SENB8604-02
Systems Operation
Glossary
Accelerator
A device that converts mechanical movement into
a digital voltage pattern to the logics for variable
drive motor speed.
Activate
A word used with a component or circuit. To
change from the normal condition to the “activated”
condition because of an application of force or
electricity.
Ammeter
An electric meter used to measure current flow in
amperes.
Ampere (or Amp)
The unit of measurement of current flow. The
amount of current that one volt can push through a
resistance of one ohm.
Analog to Digital Converter
A device that converts an analog voltage into a
pattern of digital HIGH and LOW voltage signals.
Anode
The positive (+) side of a diode.
Armature
The rotating portion of an electric motor or
generator.
Base
The terminal of a transistor through which control
current flows (see Transistor).
Battery
Two or more cells connected together for a supply
of electric current.
BDI (Battery Discharge Indicator)
An electrically controlled display showing the
operator the state of battery charge.
Brush
A conductor, normally a block of carbon, that
makes sliding contact between the stationary and
moving part of the motor or generator.
Bus Bar
A heavy electrical conductor to which other smaller
wires are connected.
6
Capacitor
Device used to store electrical energy for short
periods of time.
Cathode
The negative (-) side of a diode.
Circuit
A way for current to go from the positive (+) side of
an electrical power source to the negative (-) side
of an electrical power source. This can be through
wires and electrical components.
Coil
A component made from many circles or turns of
wire used to concentrate a magnetic field.
Collector
A terminal of a transistor through which main
current flows (see Transistor).
Commutator
An armature component used to transfer current
from the brushes to the armature windings.
Compound Motor
A motor which has a field winding in series with the
armature and a shunt field winding in parallel with
the series winding and armature.
Compound/Series Motor
Similar to a compound motor, except the parallel
shunt field windings are controlled on and off to
vary speed and torque.
Conduct
To allow the flow of current.
Conductor
A material that provides a path for current flow.
Connector
Part of a wire assembly or harness that connects
with another wire assembly or harness. Used for
ease of assembly and disassembly.
Contactor Assembly
An electrical component consisting of an electro-
magnetic coil and a set of heavy contact tips.
Control current passes through the coil, building a
magnetic field which closes or opens the contact
tips.
Contactor Coil
An electromagnet used to close or open contact
tips in a contactor assembly.

Contact Tips or Contacts
The portion of a switch, relay or contactor where
the circuit can be opened or closed.
Continuity
Having the ability to allow current flow.
Control Circuits
The wires and components carrying low current
used to signal the logics unit, turn on main compo-
nents, or support auxiliary circuits (indicated by
thin lines on a schematic).
Counter Electromotive
An opposing voltage set up by a collapsing or
increasing magnetic field within a Force (CEMF)
coil.
Current
The movement or flow of electricity through a
conductor. A circuit must be complete for current
to flow.
Current Limit
The maximum allowable armature current of a
stalled drive motor during pulsing.
Current Sensor
A hall-effect sensor in the drive motor circuit that
produces an increasing voltage output as the drive
motor current increases.
Current Shunt
A precision low-value resistor connected in series
with the armature of a motor. The logics uses the
measured voltage drop across the shunt to control
maximum current allowed in selected power
circuits.
Deactivate
To change from the activated condition back to the
normal (deactivated) condition. It can be caused
by the application of force, the removal of force, or
the removal of electricity.
Digital Signal
A signal in which the elements may be either of
two distinct values. For example high voltage, low
volt age.
Diode
A semiconductor device that allows current to flow
in one direction, from the anode to the cathode.
Display
An electrical device that converts voltage inputs to
a visual output.
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Drain
Terminal of a MOSFET through which main current
flows (see MOSFET).
Electrical Braking
Electrically trying to rotate the drive motor opposite
to the direction of truck movement.
Electromagnet
A coil of wire, most often wound on an iron core,
which produces a strong magnetic field when
current is sent through the coil.
Electromotive Force (EMF)
The force that causes an electric current to flow in
a circuit. This force is measured in volts.
Emitter
A terminal of a transistor through which low control
current and main current flow (see Transistor).
Ferrite Bead
A small bead located on the base connection of
the power transistors to reduce high frequency
oscillation at the power transistor.
Field Windings
The stationary coils that produce a magnetic field
in motors and generators.
Filter
An electrical device or component for restriction or
suppression of undesired voltage spikes.
Fuse
A component in an electrical circuit that will open
the circuit if too much current goes through it.
Gate
Terminal of a MOSFET where voltage is applied to
control the device (see MOSFET).
Grounded
A wire or wires that are in contact with the metal
chassis of the vehicle (ground). Can be caused by
a loss of insulation from the wire, or by connecting
the wire to the vehicle.
Harness
An assembly made of two or more wires that are
held together.
Heat Sink
A mounting frame used for semiconductor cooling.
Hour Meter
An electrically activated device used to record the
amount of usage a truck receives.
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SENB8604-02
Indicator
A lamp or LED that gives an indication of some
vehicle condition when it turns on or flashes.
Input
A voltage change at the incoming connection of a
component.
Insulator
A material that has a very large resistance so that
it will not let current flow through it.
LED
Light Emitting Diode - a diode that emits light
(lights) when current flows in the forward direction.
Linear Output Hall Effect Transducer (LOHET)
A device that converts an increasing magnetic field
to an increasing linear output voltage
Logics or Logic Unit
The main printed circuit board containing a micro
processor and circuits to condition the voltage
signals that go into or come out of the logics. It
electronically monitors and controls the truck’s
functions.
Magnetic Field
The area around a magnet where magnetic forces
can be detected.
Microprocessor
A small computer chip preprogrammed to control
the various electrical functions on a lift truck.
MOSFET
A semiconductor component used in electrical lift
trucks as an electronic switch. A MOSFET most
often has three terminals: a Gate (G) a Source (S)
and a Drain (D). The main current flows between
the drain and the source. The main current flow is
controlled by a voltage applied between the gate
and the source.
8
Normal Condition
Words used with a switch or relay. Their normal
condition is their condition when they are not
controlled by the application of force, temperature,
pressure, or electricity.
Normally Closed (N.C.)
A switch or relay whose contacts are closed in the
normal condition.
Normally Open (N.O.)
A switch or relay whose contacts are open in the
normal condition.
OFF-Time
The amount of time current does not flow through
a transistor.
Ohm
The unit of measurement of resistance. The
amount of resistance that will let one volt push
only one ampere of current through it.
ON-Time
The amount of time current flows through a
transistor.
Open Circuit
Wiring or components of a circuit that have no
continuity.
Optical Switch
An electronic device made up of an infrared light
signal generator and photosensitive signal receiver
that changes a digital voltage when the light
pattern is conducting or blocked.
Output
The current flow from a component which is initiated
from a voltage change at the component’s input.
Source
Terminal of a MOSFET through which the main
current flows (See MOSFET).

