Specifications Systems Operation Testing & Adjusting: Microcontroller Control System

SB2077E03
Jan 2002
Specifications
Systems Operation
Testing & Adjusting
MicroController Control System
Models : B13T-2, B15T-2, B18T-2
(48V: P/N A154600, P/N A154240)
(36V: P/N A154600, P/N A154701)
for Electric Lift Trucks

Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skill and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operater or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING” as
shown below.
WARNING
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this pulication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
MicroController Control Systems 1 Specifications

Index
Specifications
Component Measurements....................................... 5 Location of Control Panel Components .................. 16
Console ..................................................................... 7
Contactors................................................................. 8 Logic Unit ................................................................ 18
Control Panel (Layout) .............................................. 9
Current Measurements ............................................. 5 Operational Circuit Elements .................................. 19
Accelerator Control ............................................. 24
Direction Switch ........................................................ 7 Battery Discharge Indicator (BDI)....................... 23
Display Layout .......................................................... 7 Central Vehicle Monitoring System..................... 19
Contactors .......................................................... 22
Fuses ........................................................................ 8 Current Sensor ................................................... 22
CVMS International Pictorial Symbols................ 21
Head Capacitor ......................................................... 8 On Board “Run Time” Diagnostics
(Fault Detection) ................................................. 19
Instrument Panel ....................................................... 7 Steer Angle Control ............................................ 24
Wait Mode........................................................... 22
Thermal Switch - Control Panel ................................ 8
Transistor Connections ............................................. 6 Symbol Library ........................................................ 15
Transistor Measurements ......................................... 6
Testing And Adjusting

Systems Operation
Built-In Diagnostic Operation .................................. 47
Accessory Circuits .................................................. 25 Accessing Stored Error Codes ........................... 52
DC - DC Converter ............................................. 25 Erased Stored Error Codes ................................52
Horn Circuit......................................................... 25 “Run Time” Diagnostics
Hour Meter Circuit .............................................. 25 (Lift Truck in Operation) ...................................... 47
Quick Diagnostic Procedure ............................... 53
Actuation Circuit ...................................................... 26 Saving Service Records ..................................... 52
“Self” Diagnostics
Drive Circuit ............................................................ 34 (Lift Truck not in Operation) ................................ 49
Bypass Circuit..................................................... 39 Stored Error Codes............................................. 53
Control Circuit ..................................................... 34
Current Limit ....................................................... 38 Component Tests .................................................. 105
Electrical Braking (Plugging) .............................. 40 Capacitor (Head) .............................................. 108
Failure Protection Circuit .................................... 42 Conductor and Switch Continuity ..................... 108
Flyback Circuit .................................................... 37 Contactors ........................................................ 109
Power Circuit ...................................................... 35 Contactor Components..................................... 109
Thermal Protection Circuits ................................ 42 Current Sensor .................................................. 111
Diode Replacement .......................................... 112
General Information ................................................ 18 Diodes ............................................................... 112
Driver Board (Off Vehicle) ................................. 116
Glossary .................................................................. 11 Driver Board (On Vehicle)................................. 113
Logic Unit Quick Reference Voltage Check ..... 105
Hydraulic Pump Motor Circuit ................................. 27 Resistors (DR1, DR2, and PR1) ....................... 119
Flyback Circuit .................................................... 31 Thermal Switch ................................................. 120
Lift Circuit............................................................ 33 Transistors DTR1, DTR2 and PTR1 ................. 118
Lift Control Circuit ................................................32 Transistors Replacement
Power Steering Circuit .........................................27 DTR1, DTR2 and PTR1.................................... 118
Power Steering Idle .............................................28
MicroController Control Systems 3 Index

Control and Power System Operational
Checks .................................................................... 46
Electrical System Adjustments ...............................121

