are pre-adjusted 1. Turn current limit potentiometer P1 fully
from the factory and their programmable features are counterclockwise, then eight turns clockwise.
set to the default values. However, Option #30 must be
programmed to the correct truck type and size. The 2. Turn electrical braking potentiometer P3 fully
current limit, electrical braking, and BDI should be counterclockwise, then eight turns clockwise.
checked and adjusted by certified technicians. 3. Make the final adjustments, as specified in each
of the Testing and Adjusting Procedures, before
putting the truck back into service. Perform these
procedures in the following order.
1. Battery Discharge Indicator (BDI)-P5
2. Current Limit-P1
3. Electrical Braking-P3
Logics Board
165
SENB8604-02
Current Limit Test and Adjustment 4. For ease in reading the equipment, a 6V7070
Digital Multimeter may be set to the 2VDC range
and connected to the 8T0900 Digital Ammeter
! WARNING using a 6V6014 Cable. For more information,
refer to Special Instruction SEHS8030.
The lift truck can move suddenly. Injury to
personnel or damage to the lift truck is possible. 5. Get on the truck. Turn the key switch on. Clear
Safely lift the drive wheels off the floor. Put blocks any SRO conditions if necessary. Release the
of wood under the frame so that both drive wheels park brake.
are free to turn. 6. Place the direction lever in either forward or
NOTICE: Damage can be caused to the control panel. reverse. Depress the service brake. The drive
Do not switch the direction lever from one direction to wheels must NOT turn during this procedure.
the other (plug the truck) when the drive wheels are 7. Depress the accelerator fully. Measure the
off the ground and in rotation at full speed. current in A1. Values should be as follows:
NOTE: Current limit is preset and sealed at the factory
and should only be adjusted by certified mechanics MODEL CURRENT LIMIT (AMPS)
with calibrated equipment.
36/48V 72/80V
2EC15 / 18 400 ± 5% 425 ± 5%
2EC20 / 25 / 25E 525 ± 5% 425 ± 5%
1 2EC30 525 ± 5% 450 ± 5%

NOTICE: Do not stall the drive motor for more
than three seconds. Damage to the motor will result.
Between stalls allow the drive wheels to turn with the
tires off the floor to cool the motor. If the motor remains
stalled for more than three seconds, the line contactor
will open and “20” will appear in the display.
8. If the current value is not acceptable, adjust
(1) 8T0900 Digital Ammeter
potentiometer P1 until the value is correct. Turn
the adjustment screw clockwise to increase
1. Begin this procedure with the key switch OFF current. Turn the adjustment screw counterclock-
and the park brake applied. Put blocks of wood wise to decrease current.
under the frame so that both drive wheels are
free to turn. Between adjustments, allow the motor to turn.
This will prevent sitting on one spot on the
2. Enter Setup Mode and set the following Options: commutator, which could cause damage to the
Option 13 = 13 motor.
Option 20 = 0
Option 22 = 13 9. After the current value is correct, turn off the
truck. Use setup modes to return Options 13, 20,
3. Connect 8T0900 Digital Ammeter around the and 22 to their original values.
loop in cable A1 to check drive motor current
limit. Current Limit is now set.
NOTE: The arrow on the ammeter points in the
direction of current flow for a positive indication.
166
SENB8604-02
Electric Braking Current