Terminal
An electrical connection point on an electrical
component.
Thermal Switch
A switch that activates at a set temperature.
Transistor
A semiconductor component used in electric lift
trucks as an electronic switch. A transistor most
often has three terminals, a base (B), a collector
(C), and an emitter (E). The main current flow is
between the collector and emitter. This main
current flow is controlled by a much smaller
current flow between the base and emitter.
Turn ON
When an electrical component conducts current.
Varistor
A component terminated across the horn connec-
tions to eliminate voltage spikes when the horn is
activated.
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Volt
The unit of measurement of electromotive force.
One volt is the force needed to make one ampere
of current flow through one ohm of resistance in a
circuit.
Watt
The unit of measurement of power. The amount of
power used when one volt pushes one ampere of
current through a resistance of one ohm. The
result of amperes (current) multiplied by volts (volt
age) is watts (power).
Wire
A conductor used to provide a path for current to
flow to and from electrical components.
Wiring Diagram
A drawing using visual representation of compo
nents the way they actually look. It is used to show
the locations of components and the connections
between them.
Zener Diode
A special diode used to regulate voltage or as an
overvoltage (too high a voltage) protector.
9
SENB8604-02

Location of Control Panel

Components
MicroCommand II Control Panel
1. Logic unit (logics)
2. Head capacitors
3. Line fuse
4. Battery negative connection
5. Line contactor
6. Battery positive connection
7. Lift contactor
8. Bypass contactor
9. Forward contactor
10. Reverse contactor

CP Components

10
 SENB8604-02

Symbol Library

1 2 3 4 5 6 7 8
9

10

11

12

13

14

15

16

24 17
23 22 21 20 19 18

24 25
28

26 27

Schematic Symbols
(1) Power Transistor (2) Zener Diode (3) Ferrite Bead
(4) NPN Transistor (5) PNP Transistor (6) Thermal Switch
(7) Switch (8) Battery (9) Resistor
(10) Diode (11) Normally closed contacts
(12) Normally open contacts (13) Armature
(14) Male contact of a connector (pin)
(15) Female contact of a connector (socket)
(16) Wire Connection (17) No wire connection
(18) Contactor Coil (19) Current Shunt
(20) Field Windings (21) Capacitor (22) Varistor of Wires
(23) Fuse (24) Switch (25) N-Channel MOSFET
(26) P-Channel MOSFET (27) Twisted Pair
(28) Hall Effect Current Sensor (29)Thermistor

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SENB8604-02

Components Behind Logic Unit (1)

1)Pump driver board 13)P5 Main wiring harness connector 14)Auxiliary fuse holder 15) Key fuse 16)Accessory
fuse 17) Resistor R312 18)T2P transistor 19) Drive Driver Board 20) T1P(Transistor one pump) 21) T1D
(Transistor one drive) 22)Thermal Switch 23)T2D(Transistor two drive ) 24)Negative heatsink

Control Panel and Driver Board with Regen / 10300V2

Control Panel and Driver Boards Plug Only / 10200V2

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 SENB8604-02

MicroCommand II Control Panel

1)PS main wiring harness connector 2)Head capacitors 3)Line Fuse 4) Battery negative connection 5)Line
contactor 6)Battery positive connection 7)Pump Contactor 8)Traction Bypass Contactor 9)Forward contactor
10)Reverse contactor

Control Panel Cover off with Regen / 10300V3

Control Panel Cover off Plug Only / 10200V3

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SENB8604-02
General Information
When the term 2EC is used, it refers to the 2EC family
of lift trucks, which includes the 2EC15, 2EC18,
2EC20, 2EC25, 2EC25E, and 2EC30 models.
The MicroCommand II panel is the control center of the
2EC family of lift trucks. The Logic Unit (logics) is the
decision-making part of the control system. The logics
provides a self-contained Battery Discharge Indicator
(BDI) with lift interrupt and built-in diagnostics capability.
The logics monitors the battery state of charge and the
diagnostics. It also displays related information to the
operator on the liquid crystal display (LCD) panel located
on the steer console.
Four jumper connectors located on the logic card are
used to select the appropriate battery voltage:
J1=36V J2=48V J3=72V J4=80V
If the wrong voltage is selected by the jumper position,
the lift truck will not operate, and the display will show a
fault code (68 or 69). See the topic, On-Board “Run Time”
Diagnostics later in this section of the manual.
C0000
If the jumper is lost, the default voltage is 36V for the
logic card.
14
The MicroCommand II control system operates the
drive motor and the hydraulic pump motor systems on
the 2EC family of lift trucks. The steering system is
activated when the truck is powered up and the line
contactor closes. The truck uses a combined power
steering/hydraulic system where the hydraulic fluid
power for steering is provided by a hydraulic motor,
pump, and priority valve.
The speed of the hydraulic motor is controlled by volt-
age inputs to and outputs from the logics. Inputs are
generated by a pressure switch (steering) and valve
control switches (lift 1, lift 2, auxiliary 1 and auxiliary 2).
Outputs pulse hydraulic pump power transistors and the
pump shunt field, and they control the pump contactor
coil. The power transistors pulse in order to control the
speed of the hydraulic pump motor. To provide full
speed, the logics activates the pump contactor, stops
pulsing the power transistors, and turns off the pump
shunt field. A failure protection circuit is also included to
protect against malfunctions of the power circuit.
The speed and direction of the drive motor is controlled
by voltage inputs to and outputs from the logics. Inputs
to the logics are generated by the accelerator control
and direction switch. Outputs from the logics control
contactor coils, drive transistor pulsing, and drive shunt
field.
The drive circuit pulses transistors to provide travel
speed control up to 90% of full speed. Above that, the
bypass contactor closes and the drive shunt field turns
off to provide full speed. The drive circuit includes a
failure protection circuit that detects malfunctions of
the drive power circuit, a regenerative braking circuit
(standard on 2EC20 - 30 models), or a plugging circuit
(standard on 2EC16 - 18 models), and a current limit
circuit to prevent excessively high currents during
transistor pulsing.
Thermal protection circuits are used on the hydraulic
pump motor, the drive motor, and the control panel to
prevent permanent damage caused by overheating.
 SENB8604-02

Programmable Setup Options

Thirty one programmable setup options are available
on the 2EC family of electric lift trucks equipped with
MicroCommand II control system. These options can
be set by the user so that truck performance best
matches the operating conditions under which the truck
will be used.
The thirty options are divided into three groups:
Group 1: Setup options 1 - 9
Group 2: Setup options 10 - 27
Group 3: Setup options 28 - 35
The following chart shows a list of all thirty-one options
in their three groups. Minimum settings, maximum set-
tings, and the factory defaults are given in the chart.
For more information on using the Programmable
Setup Options, see the following topics in this section
of the manual.
• Functional Descriptions of Programmable Setup
Options
• Accessing Programmable Setup Options
• Programming Setup Option 1
• Programming Setup Options (Other than Option 1)
• Activating Default Settings.

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SENB8604-02

PROGRAMMABLE SETUP OPTIONS

FIRST GROUP
Settings
Option No. Min. Max. Default Description
1 A E A Truck Mode Option
2 0 10 5 Lift 1 Speed (Pump Motor Speed)
3 0 10 8 Lift 2 Speed (Pump Motor Speed)
4 2 7 3 Tilt Speed
5 0 10 3 Aux 1 Speed
6 0 10 0 Aux 2 Speed
7 5 20 16 Top Drive Speed
8 1 16 10 Variable Acceleration
9 0 = Disable .1 = for sales demo only Service Reminder Interrupt
100.0, 150.0, 200.0, 250.0, 300.0, 350.0,
400.0, 450.0, 500.0 0
SECOND GROUP
10 0 4 0 Auxiliary Input for Lift and Drive Speed
11 1 20 10 Auxiliary Travel Speed Limit
12 3 15 5 Pulsing Stall Timer
13 0 15 3 Park Brake Duty Cycle Limit
14 0 1 1 BWI Operation
15 0 1 1 80% Bypass Option
16 0 10 5 BDI Reset Value
17 0 1 1 Dead Battery Lift Lockout
18 0 20 10 Dead Battery Travel Speed with Disable
19 0 1 0 Variable Regen on Accelerator (Regen only)
20 0 3 3 Regen Function on Accelerator or Brake (Regen only)
21 0 1 0 Regen Enable for 1T 2EC 36/48V Trucks
22 0 15 3 Service Brake Duty Cycle Limit
23 0 20 5 Chat Timer
24 0 1 0 French BDI Option (nonactive)
25 0 1 0 Pump and Drive Pulsing Frequency
26 3 10 5 Regen Adjustment for Brake Regen
27 0 2 0 Pump Transistor Upgrade
THIRD GROUP
28 0 2 0 EE Option
29 0 40 20 Tire Size Adjustment
30 0 C 0.0 C 1.5 C 2.0 C 2.5 C 3.0 Truck Size and Type
31-34 0 0 0 Blank
*35 1.5 20 1.5 Bypass Stall Timer
* Any setting above 3 seconds may cause severe damage to traction motor. Contact Service Engineering before changing.
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 SENB8604-02