Accelerator Control Linkage ..............................121
BDI Adjustment ..................................................124
Bypass Dropout Adjustment ..............................128
Current Limit Test and Adjustment.....................127
Electrical Braking (Plugging) Current
Test and Adjustment ..........................................128
Lift Sensor..........................................................122
Parking Brake Switch.........................................121
Rapid Tune - Up Procedure...............................124
Tilt and Auxiliary Switches .................................123
Valve Control Card Adjustment..........................122
Preparation Tests and Checks .................................43
Programmable Features ........................................129

Activating Default Settings.................................129
Programmable or Settable Option
Features.............................................................130
Quick Procedure for Programmable
Features.............................................................132
Setting Procedure Option Features ...................129
System Tests and Adjustments ..............................102

Discharging Head Capacitor
(HEAD CAP) ......................................................102
Logics Removal .................................................103
“Run Time” Tests................................................103
Test Equipment ..................................................102
Troubleshooting........................................................43
Troubshooting Problem List ....................................54
MicroController Control Systems 4 Index

Specifications
Component Measurements
Meter Meter Positive Meter Negative

Component Desired Indication
Scale (+) Test Lead (-) Test Lead
DIODES (voltage indication)
All Diode Anode Cathode 0.3 to 0.9 volts
All Diode Cathode Anode OL
RESISTORS (resistance indication) Panels With D557003(927566) Transistor
DRI, DR2, PR1 200Ω 90 ohms L 5%
R2, R5, R9 200Ω 7.5 ohms L 5%
HEAD CAPACITOR (resistance indication)
Positive side of Negative side of 0 then change to
Head capacitor 200Ω
capactior (+) capactior (-) above 10K ohms
CONTACTOR COILS (resistance indication)
Direcitional 200Ω X Y 40 to 50 ohms
Line, Pump 200Ω X Y 95 to 115 ohms
Bypass 200Ω X Y 40 to 50 ohms
Current Measurements
CURRENT VALUES (AMPS)

Transistor Current Limit Plugging Limit
D557003 (927566) 250 L 10A 250 L 10A

Transistor Measurements
SPECIFICATIONS
Multimeter (+) (-) D557003 (927566)
Setting Test Lead Test Lead Results
Resistance Emitter Base 45 to 135 ohms
Diode Base Collector .3 to .9V
Diode Collector Base OL
Diode Emitter Collector .3 to .9V
Diode Collector Emitter OL
Transistor Connections
D557003 (927566)-for Pump(48V) D557065 - for Pump(36V)
1 2 1
2
3
3
(1) Emitter connection
(2) Base connection
(3) Collector connection

Display Layout Console
Instrument Panel
(1) Tighten bolts that fasten the cover to a torque
of ............................1.5 to 2.5 N•m (13 to 22 lb•in)
Direction Switch
1 2
(1) Tighten screws that fasten the instrument panel to

a torque of
....................................0.5 to 0.7 N•m (4 to 6 lb•in)
(1) Torque bolts that hold bracket to steering

column to ................2.8 to 3.4 N•m (25 to 31 lb•in)
(2) Torque bolts that hold bracket to switch to

............................143.4 to 3.9 N•m (31 to 35 lb•in)

Head Capacitor Thermal Switch - Control Panel
Contacts open at ................81 to 89°C (178 to 192˚F)
Contacts close at................69 to 77°C (156 to 171˚F)
1
2 Contactors
3 Torque for nuts that hold contactor bridge
4
assembly .........................................2.2 N•m (20 lb•in)
5
Fuses
Line .....................................................................600A
Pump ...................................................................150A
Key ....................................................................... 10A
NOTE : Proper torque and assembly of capacitor
Horn...................................................................... 10A
hardware is critical. Avoid disassembly
Voltage Converter................................................. 10A
unless capacitor has to be replaced.
Light...................................................................... 10A
Back up ................................................................ 10A
(1) Tighten capacitor terminal bolt to a torque
of.............................4.5 to 5.5 N•m (40 to 50 lb•in)
(2) Spring washer D917069.
(3) Ring terminal of wire assembly.
(4) Lockwasher D917071.
(5) Head capacitor terminal.