Test and Adjustment
1. Make sure the current limit is adjusted to
specification before adjusting electric braking
current. If current limit is changed after setting 1
plugging current, plugging current will change.
2. Connect 8T0900 Digital Ammeter (1) around
cable A1 to check plugging motor current. Check
the jaws of the meter to make sure they are fully
closed.
NOTE: The arrow on the ammeter points in the
direction of current flow for a positive indication.)
(1) 8T0900 Digital Ammeter
3. For ease in reading current, a 6V7070 Digital
Multimeter may be set to the 2V DC range and
connected to the 8T0900 Digital Ammeter using
a 6V6014 cable. Refer to Special Instruction
SEHS8030 for more information.
4. Move the lift truck FORWARD at full speed.
Keep the accelerator pedal fully depressed and
change the direction control to REVERSE.
5. The current measured during electrical braking
(plugging) must be 300 amps ±-5%.
NOTE: Though the plugging distance is an
application adjustment, plugging current should
not exceed 315 amps. If the recommended cur
rent produces a short stopping distance, the
distance may be lengthened by turning poten-
tiometer P2 counterclockwise to reduce plugging
current.
167
SENB8604-02
Logic Board Layout 1. Disconnect the battery and discharge the head
capacitor. Remove logics cover and verify the
DIAG/RUN switch is in the RUN position.
! WARNING
2. Make sure BDI jumper is positioned properly:
IMPORTANT!
Since many battery manufacturers have different J1 for 36V J2 for 48V J3 for 72V J4 for 80V
types of batteries available, the Battery Discharge
3. Set the multimeter to measure battery voltage.
Indicator (BDI) should be adjusted to meet the bat-
Connect the multimeter positive lead to logic
tery manufacturer’s specifications for a discharged
terminal P3-18. Connect the multimeter negative
state.
lead to control panel battery negative (negative
The BDI Information provided is to be used FOR heatsink).
REFERENCE ONLY. Please consult the battery man-
4. Put the direction lever in Neutral and connect
ufacturer for the correct discharge state for your
the battery.
particular batteries.
5. Close the seat switch and turn the key ON. The
Before adjusting BDI, remove battery surface
measurement should be battery voltage. The
charge by operating hydraulic system against tilt
display must show the correct number for the
pressure relief for five seconds.
voltage measured as shown in the charts that
follow:
168
SENB8604-02
Battery Discharge Indicator FRENCH BATTERY DISCHARGE INDICATOR

Adjustment Charts ADJUSTMENT CHART
(FOR FRENCH TUBULAR TYPE BATTERIES) — 36 VOLT/48 VOLT
NORMAL BATTERY DISCHARGE INDICATOR
BDI # 36 VOLT BATTERY 48 VOLT BATTERY
BDI# 36V BATTERY 48V BATTERY
0 0 - 36.0 0 - 48.0
0 0 - 36.0 0 - 48.0
1 36.0 - 36.2 48.0 - 48.2
1 36.0 - 36.2 48.0 - 48.5
2 36.2 - 36.5 48.2 - 48.7
2 36.2 - 36.7 48.5 - 48.9
3 36.5 - 36.7 48.7 - 48.9
3 36.7 - 36.9 48.9 - 49.4
4 36.7 - 36.9 48.9 - 49.4
4 36.9 - 37.1 49.4 - 49.6
5 36.9 - 37.4 49.4 - 49.6
5 37.1 - 37.6 49.6 - 50.1
6 37.4 - 37.6 49.6 - 50.1
6 37.6 - 37.9 50.1 - 50.6
7 37.6 - 37.9 50.1 - 50.3
7 37.9 - 38.1 50.6 - 51.0
8 37.9 - 38.1 50.3 - 50.8
8 38.1 - 38.6 51.0 - 51.3
9 38.1 - 38.3 50.8 - 51.0
9 38.6 - 38.8 51.3 - 51.8
10 38.3 - 51.0
10 38.8 - 39.1 51.8 - 52.1 1= Display is Incrementing
1= Display is Incrementing
FRENCH BATTERY DISCHARGE INDICATOR

NORMAL BATTERY DISCHARGE INDICATION ADJUSTMENT CHART
ADJUSTMENT CHART— 72 VOLT / 80VOLT (FOR FRENCH TUBULAR TYPE BATTERIES) — 72 VOLT/80 VOLT
BDI# 72V BATTERY 80V BATTERY BDI # 72 VOLT BATTERY 80 VOLT BATTERY
0 0 - 72.0 0 - 80.0 0 0 - 72.0 0 - 80.0
1 72.0 - 72.6 80.0 - 80.9 1 72.0 - 72.6 80.0 - 80.6
2 72.6 - 73.6 80.9 - 81.9 2 72.6 - 73.2 80.6 - 81.2
3 73.6 - 74.3 81.9 - 82.6 3 73.2 - 73.8 81.2 - 81.8
4 74.3 - 75.0 82.6 - 83.5 4 73.8 - 74.1 81.8 - 82.3
5 75.0 - 76.0 83.5 - 84.2 5 74.1 - 74.7 82.3 - 82.9
6 76.0 - 76.7 84.2 - 85.2 6 74.7 - 75.3 82.9 - 83.5
7 76.7 - 77.4 85.2 - 86.1 7 75.3 - 75.7 83.5 - 84.1
8 77.4 - 78.3 86.1 - 86.8 8 75.7 - 76.3 84.1 - 84.7
9 78.3 - 79.0 86.8 - 87.7 9 76.3 - 76.9 84.7 - 85.3
10 79.0 - 87.7 - 10 76.9 - 85.3 -
1= Display is Incrementing 1= Display is Incrementing
EXAMPLE: If the measurement is 36.8 volts for a