Functional Descriptions of Option 4 - Tilt Speed

• Settings: 2/7/3
Programmable Setup Options This option performs the same function as option
2, except that it sets up the tilt control.
NOTE: The three numbers separated by “/ ” following
“Settings” indicate the minimum value/maximum Option 5 - Aux 1 Speed
value/factory default value. These are the same values • Settings: 0/10/3
given in the Programmable Setup Options table on the This option performs the same function as option
preceding page of this manual. 2, except that it sets up the Aux 1 control.
First Group
Option 6 - Aux 2 Speed
Option 1 - Truck Mode • Settings: 0/10/0
• Settings: 1/5/1 This option performs the same function as option
This option is used to preset the value of seven 2, except that it sets up the Aux 2 control.
other options. This allows the user to set the truck
up for one of five various modes of operation: Option 7 - Top Speed Option
standard Factory, Hi-Performance, Economy, • Settings: 5/20/16 (5-20 KPH)
Long-Travel, or Dock. Option 1 is a convenient This option can be used to control the top speed
way to program truck performance without having of the truck. This option will NOT apply the
to program many options individually. It is never- brakes if the speed limit is exceeded (i.e. going
theless possible to modify the preset values of the down a hill). Also, you must be careful not to set
options that make up the chosen application. See the speed limit to a value that would keep the
the topic, “Programming Setup Options - Option truck out of bypass unless this is absolutely
1” later in this section. necessary. Without bypass the panel will be
more likely to overheat in an application.
Option 2 - Lift 1 Speed
• Settings: 0/10/5 Option 8 - Variable Acceleration
This option, and options 3, 4, 5, and 6 (see below), • Settings: 1/16/10 (SLOWEST/FASTEST)
allow the user to select the preferred pump motor This option will allow the acceleration of the
speed for the Lift 1 speed control. The chart below truck to be controlled. It is much like the
shows the range of possible speeds that can be rabbit/turtle switch that other lift trucks offer.
programmed.
Pump Speed Armature Shunt Field Duty Pump Option 9 - Service Reminder Interrupt (SRI)
Duty Cycle Cycle Contactor • Settings:
• Increment Values:
0 0% 100% Off 0 = Disable
1 15 100 Off 000.1 For sales use only. 100.0, 150.0, 200.0,
250.0, 300.0, 350.0, 400.0, 450.0, 500.0
2 20 100 Off This option allows you to do either of two things.
3 25 100 Off You can merely have the Service Reminder
action light come on when the selected time
4 35 100 Off
increment is reached; or, you can activate the
5 45 100 Off light and also shut off the lift, tilt, and auxiliary
6 55 100 Off functions and slow the truck to the dead battery
travel speed (option 18). The increment values
7 70 100 Off represent hundreds of hours. They appear on the
8 0 100 On display in two groups. The second group, which
is indicated by an equal sign preceding the incre-
9 0 50 On
ment value, will shut off the lift, tilt, and aux func-
10 0 0 On tions and reduce travel speed. The SRI will be
reset every time the DIAG/RUN/SETUP switch is
Option 3 - Lift 2 Speed toggled past this option. If you enter this option
• Settings: 0/10/8 and do NOT wish to reset the SRI, simply turn off
This option performs the same function as option the key switch.
2, except that it sets up the Lift 2 control.

17
SENB8604-02
Second Group
Option 10 - Auxiliary Input For Lift And Drive Speed
• Settings: 0/4/0
0 Disabled
1 Disable Lift On Low
2 Speed Limit On Low
3 Disable Lift On High
4 Speed Limit On High
• This option is used in conjunction with the lift limit
input P1-14. This input is internally pulled up on
the logic to +15V.
Option 11 - Auxiliary Travel Speed Limit
• Settings: 1/20/10
This option is used in conjunction with option 10
when the speed limit portion of option 10 is used.
Option 12 - Pulsing Stall Timer
• Settings: 3/30/5
This option allows some adjustment (3 to 30
seconds) to the time it takes the truck to shut
down when the drive motor current is too high for
too long in transistor mode. This condition, called a
drive stall timer failure, produces an error code 20
on the display. Option 12 helps prevent drive motor
abuse.
Option 13 - Park Brake Duty Cycle Limit
• Settings: 0/15/3
This option controls the maximum drive duty cycle
when the park brake is applied. It allows the drive
system to operate much like a car when the park
brake is applied. The truck will try to move, but be
unable. This should help remind the operator that
the park brake is applied.
Option 14 - BWI Operation
• Settings: 0/1/1
NO EFFECT/BWI AFFECTS TRUCK OPERATION
This option determines what will happen if either
the drive or pump motor brush wear indicator
(BWI) is activated:
• Pump BWI active - Lift Lockout
• Drive BWI active - Truck is slowed to 1/2 of
current maximum speed or 6 KPH, whichever
is slower.
Option 15 - 80% Bypass Option
• Settings: 0/1/1 OFF/ON
If enabled, this option will not allow the truck to
enter bypass when the truck is in current limit. This
option in conjunction with the drive pulsing stall
timer (option 12) will help to reduce drive motor
abuse in hard applications.
18
Option 16 - BDI Reset Value
• Settings: 0/10/5 0-10 RESET VALUE
This option sets the value above which we
consider a battery to be recharged. If the truck
enters a dead battery condition, it will remain in
this state even if the key switch is cycled until a
battery that equals or exceeds the BDI reset value
is connected to the truck.
Option 17 - Dead Battery Lift Lockout
• Settings: 0/1/1 OFF/ON
This option determines the action of the lift during
a dead battery condition.
Option 18 - Dead Battery Travel Speed With Disable
• Settings: 0/20/10 1 - 20 KPH WITH 0 = DISABLE
This option determines the maximum truck speed
during a dead battery condition.
Option 19 - Variable Regen On Accelerator
• Settings: 0/1/0 OFF/ON
When enabled, this option allows the accelerator to
control the level of braking in regen. The option
works only on trucks equipped with regen. It is
influenced by the setting of option 20. (It will not
work with settings EAB1 or EAB3 because they
require the accelerator to be off.)
Option 20 - Regen Function On Accelerator Or Brake
• Settings: 0/3/3
0 DISABLED/EAB1/EAB2/EAB3
1 EAB1 - Service Brake is on; Accel must be off
2 EAB2 - Service Brake is on; Accel does not matter
3 EAB3 - Whenever accel is off
This option allows the use of the Electrical
Assisted Braking (EAB). The three modes are
defined above. Only one mode can be enabled at a
time. This option works only on trucks equipped
with regen because the added braking load would
overheat a truck equipped only with plugging.
Option 21 - Regen Enable For 2EC15/18 36/48V Truck
• Settings: 0/1/0 DISABLED/YES
This option allows a person to enable regen on a
truck that did not previously have regen. After the
necessary components have been added, this
option is enabled.
Option 22 - Service Brake Duty Cycle Limit
• Settings: 0/15/3 ACCEL POS LIMIT
This option controls the maximum drive duty cycle
when the service brake is applied. This allows
some drive while the service brake is on so that the
truck can be two-footed. If the truck is being
abused because of two-footing, option 22 can be