Control Panel (Layout)
Control Panel - Drive
2 3 6 4 7 11
12
5
2 8 10 9
Control Panel - Pump (48V)
3 2 6 10 9
11
5 4 7 12

12 10 9
3
4
7
1 5 11 6 11
NOTE : Apply a small amount of D557047 Thermal (7) Tighten diodes DD1, DD2, DD3, DD4 and PD to a
Joint Compound on the surface of the torque of ......................9 to 11 N•m (81 to 99 lb•in)
transistor, diode or thermal switch that
contacts the heatsink. (8) Tighten Head Capacitor terminal bolts to a torque
of ............................4.5 to 5.5 N•m (40 to 50 lb•in)
(1) Control panel plate. Apply a small amount of
D557047 Thermal Joint Compound on control (9) Tighten all bolts that fasten bus bars of cables to
panel plate and mating surface prior to assembly. either heatsink to a torque of
................................5.5 to 9.5 N•m (50 to 85 lb•in)
(2) Apply Sealant (Loctite catalogue No. and name-
No. 242, Adhesive/Sealant) on the threads of all
screws that are used to fasten components on the (10) Tighten bolts that hold the negative heatsink to
control panel. the control panel to a torque of .......10 to 14 N•m
(90 to 125 lb•in)
(3) Apply Sealant (Loctite catalogue No. and name-
No. 242, Adhesive/Sealant) to the bolts used to (11) Apply Sealant (Loctite catalogue No. and name-
tighten the positive heatsink to the control panel No. 242, Adhesive/Sealant) on portion of
to a torque of ..........10 to 14 N•m (90 to 125 lb•in) setscrew threads that are in the insulator and
control panel plate. Tighten bolts to a torque of
(4) Use a backup wrench to hold nuts and tighten ................................5.5 to 9.5 N•m (50 to 85 lb•in)
bolts the fasten bus bars to the power transistors
to a torque of ...............4 to 6 N•m (35 to 55 lb•in) (12) Use a backup wrench to hold bolts and tighten
the nuts that fasten the cables or bus bars to the
(5) Tighten screws that fasten power transistors to contactors to a torque of .....................4 to 6 N•m
positive heatsink to a torque of (35 to 55 lb•in)
......................................4 to 6 N•m (35 to 55 lb•in)
(6) Tighten screws that fasten wires to the base of

the power transistors to a torque of
.............................1.3 to 1.7 N•m (11.5 to 15 lb•in)

Systems Operation
Glossary
NAME DESCRIPTION
Accelerator A device that converts mechanical movement into a analog voltage pattern to the
logics for variable drive motor speed.
Activate 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.
Capacitor Device used to store electrical energy for short periods of time.
Cathode The negative (-) side of a diode.
CVMS Central Vehicle Monitoring System.
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.
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.
MicroController Control Systems 11 Systems Operation

NAME DESCRIPTION
Contactor Assembly An electrical component consisting of an electromagnetic 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 logic unit, turn
on main components, or support auxiliary circuits (indicated by narrow lines on a
schmatic).
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.
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 voltage.
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.
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).
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.
Harness An assembly made of two or more wires that are held together.
Heat Sink A mounting frame used for semiconductor cooling.

NAME DESCRIPTION
Hour Meter An electrically activated device used to record the amount of usage a truck
receives.
Indicator LCD 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.
LCD Liquid Crystal Display.
Logics or Logic Unit The main printed circuit board containing a microprocessor 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.
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 Close (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 opened 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.
Output The current flow from a component which initiated from a voltage change at the
component's input.
Overload The presence of voltage or current which is greater than an electrical circuit or
component is designed to handle.
Pin The male contact of a connector that fits into a female contact (socket) of another
connector.
Plugging A portion of electrical braking where the generated current is directed back through
the armature.
Plugging Current Limit The maximum allowable current at the drive motor armature during the plugging
portion of electrical braking.
Potentiometer An adjustable resistor to preset electronic controls for proper specifications.
Power Circuits The main current carrying components and conductors (indicated by the heavy
lines on a schematic).
Power Transistor A component in the power circuit which allows main motor current to pass through
when turned on.
Pulsing Current flow in a circuit being turned on and off.