36 volt battery, the display should be at 6.
169
SENB8604-02
6. If the display is not correct, turn the key OFF and If the display shows a “0”, this indicates that the
make an adjustment to potentiometer 5. Adjust battery is discharged. The display will not show any
potentiometer P5 a small amount. Turn it clock battery charge level unless the battery voltage is above
wise to increase and counterclockwise to a level “6”. See the topic “Programmable Options:
decrease the display number. Repeat step 5. Option 17” in the Systems Operation section.
Turn the key to OFF between each adjustment.
There are two battery discharge indicator ranges that
7. If the voltage was 36.8, the potentiometer should can be selected. See Programmable Option 25.
be tuned to find the transition point between 7
and 6 on the display. This will assure that the
logics is calibrated at high 6.
NOTE: Approximately 1/4 turn of potentiometer P5
changes the display one number.
When the BDI of the lift truck suggests that the battery
is discharged 80%, the specific gravity of the battery
should be checked also. The specific gravity should
then be compared to the battery manufacturer’s rec-
ommended specific gravity for 80% discharge. If the
specific gravity is too low, P5 should be turned coun-
terclockwise to reduce the BDI number. If the specific
gravity is too high, P5 should be turned clockwise to
increase the BDI number. Logics Board
170
SENB8604-02
Harness Wiring Circuit Guide The following chart can be used when troubleshooting
The main lift truck electrical harness uses multicolored as a guide to the circuit function. This guide applies only
wires connected to different components on the truck. to the main harness wiring, not the component wiring.
EP MicroCommand II WIRE CONNECTIONS

WIRE # COLOR CONNECTOR PIN # WIRE TERMINATIONS
1A BROWN P13-1, P5-1 HYD. SW., LOGICS, BATTERY NEG
1B BLUE P7,P5-2,T18,P24-1, P9-A, P6-1, DIR. CTRL,LOGICS,SEAT SW.,PRESS.SW,ACCEL.,DISPLAY,SEAT BRAKE
P60-A SW,FOOT DIR. CTRL,BATT NEG
1C YELLOW P5-36,P33,P40-A,T17,T9,T7 LOGICS,BRAKE FLUID,FOOT BRAKE SW,PARK BRAKE SW,BATTERY NEG
1D BLACK P39-7,P32-3,P38-1,P39-8 DC/DC CONV, SHUNT FIELD CONN., REAR OPTION, BATTERY NEG
1E RED P5-37,T14,T13 LOGICS,HORN,HORN FILTER,BATTERY NEG
3 ORANGE P5-3,P46-2 LOGICS,CONSOLE GENERAL, BATTERY POS
3A WHITE/ T1, WIRE 3 HORN SW., BATTERY POS.
ORANGE
3B ORANGE P39-1, P32-4 DC/DC CONV., SHUNT FIELD CONN.,BATTERY POS.
4 WHITE P5-4, P46-1, P9-B,39-6, P38-2, P6-2, P38-3 LOGICS,CONSOLE GENERAL, ACCEL,DC/DC CONV, REAR OPTIONS, DISPLAY
7 BLACK P5-7,T19,P60-C LOGICS,SEAT SWITCH,SEAT BRAKE SWITCH
8 YELLOW P5-8, P9-C LOGICS, ACCEL
12 BROWN P5-12, P6-4 LOGICS DISPLAY
13 GRAY P5-13, P13-5 LOGICS, HYD. SW.
14 WHITE/ P5-14, P7, P61-2 LOGICS, DIR. CONTROL, FOOT DIR. CTRL.
BROWN
15 WHITE/ P5-15, P7, P38-8, P61-3 LOGICS, DIR. CTRL.
GREEN
16 BROWN P5-16, P6-3 LOGICS, DISPLAY
24 GREEN T2, T15, T12 HORN, HORN SW., HORN FILTER
53 BLACK P39-4, P41-1,P42-1,P38-5,P39-5 DC/DC CONV.,HEAD LAMP RIGHT, HEAD LAMP LEFT, REAR OPTIONS
55 YELLOW/ P48,P38-6 LIGHT SW., REAR OPTIONS
BLACK
56 YELLOW P48,P41-2,P42-2 LIGHT SW., HEAD LAMP RIGHT, HEAD LAMP LEFT
66 GREEN P39-2,P46-3,P46-7,P39-3 DC/DC CONV.,CONSOLE GENERAL
68 RED P32-6,T24 SHUNT FIELD CONN.,TRACTION MOTOR SHUNT FIELD
69 GREEN P32-5,T22 SHUNT FIELD CONN., PUMP MOTOR SHUNT FIELD
71 WHITE P32-2, T21 SHUNT FIELD CONN., PUMP MOTOR SHUNT FIELD
76 BLACK P5-24,T8 LOGICS,TRACTION MOTOR THERMAL SW.
77 BLUE P5-25,T6 LOGICS,PUMP MOTOR THERMAL SW.
78 BLUE P5-26,P24-2 LOGICS,PRESSURE SW.
81 BLUE P5-27,P13-6 LOGICS,HYDRAULIC SW.
82 WHITE P5-28,DU2-2 LOGICS, DIODE BLOCK 2
83 BLUE P5-29,DU1-2 LOGICS, DIODE BLOCK 1
87 BLUE P5-32, P13-4 LOGICS, HYDRAULIC SW.
88 YELLOW P5-33,P13-3 LOGICS, HYDRAULIC SW.
89 YELLOW P5-34,P13-2 LOGICS, HYDRAULIC SW.
91 BLACK P5-19,T16 LOGICS, PARK BRAKE SW.
92 WHITE P32-1,T23 SHUNT FIELD CONN.,TRACTION MOTOR SHUNT FIELD
106 GREEN P5-22,P33 LOGICS, BRAKE FLUID SW.
107 YELLOW DU2-1,T11 DIODE BLOCK 2, TRACTION MOTOR BWI
108 YELLOW DU2-3,T10 DIODE BLOCK 2,TRACTION MOTOR BWI
109 GREEN DU1-1,T4 DIODE BLOCK 1,PUMP MOTOR BWI
110 YELLOW DU1-3,T5 DIODE BLOCK 1,PUMP MOTOR BWI
113 RED P5-23, P40-C LOGICS, FOOT BRAKE SW
115 RED P5-30, P52-1 LOGICS, SPEED SENSOR
116 GREEN P5-31,P52-2 LOGICS, SPEED SENSOR
122 YELLOW P46-8,P48 CONSOLE GENERAL, LIGHT SW.
171