used to prevent the situation.
Option 23 - Chat Timer
• Settings: 0/20/5
1-20 SECOND TIMER WITH 0=DISABLE
This option controls the amount time required to
enter chat mode.
Option 24 - French BDI Option (nonactive)
• Settings: 0/1/0 OFF/ON
This option allows the use of a different BDI
discharge curve for use with tubular plate batteries.
These batteries have a flatter discharge curve than
normal so the voltage at which they are considered
dead is higher than the normal battery. See the
topic, “Battery Discharge Indicator (BDI)
Adjustment,” in the Testing and Adjusting section
of this manual.
Option 25 - Pump And Drive Pulsing Frequency
• Settings: 0/1/0 NORMAL/DOUBLE FREQUENCY
This option allows the 187.5 Hz transistor pulsing
frequency used for drive and lift related pump
operation to be changed to 375 Hz. For some
people the 375 Hz pulsing may be more accept-
able than 187.5 Hz pulsing. The 15 kHz used for
pump steering functions is unaffected by this
option and remains at 15 kHz.
Option 26 - Regen Adjustment For Brake Regen
• Settings: 3/10/5
50% TO 100% OF P3 POT IN 10% INCREMENTS
This option allows the EAB regen to be adjusted
independent of the level of regen set by pot P3. It
is independent as long as the desired EAB regen
level is lower than that set by P3. This allows the
user to set the EAB regen softer than normal regen.
Option 27 - Pump Transistor Upgrade
• Settings: 0/2/0 DISABLED/2 200A/2 300A
In an 2EC16 OR 2EC18, option 27 allows the user to
upgrade the pump transistor to a higher capacity
configuration. In a heavy application where the user
is suffering too many pump transistor failures, this
option along with the addition of bigger pump
transistors improves reliability.
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Third Group
Option 28 - EE Option
• Settings: 0/2/0
OFF/EE DRIVE ONLY/EE DRIVE&PUMP
The EE option is used to slow down the pump and
drive system, which results in cooler running motors.
The EE option accomplishes this by always keeping
the shunt field on when the motor is operating.
Option 29 - Tire Wear Adjustment
• Settings: 0/40/20 =
NO ADJUSTMENT SMALLEST/LARGEST
This option allows the speedometer to be adjusted
based on the amount of tire wear. The speedometer
calculations are based on a certain tire size. If we
deviate from this tire size, the speedometer will not
work.
Option 30 - Truck Size and Type
• Settings: SIZES SHOWN:
O 0 0.0 C 1.6 C 1.8 C 2.0 C 2.5 C 3.0
This option is used to tell the logics the size and
type of the truck. Special care should be applied
here. The value of this option is used to configure
the drive and pump operation for the truck and if
set incorrectly could result in erratic truck operation.
When the logics are received out of the parts system
or initially put on a truck on the production line,
option 30 is set to 0 0.0. If the truck is powered up
in RUN mode without first setting this option to
some value other than 0 0.0, the truck will shut
down and an error code 65 will be displayed.
Option 31 - 34 - Blank
• Settings: 0
These options are intentionally left blank.
Option 35 - Bypass Stall Timer
• Settings: 1.5/20/1.5
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SENB8604-02

Accessing Programmable Setup

Options
You can access any of the three groups of setup
options directly in order to make programming changes.
To access the First Group (Options 1 - 9):
1. Place the DIAG/RUN/SETUP switch in SETUP.
2. Turn the key switch ON.
The display will show the value of Option 1
(APP-[ ] 01, where [ ] = the selected application.).
To access the Second Group (Options 10 - 27):
1. Place the DIAG/RUN/SETUP switch in SETUP.
2. Pull back on and hold the LIFT and TILT levers
and turn the key switch ON.
The display will show the value of Option 10.
To access the Third Group (Options 28 - 35):
1. Place the DIAG/RUN/SETUP switch in SETUP.
2. Pull back on and hold the LIFT, TILT, and AUX 1
levers and turn the key switch ON.
The display will show the value of Option 28.
Changing Programmable Setup
Options
1. Set Park Brake.
2. Turn key off.
3. Open door (panel).
4. Remove Logic Cover.
5. Place DRS switch in Setup.
6. Plug in battery (if unplugged).
7. Turn on key.
8. Move the directional lever from neutral to forward
or reverse and back to neutral. You have now
increased or decreased the setting value.
9. Move the DRS switch back to Run (center). You
will see triple bars on the display. Triple bars tell
you that the value selected has been stored in
memory.
10. Toggle DRS switch from Setup to Run and then
back to Setup to change to another option.
11. Change value with Forward and Reverse lever.

20
 SENB8604-02

Programming Setup Option 1 Application A - Factory

Option 1 allows you to set the truck to one of five pre- Application b - Hi-Performance
defined modes of operation, according to how your Application C - Economy
truck is used. It changes the truck travel speed, accel-
eration rate, and hydraulic pump speeds. The modes Application d - Long-Travel
(applications) are: Application E - Dock
The modes are defined by the values of options 2, 3, 4,
7, 8, 26, and 28. The following table gives the values
for these options as they correspond to each mode.

OPTION 1 MODES / VALUES

Truck Mode Value of Option
2 3 4 7 8 26 28

APP-A
(FACTORY) 5 8 3 16 10 5 0

APP-b
(HI-PERF) 6 10 6 20 16 5 0
APP-C
(ECONOMY) 5 8 2 20 1 5 1

APP-d
(Long-travel) 5 8 3 20 4 5 0

APP-E
(DOCK) 5 8 4 16 8 10 0

NOTES:
1. Option 28 (EE Mode) is controlled by Option 1 3. You can toggle past Option 1 without resetting it
only if Option 28 is set to 0 or 1. If it is set to 2 by to the preset values, even if any of the values have
the user, Option 1 will not change this value, been modified, by not changing the mode in the
which represents a fully EE’d truck. hour meter area.
2. If the option number is flashing when you first
access the option, this means that one of the
effected values has been changed from its preset
value (the value in the table). Probably one of the
values was modified to further customize opera-
tion of the truck.

Option 1 Applications

21
SENB8604-02
Programming Setup Options
(Other than Option 1)
1. Access the option you want to change, using the
appropriate method described in the previous
section, “Accessing Programmable Setup
Options.”
2. Change the value:
• To increase the value of the option, move the
direction lever to FORWARD, then back to
NEUTRAL.
• To decrease the value of the option, move the
direction lever to REVERSE, then back to
NEUTRAL.
3. To move to the next option:
• Move the DIAG/RUN/SETUP switch from
SETUP to RUN, then back to SETUP. The
option number displayed will increment to the
next number.
• New values are locked in each time you move
the DIAG/RUN/SETUP switch from SETUP to
RUN.
After programming any option(s), test the lift truck to
be sure that its operation is correct.
22
Activating Default Settings
Options 1 -27 can be set to their factory default values
by the following procedure.
NOTE: Options 28 - 35 do not reset to default values
with this method. Each of these options must be reset
individually.
1. Place the DIAG/RUN/SETUP switch in the
SETUP position.
2. Place the direction lever in REVERSE.
3. Make sure the seat switch is OPEN (no operator
on the seat).
4. Hold down the accelerator and turn ON the key
switch.
5. Watch for flashing “donE” on the display. This
indicates that Options 1-27 have been set to
their factory default values.
6. Turn the key switch to OFF.
7. Return the DIAG/RUN/SETUP switch to the
normal operation mode (RUN).
Programming the Clock
1. Turn key ON.
2. Push and hold down left orange button for
approximately 5 seconds or until the minutes
area of the clock starts to flash. Release button.
3. Push the right orange button to advance the
minutes of the clock.
4. Press and release the left orange button. The
hours section of the clock will start to flash.
5. Push the right orange button to advance the
hours of the clock.
6. When finished setting the clock, press and
release left orange button.
 SENB8604-02

Operational Circuit Elements

Logic Unit
The Logic Unit (logics) has one printed circuit board
contained in a vertical sheet metal box on the control
panel. Most of the circuitry on the board conditions
voltage signals into and out of the microprocessor.
Software in the microprocessor controls the logics
outputs for power components in the pump system,
traction system, contactor coils, and display. Access to
the board is provided by two lock screws, which allow
the cover to be removed.

Logic Board

A jumper should be installed on one of the jumper

blocks according to truck battery voltage:
J1 = 36 volts
J2 = 48 volts
J3 = 72 volts
J4 = 80 volts

23
SENB8604-02

Vehicle Monitoring System Battery Discharge Indicator

Display Unit
The vehicle monitoring system display unit is located in
the steering console. It is a self-contained, solid-state
instrument panel with a liquid crystal display (LCD) that
has areas for showing: BDI; truck, drive motor, and
pump motor hours; clock; truck speed; and fault
codes. A separate action light strip below the LCD dis-
play uses seven international pictorial symbols to alert
the operator of conditions that need attention.
The display unit interacts with the logics and failure
protection circuits. It functions as a BDI, and provides
on-board diagnostic data on the operational condition
of the truck during normal use (“Run-Time” diagnos-
tics) as well diagnostics during troubleshooting (“Self”
diagnostics). See the topic, “Built-in Diagnostic
Operation” in the Troubleshooting section of this
manual.
3. Speed Fault
Code Indicator
1. Battery Discharge Indicator (Run-Time and
Self Diagnostics)
This liquid crystal display (LCD) uses bars and a bat-
tery symbol to indicate the level of battery discharge.
When all ten bars appear, the battery is fully charged.
As the battery discharges, bars disappear from the dis-
play one by one. When only one bar remains on the
display, the battery is 70% discharged and the battery
symbol will flash. At 80% discharge, the battery symbol
is solid and no bars appear. The drive and lift (hydraulic)
motors run at a slower speed. The operator should
complete the current lift operation and travel to the
battery replacement or charge area. Replacement of
the discharged battery will reset the BDI, and normal
operation will resume.
Hour Meter and Clock
At start-up, the five LCD numbers and the three sym-
bols above them indicate service hours for the truck,
for the drive motor, and for the pump motor. Each sym-
bol momentarily lights and its respective hours appear
on the LCD display, in cycle. Periodic maintenance is
based on the number of pump hours recorded. After
start up and while the truck is operating, the LCD num-
bers display the time of day.

Speed / Fault Code Indicator

During normal operation, truck speed is indicated by
the two LCD numbers in this area. Either miles per hour
2. Hour Meter 4. Vehicle or kilometers per hour can be chosen for the display by
and Clock Monitoring System pushing the left orange button. The numbers will
Action Lights
change to a fault code if a run-time fault is detected.
The “!” action light will flash on and off while the code
is displayed.

Display Unit
1. Battery Discharge Indicator 2. Hour Meter and Clock
3. Speed/Fault Code Indicator (Run-time and Self- Diagnostics).
4. Action Lights.

24
 SENB8604-02

Action Lights
These symbols glow red when specific problems are
detected. The truck should be stopped and corrective
action taken immediately.

3 4
2 5 6 7
1

Action Lights

1. Service Reminder - The wrench symbol lights

when it is time for periodic maintenance.
Maintenance intervals are programmable. See
the topic, “Programmable Setup Options,”
Option 9.
2. Brush Wear Indicator - The motor symbol lights
if the drive or pump motor brushes need
service. Truck operation can be slowed or
stopped. See the topic, “Programmable Setup
Options,” Option 14.
3. Over Temperature - The thermometer symbol
glows if an overtemperature condition develops
in either drive motor, pump motor, or the control
panel. Reduced drive and/or lift performance
can be programmed into the control system.
See the topic, “Programmable Setup Options,”
Options 10 and 11.
4. Battery Charge - The battery symbol flashes if
the battery charge reaches the 70% discharged
level. At 80% discharge, the symbol glows
constantly (no flashing). Reduced drive and/or
lift performance can be programmed. See the
topic, “Programmable Setup Options,” Options
16, 17, 18.
5. Brake Fluid Level - The brake fluid symbol
flashes if the brake fluid reaches a predeter-
mined low level.
6. Park Brake - The park brake symbol flashes
when the park brake is applied.
7. Fault Detection - At start-up and during truck
operation, drive and pump circuits are moni-
tored for failures.If a fault is detected, the truck
shuts down and cannot be operated until the
cause of the fault is repaired.The fault symbol
will flash and a fault code number will appear in
the Speed/Fault Code Indicator.

25
SENB8604-02
Run-Time Diagnostics
The MicroCommand II Control System controls and
monitors all the electrical and hydraulic operations of
the lift truck. An important part of its job is to detect
problems and signal the operator or maintenance per-
son to take corrective action. Run-time diagnostics
function during truck operation.
During truck start-up or operation, if the logics detects
a problem, a diagnostic code will appear in the
Speed/Fault Code Indicator instead of vehicle speed.
The “!” symbol flashes in the action light strip at the
same time the code is displayed. The codes indicate
an improper operating sequence or a defect in the
truck electrical system.
Run-time diagnostics cover the following areas of truck
operation and protection:
• Truck, drive motor, and pump motor hours
• Service reminder hours
• Motor brush wear
• Stall protection
• Overtemperature protection of the drive motor,
pump motor, and the control panel.
• Brake fluid level
Listed below are all the possible Run-time error codes,
the components involved and their location (if applica-
ble), the cause of the error code, and the truck
response to the problem. Also see the “Troubleshooting
Problem List” and the troubleshooting flow charts in
the Testing and Adjusting section of this manual.
DISPLAY = 10 - Drive armature transistor emitter high
when not expected
Components Involved: T1D and/or T2D
Location: Panel
Cause: A code 10 results when the processor
senses the drive armature transistor emitter
being high when it should be low. This error is
detected during the Close Line Contactor
Routine (CLOSLC) and anytime the line
contactor is in.
Response: Truck shuts down and the error code
is displayed.
26
DISPLAY = 11 - Drive armature transistor’s emitter low
when not expected
Components Involved: T1D and/or T2D
Location: Panel
Cause: A code 11 results when the processor
senses the drive armature transistor emitter
being low when it should be high. This error is
detected during the Close Line Contactor
Routine (CLOSLC).
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 15 - D6D anode low when not expected
• REGEN-EQUIPPED PANELS
Components Involved: D6D, Regen Contactor,
Sense Wire
Location: Panel
Cause: A code 15 results when the processor
senses the D6D anode low when it should be
high. This error is detected during the first
50mS of regen. This check prevents a regen
contactor that is welded shut from causing the
truck to act unpredictably. It is also possible
that this error is caused by a broken wire.
Response: Truck shuts down and the error code
is displayed.
• PLUG-ONLY PANELS
Components Involved: Sense Wire
Location: Panel
Cause: A code 15 results when the processor
senses the D6D sense wire is low. Since this
truck lacks regen, this sense wire is perma-
nently connected +BAT. If this wire is sensed
low it means that the wire is broken or the
truck size and type have been set to indicate
that the truck is equipped with regen when it
really isn’t. This error is sense during the Close
Line Contactor Routine (CLOSLC) and anytime
the regen contactor is closed.
Response: Truck shuts down and the error code
is displayed.