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SENB8604-02

Troubleshooting Troubleshooting Checklist

Preparation Tests and Checks Cell Voltage Test

4. Operation with a low battery must be prevented. Visual Checks

Removal Of Shorts To Chassis

Control And Power System Check 5: Reverse Drive Performance

Built-In Diagnostic Operation Brush Wear Indicator ON - lift truck operation

C0000 Logics Board

6. Move the switch to the DIAG position. This

3. Disconnect the line fuse (1) to prevent lift truck

Circuit Tests Test F: Service Brake Circuit

Test D: Direction Switch Circuit

Test E: Park Brake Circuit

Test J: Lift Switch Circuit Test M: Aux2 Switch Circuit

Tests “O” Through “T” Test R: Forward Contactor Circuit

Test S: Reverse Contactor Circuit

Test P: Pump Bypass Contactor Circuit 2

Problem # Problem Type

Battery Voltage Less Than Battery

Continuity No Make correction

Battery Voltage Less Than Battery

Cannot Adjust to Specifications

Overtemperature Indicator Still ON Display OK

Overtemperature Indicator Still ON Display OK

Overtemperature Indicator Still ON Display OK

Tips not shorted Tips shorted

NOTICE: Damage to the control panel could Field Failure Notes:

Correct Not Correct

Correct Not Correct

Not Failed Failed

Not Shorted Shorted Display = Display

Correct Not Correct

Correct Not Correct

Field Failure Notes:

Correct Not Correct

Display = “16” Display Normal

Not Failed Failed

Not Shorted Shorted

Wires OK Wires Defective

Tests OK Low Resistance

Not Failed Failed

Display = “19” Display Normal

Not Failed Failed

Truck Powers Up Normally Display = “21” Voltage Voltage Not ON

Continuity OK Continuity Not OK

Resistance OK Resistance Not OK

Test OK Test Not OK

Adjustment OK Adjustment Not OK

Adjustment OK Adjustment Not OK

Resistance OK Resistance Not OK

Wires OK Wires Not OK

Voltage OK Voltage Not OK

Tips Not Shorted Tips Shorted

No Continuity Continuity Test pump driver board. Replace failed

*NOTICE: Damage to the control panel could result.

Display = “31” Display Normal

Not Failed Failed

Not Failed Failed

Not Failed Failed

Display = “32” Display Normal

Not Failed Failed

Not Failed Failed