DISPLAY = 16 - D6D anode high when not expected
REGEN-EQUIPPED PANELS
Components Involved: D6D, Regen Contactor,
Sense Wire
Location: Panel
Cause: A code 16 results when the processor
senses the D6D anode high when it should be
low. It can be caused when the truck type and
size are set to indicate that it is a plug-only
truck when it isn’t. It can also be caused by a
bad regen contactor or logic.
Response: Truck shuts down and the error code
is displayed.
PLUG-ONLY PANELS
Components Involved: Sense Wire
Location: Panel
Cause: This error is not used on plug-only panels
because the sense wire is permanently tied to
+BAT and therefore should always be high.
DISPLAY = 18 - Drive shunt field transistor’s drain is
high when not expected
Components Involved: T371
Location: Drive Driver Board
Cause: A code 18 occurs when the processor
senses the drive SF collector being high when
it should be low. This error is detected during
the Close Line Contactor Routine (CLOSLC).
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 19 - Drive shunt field transistor’s drain is
low when not expected
Components Involved: T371
Location: Drive Driver Board
Cause: A code 19 occurs when the processor
senses the drive SF collector being low when
it should be high. This error is detected during
the Close Line Contactor Routine (CLOSLC).
Response: Truck shuts down and the error code
is displayed.
SENB8604-02
DISPLAY = 20 - Drive stall timer failure
Components Involved:
Location: Logics Panel
Cause: A code 20 occurs when the processor
senses that the drive motor has been drawing
too much current for too long. The time before
the failure occurs will be dependent on the
level of current being drawn. The more the
overload, the shorter the time before a failure.
This error is detected anytime the drive motor
is being driven. The stall timer failure timer can
be set in setup mode. See the topic,
“Programmable Setup Option,” option 12, in
this section of the manual.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 21 - Drive current sensor not operating
Components Involved: E361 (Current Sensor)
Location: Panel
Cause: A code 21 occurs when the processor
senses a zero reading that is outside of the
allowed bounds. This is an indication that the
sensor is not working correctly or has failed.
This error is detected anytime the directional
contactors are open and the truck is in neutral.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 24 - Drive output overcurrent fault
Cause: A code 24 occurs when the processor
senses that the output driver(Q109) is going
into a current limit situation.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 25 - Accelerator fault low
Cause: A code 25 occurs when the processor
senses that the pulse width modulation (PWM)
voltage from the accelerator is too low. This
error is detected at all times.
Response: Truck shuts down and the error code
is displayed.
27
SENB8604-02
DISPLAY = 26 - Accelerator fault high
Cause: A code 26 occurs when the processor
senses that the pulse width modulation (PWM)
voltage from the accelerator is too high. This
error is detected at all times.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 29 - Speed sensor failure
Cause: A code 29 occurs when the processor
senses that the speed sensor is not working
correctly.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 30 - Pump armature transistor’s emitter is
high when not expected
Components Involved: T1P and/or T2P
Location: Panel
Cause: A code 30 occurs when the processor
senses that the pump armature transistor emit-
ter is high when it should be low. This error is
detected during the Close Line Contactor
Routine (CLOSLC) and any time the line con-
tactor is in.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 31 - Pump armature transistor’s emitter is
low when not expected while driving B terminal
Components Involved: T1P and/or T2P
Location: Panel
Cause: A code 31 occurs when the processor
senses that the pump armature transistor
emitter is low when it should be high while
driving the B terminal of the transistor(s). This
error is detected during the Close Line
Contactor Routine (CLOSLC).
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 32 - Pump armature transistor’s emitter is
low when not expected while driving b0 terminal
Components Involved: T1P and/or T2P
Location: Panel
Cause: A code 32 occurs when the processor
senses that the pump armature transistor
emitter is low when it should be high while
driving the B0 terminal of the transistor(s). This
error is detected during the Close Line
Contactor Routine (CLOSLC).
Response: Truck shuts down and the error code
is displayed.
28
DISPLAY = 33 - Combination of 31 and 32
Cause: A code 33 occurs when the processor
senses that the pump armature transistor
emitter is low when it should be high while
testing the B and B0 terminals. This error is
detected during the Close Line Contactor
Routine (CLOSLC).
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 38 - Pump shunt field transistor’s drain is
high when not expected
Components Involved: T351
Location: Drive Driver Board
Cause: A code 38 occurs when the processor
detects the pump SF transistor collector high
when it should be low. This error is detected
during the Close Line Contactor Routine
(CLOSLC).
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 39 - Pump shunt field transistor’s drain is
low when not expected
Components Involved: T351
Location: Drive Driver Board
Cause: A code 39 occurs when the processor
detects the pump SF transistor collector low
when it should be high. This error is detected
during the Close Line Contactor Routine
(CLOSLC).
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 40 - Pump stall timer failure
Cause: A code 40 occurs when the processor
senses that the pump motor has been
drawing too much current for too long. This
error is detected any time the pump motor is
being driven.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 41 - Pump current shunt not operating
Components Involved: Pump Shunt, Wires #29
and 119
Location: Panel
Cause: A code 41 occurs when the processor
senses that the pump shunt is not registering
current when it should be.
Response: Truck shuts down and the error code
is displayed.

DISPLAY = 44 - Pump output overcurrent fault
Cause: A code 44 occurs when the processor
senses that one or more of the output drivers
(Q106 - Q108) are going into a current limit
situation.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 50 - Combination of 10 and 30
Cause: Combination of 10 and 30.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 51 - Combination of 11, 31, and 32
Cause: Combination of 11 and 31.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 60 - Serial communication fault
Cause: A code 60 occurs when the serial
communication system fails to communicate a
message in a given amount of time between
the logics and display.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 61 - EEPROM error
Cause: A code 61 occurs when the processor
cannot program a location correctly, or when
reading an EEPROM value and its comple-
ment, they don’t agree.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 62 - Frame Fault positive voltage (nonactive)
Cause: Connection between the lift truck
frame and a positive voltage source.
Response: Truck shuts down and the error code
is displayed.
SENB8604-02
DISPLAY = 63 - Frame Fault Negative voltage (nonactive)
Cause: Connection between the lift truck
frame and a negative voltage source.
Response: Truck shuts down and error code
is displayed.
DISPLAY = 65 - Truck size not initialized
Cause: A code 65 occurs when the truck is
powered up in RUN mode with option 30
(Truck size and type) equal to 0 0.0.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 66 - Watchdog timer failure
Components Involved: Logic Card
Location: Panel
Cause: A code 66 occurs when the logic senses
that its watchdog timer is not functioning.
Because this circuit monitors the processor
proper operation it must always be functional.
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 67 - Battery volts too low
Cause: A code 68 occurs when the processor
senses that the battery volts are too low for
the battery voltage chosen by the jumper.
24 > 36/48V BATTERY
60 > 72/80V BATTERY
Response: Truck shuts down and the error code
is displayed.
DISPLAY = 69 - Battery volts too high
Cause: A code 69 occurs when the processor
senses that the battery volts are too high for
the battery voltage chosen by the jumper.
36/48V BATTERY > 60
Response: Truck shuts down and the error code
is displayed.
29
SENB8604-02

Chat Mode Pedal Position Duty Cycle (%) Voltage on P1-15

If the seat switch is closed, key switch turned ON, and 0 10.1 12.3
the direction lever is left in NEUTRAL with no other 1 17.6 11.2
operator requests, the line contactor will deactivate
after approximately five seconds. The lift truck will 2 22.6 10.6
remain in this condition until the operator activates the 3 27.6 9.9
direction switch, accelerator pedal, or a control valve 4 32.6 9.2
lever. The line contactor then reactivates, and the truck
5 37.6 8.5
is ready for normal operation.
6 42.6 7.8
Contactors 7 47.6 7.2
The control panel is equipped with 36/48 and 72/80 8 52.6 6.5
volt contactors. The logics will control the “effective
voltage” supplied to the coils. When a contactor is first 9 57.6 5.8
activated, full battery voltage is applied to the coil. 10 62.6 5.1
After the contact tips have closed, the logics will pulse 11 67.6 4.4
the coil to reduce the voltage across the coil to
12 72.6 3.8
between 15 and 35 volts.
13 77.6 3.1
Accelerator Control 14 82.6 2.4
The EP16 family MicroCommand II accelerator uses a 15 87.6 1.7
single wire to communicate pedal position to the log-
ics. The accelerator uses a three-wire connector: As shown, the duty cycle is never 0% or 100% during
Pin 1 - BAT- (Wire #1) normal operation. This means that if you measure 0V or
Pin 2 - Switched Positive (Wire #4) 15V at the input to the logics, something is not working
Pin 3 - Signal Wire (Wire #8) correctly.
The accelerator uses a pulse width modulated (PWM)
signal to communicate the position of the pedal to the
logics. This is very similar to the way the transistors
control the drive and pump motors. The accelerator
changes the duty cycle of the PWM signal to indicate
different positions. The accelerator output is simply a
switch to ground. The switch is turned on and off at a
rate of 500 Hz or 500 times a second. One on/off cycle
is called a period. The on time of the switch compared SIGNAL VANE
RECEIVER
to the period is the duty cycle. In the chart below, it is
shown as a percentage, where 0% means that the SIGNAL
switch never turns on, 50% means the switch is on half GENERATOR
the time, and 100% means the switch is on all of the
time. The logic input for the accelerator is simply a
resistor pulled up to +15V. When the accelerator switch
is on, the resistor pulls this input low; when the accel-
erator switch is off, the resistor pulls this input high.
Additional circuitry in the logics converts this on/off
wave form to a voltage that the logics can read and
convert back to a position. The duty cycles for the
accelerator as are follows:
OPTICAL SWITCH

B75533P1

30
 SENB8604-02

Circuits
Accessory Circuits
Horn Circuit
The horn will operate when the battery is connected
and the horn button is pushed. Current flows from bat-
tery positive through the lights’ fuse, horn button and
horn, back to battery negative.

DC-DC Converter
The DC-DC Converter changes the lift truck battery volt-
age to 12 volts. This 12 volts is used to power acces-
sories such as floodlights, brake/side lights, and horn.
The positive of the 12 volt output is common to the pos-
itive of the battery voltage. The negative of the 12 volt
output is pulsed to maintain a steady 12 volt supply.
The 12 volt output of the converter is protected against
short circuits and overloading by an internal 15 amp
current limit circuit. A fuse on the converter protects it
from reverse connection to battery voltage.

97812-15600

NOTICE: Do not connect the 12 volt negative output

of the DC-DC converter to battery negative. Damage
to system components could occur.

31
SENB8604-02

Drive Circuit Depressing the accelerator pedal will cause the accel-
erator voltage on P1-15 to change as explained under
Control Circuit Accelerator Control. The logics detects the voltage
change at P1-15, activates the correct direction con-
With the actuation circuit complete, the logics supplies tactor, regen contactor (if used) and starts pulsing the
a HIGH voltage (15 volts) to the direction switch at P1- drive power transistors.
9 and P1-10. A HIGH voltage is also supplied to the
accelerator control at P1-15. Battery voltage is sup- With the forward direction selected, current flows from
plied to the accelerator at P9-B. the logics P3-18 through the forward direction and
regen contactor coils (if used) to logics P3-12 and P3-
Selecting a direction will change the voltage from HIGH 14 back to battery negative. The forward and regen
to LOW on P1-10 for forward or P1-9 for reverse. contact tips close.

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

32
 SENB8604-02

Drive Circuit controlled separately from the pump motor circuit by

Power Circuit
NOTE: Shaded lines illustrate current flow in the
circuit diagrams. Other circuits can be activated at
the same time, but each one is shown separately to
illustrate current flow in each individual circuit.
The high amperage current that provides the power
and torque necessary to drive the lift truck flows
in this circuit. The speed of the drive motor is
the MicroCommand II Control System.
The logics generates an optional 375Hz or 187.5Hz
pulsing signal on P2-5. This is faster than can be seen
on a voltmeter and must be viewed with an oscillo-
scope. When this signal is low, it indicates the power
transistors T1D and T2D should be on. When this signal
is high, it indicates they should be off. When P2-5 goes
low, current flows from Battery positive through the
emitter/base junction of T314 and T315, through R-312,
through P2-5 to Battery Negative.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY
E2 A1 A2 19 P3-13
(F2) REGEN COIL
DRIVE MOTOR
75 P3-14
D6D

XY
BATTERY
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR

92
96

2EC1503

33
SENB8604-02

Power Transistors The percent “on-time” of the voltage at logics P2-5 is

When the current flows through the base emitter junc-
tion of T314 and T315, this turns the transistors ON.
When T314 and T315 are ON, current flows through
T314,T315 emitter/collector into the base of the drive
power transistors T1D and T2D, causing them to turn
ON. With the power transistors ON, high amperage
motor current can flow through them, the motor field,
forward contact tips, motor armature, forward contact
tips, current sensor, and regen contact tips back to bat-
tery negative. When T314 and T315 are OFF, the drive
power transistors are OFF.
also the percent “on-time” of the power transistors. As
the “on-time” increases, the average voltage applied to
the drive motor increases, which increases the speed of
the lift truck. The percent “on-time” out of the logics is
determined by how far the accelerator is depressed.
At the same time the logics is pulsing the drive motor
circuit, a constant voltage (about 12V) is being supplied
on P2-1 to the gate of T371, turning it 100% ON. With
T371 ON, current can flow through the drive shunt field
fuse, drive shunt field and T371 back to battery nega-
tive. When the drive shunt field is ON 100% at maxi-
mum strength, it adds to the motor torque.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY
E2 A1 A2 19 P3-13
(F2) REGEN COIL
DRIVE MOTOR
75 P3-14
D6D

XY
BATTERY
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR
P12-10

92
96

2EC1504

34
 SENB8604-02

When the drive power transistors (T1D and T2D) are

ON, battery current flows through the field windings of
the drive motor, and a magnetic field is created around
the windings. When the power transistors are turned
OFF, battery current through the windings stops, and
the magnetic field collapses. The collapsing magnetic
field induces current, which is used to power the drive
motor while the power transistors are OFF (during puls-
ing). Induced current flows from the field windings
through the forward contact tips, armature, forward
contact tips, current sensor regen contact tips and
diode D4D back to the field windings. Because of this,
the average drive motor armature current will be
greater than the average battery current. The drive
shunt field remains activated during flyback.
Average Current Flow

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY
E2 A1 A2 19 P3-13
(F2) REGEN COIL
DRIVE MOTOR
75 P3-14
D6D

XY
BATTERY
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR
P12-10

92
96

2EC1505

35
SENB8604-02

Electrical Braking
(Regenerative and Plugging)
Electrical braking permits the lift truck operator to slow,
stop, and change the direction of travel electrically
without having to use the service brake. This action
allows for smooth shuttle operation while saving wear
on the service brakes.
Trucks equipped with regenerative braking (“regen”)
use regenerative power to bring the truck to a stop.
Trucks not equipped with regen use plugging to bring
the truck to a stop. Plugging is the standard form of
electrical braking on 2EC15/18 trucks, although regen
can be added as an option. Regen is the standard
electrical braking on 2EC20-30 trucks.
Regen applies when armature generated current is
forced to flow backwards through the battery. This sys-
tem has much better braking characteristics than “plug
only” systems. The braking energy is used to charge
the battery momentarily, reduce heat build-up in the
drive motor, and extend motor brush life.

36
 SENB8604-02

Regenerative Brakes: Braking Circuit
2EC20-30 Standard Configuration)
Regen electrical braking begins when the operator
selects a direction opposite the truck’s motion while
keeping the accelerator depressed. The logics will
deactivate the regen and bypass contactors (if activat-
ed), turn the drive shunt field ON (if it was OFF), and
change the direction contactor to the new direction
selected. The logics will pulse the power transistors at
a slow rate.
When the drive power transistors (T1D and T2D) are
ON with the drive shunt field energized and the drive
motor turning opposite the direction selected, the drive
motor begins to act like a generator.
Battery current through the drive shunt field maintains
the magnetic field necessary for the motor rotation to
generate a voltage across the armature.
The generated voltage produces a current that flows
through the armature, through the direction contactor
tips, current sensor, regen diode D6D, power transis-
tors, motor series field, direction contactor tips, and
back through the armature. This generated current
energizes the drive motor series field, which tries to
turn the armature opposite the rotation caused by truck
motion. This brakes the truck electrically. The logics
controls the power transistor pulse rate to keep the
current below a preset level as monitored by the cur-
rent sensor. Refer to the Testing and Adjusting section
of this manual for proper setup procedures.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY 19 P3-13
E2 A1 A2
(F2) REGEN COIL
DRIVE MOTOR
75 P3-14
D6D

XY
BATTERY
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR
P12-10

92
96

2EC1506

37
SENB8604-02

When current peaks at its preset value, the logics will As electrical braking slows the truck, the motor gener-
turn OFF the power transistors. The generated current ates less and less current. The logics makes up for the
will flow from the drive motor field and armature, decreasing generated current by increasing the pulse
through the current sensor, D6D, line fuse, line contac- rate of the power transistors.
tor tips, battery, flyback diode D4D back to the drive
motor field. This is the charging cycle for the battery.
When the current decreases, the logics will turn ON the
power transistors, and the cycle starts again.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM
A1 A2 XY 19 P3-13
E2
(F2) REGEN COIL
DRIVE MOTOR
D6D

XY 75 P3-14
BATTERY
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR
P12-10

92
96

2EC1507

38
 SENB8604-02

Plugging Circuit
When the speed of the truck slows to less than 2kph
(1.2mph) the drive motor is no longer turning fast
enough to generate enough current to charge the battery.
The logics monitors this condition through the current
sensor and reactivates the regen contactor. To prevent
contactor tip arcing, the electrical braking of the truck
is paused while the regen contactor tips close.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY
E2 A1 A2 19 P3-13
(F2) REGEN COIL
DRIVE MOTOR
75 P3-14
D6D

XY
BATTERY
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR
P12-10

92
96

2EC1508

39
SENB8604-02

Plugging Circuit Plugging electrical braking (the standard configuration

(2EC15/18 Standard Configuration)
The logics generates a 750Hz pulsing signal on P2-5.
This is faster than can be seen on a voltmeter and
must be viewed with an oscilloscope. When this signal
is low, it indicates the power transistors T1D and T2D
should be on. When this signal is high, it indicates they
should be off. When P2-5 goes low, current flows from
BAT+ through the emitter/base junction of T314 and
T315, through R312, through P2-5 to BAT-.
for 2EC15 and 2EC18 trucks) begins when the operator
selects a direction opposite the lift truck’s motion, while
keeping the accelerator depressed. The logics will
deactivate the bypass contactor if activated and turn off
the drive shunt field. It will change the direction contac-
tor to the new direction selected. The logics will then
begin to pulse the drive shunt field. Because the motor
is turning it acts like a generator, and current begins to
flow through D5D. This causes wire #1 at the logics to
become more positive than the sensing wire #51 at P2-
17, due to the voltage drop across diode D5D.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY
E2 A1 A2 19 P3-13
(F2) DRIVE MOTOR
BATTERY
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21
P12-9
P12-10

92
96

2EC1509

40
 SENB8604-02

Drive Motor
The current in the drive motor is monitored and used to
adjust the duty cycle of the drive shunt field to maintain
plugging current. When the duty cycle on the drive
shunt field has reached 100% and the current starts to
fall below the plugging current limit, the main power
transistors T1D and T2D are turned on at a very low
duty cycle. When the transistors are ON, battery current
flows through the power transistors, drive motor field,
direction contactor tips, and current sensor back to
BAT-. The generated current will flow from the armature
through plugging diode D5D, back to the armature.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY
E2 A1 A2 19 P3-13
(F2) REGEN COIL
DRIVE MOTOR
D6D

BATTERY
XY 75 P3-14
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR
P12-10

92
96

2EC1510

41
SENB8604-02

When the power transistors are OFF, flyback current
from the collapsing motor field flows through the direc-
tion contactor tips, armature, direction contactor tips,
current sensor, and flyback diode D4D back to the
motor field. This current continues the electrical braking
action. As long as truck momentum is turning the arma-
ture opposite the pulsed direction, the motor continues
to act as a generator. The generated current flows
through the current sensor, plugging diode D5D, and
back to the armature. When the truck has come to a
stop, the armature no longer is turning opposite the
pulsed direction. The motor stops generating current, D5D
no longer conducts, and the logics no longer detects
that sensing wire #51 is lower voltage than wire #1.
The logics will switch into drive mode, and normal
acceleration in the opposite direction starts.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY
E2 A1 A2 19 P3-13
REGEN COIL
DRIVE MOTOR
D6D

BATTERY
XY 75 P3-14
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR
P12-10

92
96

2EC1511

42
 SENB8604-02

Current Limit
The logics monitors the current flow through T1D and
T2D and limits this current flow to a preset value. As Current Limit Setting
this current flows through T1D and T2D, the drive
motor and the current sensor, a voltage is created by
Current
the sensor. This voltage is proportional to the current In
flowing through the sensor and will increase or ARM “On” “Off”
decrease as current changes The logics uses this
voltage to monitor the current in the circuit. When the
current has increased too high, the logics decreases Time
the pulse rate to the transistors to prevent current
higher than the preset value. Current In Relation To Time
Current Limit

43
SENB8604-02
Thermal Protection Circuits
Control Panel
If the power transistors overheat, heat is transferred to
a thermal switch mounted in a common heatsink. The
thermal switch will open at a predetermined tempera-
ture. When it opens, voltage at logics connection P3-3
will go HIGH (15 volts). The instrument panel will dis-
play a “Run Time” diagnostic symbol. The logics will
decrease the current limit setting of the drive system. It
will also reduce hydraulic speed 6 and 7 to speed 5.
Speeds 8, 9, and 10 are not affected because these
speeds use the pump contactor, which does not add
heat to the panel.
Failure Protection Circuit
If the logics detects an improper voltage at P2-6 wire
#37 (drive circuit), P2-10 wire #45 (pump circuit) P2-2
wire #92 (drive shunt field circuit) or P2-4 wire #71
(pump shunt field circuit), the line contactor will be
deactivated and a “Run Time” diagnostic code (display
10 through 69) will replace the speedometer indicator.
Once a failure has been detected, the truck must be
repaired before normal operation can resume.
44
Hydraulic Pump Motor
If the pump motor overheats, a thermal switch mount-
ed in the pump motor housing will open at a predeter-
mined temperature. When it opens, voltage at logics
connection P3-2 will go HIGH. The instrument panel
will display a “Run Time” diagnostic symbol. To
decrease the amount of current allowed to flow through
the pump motor, the logics will restrict the hydraulic
pump motor to speed 8. When the hydraulic pump
motor cools and the thermal switch closes, the truck
will return to normal operation.
Drive Motor
If the drive motor overheats, a thermal switch mounted
in the drive motor housing will open at a predetermined
temperature. When it opens, voltage at logics connec-
tion P3-1 will go HIGH. The instrument panel will dis-
play a “Run Time” diagnostics symbol.
To decrease the amount of current allowed to flow
through the drive motor, the Logics will restrict the cur-
rent limit to 80% of P1 potentiometer and will also
deactivate the bypass contactor. When the drive motor
cools and the thermal switch closes, the truck will
return to normal operation.
 SENB8604-02

Bypass Circuit With Shunt Field
Activated
The bypass circuit bypasses T1D and T2D and con-
nects the drive motor in series with the battery, applying
full battery voltage to the drive motor. If the accelerator
pedal is fully depressed and the logics has pulsed T1D
and T2D up through 90% “on-time”, the logics will acti-
vate the BYPASS CTR in 1 to 4 seconds.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY
101 CTR CTR 102 35 P3-11
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY
E2 A1 A2 19 P3-13
(F2) REGEN COIL
DRIVE MOTOR
75 P3-14
D6D
XY
BATTERY
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR
P12-10

92
96

2EC1512

45
SENB8604-02

Bypass Circuit Without Shunt Field
Activated
With the accelerator fully depressed and the bypass
contactor closed, the logics starts to monitor drive
current and truck speed. When the drive motor current
decreases to a preset limit, the logics turns the shunt
field OFF. With the shunt field OFF, both armature current
and motor speed will increase. If the drive motor increases
above the preset limit (e.g. climbing a ramp or a hill) the
logics turns the shunt field back ON. This gives maximum
torque to climb ramps or steep grades.

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

R317
BYPASS 1
CTR
31
P12-5 1 31 P2-5
1
37 P2-6

P12-3
DRIVE
SHUNT FIELD
FUSE 15 AMP 1 101 P2-14
68 D1 82 P5-28 82 P1-7
(S1) 51 P2-17
102 P2-15
P12-4

D2 51
(S2)
68 39 P3-17
LINE FUSE DU2 LINE COIL

LOGICS
2 TO 3 TON XY 26 P3-9
36/48 VOLT
P32-6

LIFT COIL
675 AMP
600 AMP 107 108 X Y 30 P3-10
1 TON BYPASS COIL
FWD REV XY 35 P3-11
101 CTR CTR 102
LINE FWD COIL
CTR PUMP E1 XY 20 P3-12
MOTOR (F1) REV COIL
CIRCUIT ARM XY
E2 A1 A2 19 P3-13
(F2) REGEN COIL
DRIVE MOTOR
75 P3-14
D6D

XY
BATTERY
36/48 VOLT 1 HEAD REV FWD
P32-1
D5D

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

P16-1 2 P3-7
92
P16-2 42 P3-8
D361 T361
P12-7

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

P3-21
P3-20
P2-21
P1-21

REGEN
P12-9

CTR

92
96

2EC1501

46