NAME DESCRIPTION
Relay An electrical component consisting of an electromagnetic coil and a set of small

contact tips. Control current passes through the coil, building a magnetic field
which closes or opens the contact tips. When the contact tips are closed, low
current can flow in a separate isolated circuit.
Resistor A component made of a material that has a specific resistance to the flow of
current.
Schematic A line drawing of an electrical or electronic assembly which uses symbols to show
individual components. It shows how the components, wires and connectors
function electrically.
Semiconductor Components such as, transistors, diodes, thyristors, etc. Having electrical
characteristics between a conductor and an insulator.
Series Wound Motor A motor in which the armature is connected in series with the field windings.
Short Circuit An electrical connection between two or more components that is not desired.
Socket The female contact of a connector that slips over a male contact (pin) of another
connector.
Solid State Reference to semiconductor components or circuits that use semiconductor

components that have no moving parts, such as diodes and transistors.
Switch A component used to control an electric circuit . It can close or open a circuit.
Systems The electrical components, circuits, and connections that deliver power to perform
specific tasks.
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 connections to eliminate voltage spikes
when the horn is activated.
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 (voltage) 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 components 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.

Symbol Library
2 3 4 6
5
9
16
7 8
1 10
17
21
13
11 12
18
14
15
20
19
Schematic Symbols
(1) Power Transistor. (2) Zener Diode. (3) NPN Transistor. (4) PNP Transistor. (5) Thermal Switch. (6) Battery. (7) Resistor.
(8) Diode. (9) Normally Close Contacts. (10) Normally Open Contacts. (11) Male Terminal of Connector (pin).
(12) Female Terminal of Connector (socket). (13) Wire Connection. (14) No wire Connection. (15) Contactor Coil.
(16) Current Sensor. (17) Armature. (18) Field windings. (19) Capacitor. (20) Fuse. (21) Switch.

Location of Control Panel Components
Control Panel - Drive
3 4
1
5
2
6
8 9 10
11
13 14 12
MicroController Control Panel

(1) Logic Unit (Logics). (2) DR1, DR2. (3) Key Fuse. (4) Bypass Contactor. (5) Right Dir. Contactor. (6) Left Dir. Contactor. (7) PR1
(8) Board as – HYD. (9) Thermal Switch – HYD. (10) Fuse – HYD. (11) Line Fuse. (12) Line Contactor.
(13) PTR1 (Pump Transistor one). (14) PD (Pump Diode) Flyback Diode.

9 13 25
8
7
14
10 12 11
Behind Logic Unit
16 17 18 19 20
15
24 23 22 21
Components Behind Logic Unit (1)

(15) Head Capacitor. (16) Drive Board. (17) DTR2 (Drive Transistor Two). (18) Thermal Switch.
(19) DD3 (Drive Diode Three) Flyback Diode. (20) DD1 (Drive Diode One) Flyback Diode. (21) Current Sensors.
(22) DD2 (drive Diode Two) Plugging Diode. (23) DD4 (Drive Diode Four) Plugging Diode. (24) DTR1 (Drive Transistor One).
(25) Pump Bypass Contactor(36V only)

General Information
The speed of the hydraulic pump motor is controlled
The MicroControl Panel is the control center and the by switch inputs to and outputs from the logics.
Logic Unit (logics) is the decision making part of the Outputs pulses the hydraulic pump power transistor.
MicroController System. The logics provide a self The power transistor pulse to control the speed of the
contained Battery Discharge Indicator (BDI) with lift hydraulic pump motor. To provide full speed the
interrupt and built-in diagnostic capabilities. The logics turns the power transistor ON 100%. The
battery charge state and built-in diagnostic are hydraulic pump system includes a failure protection
monitored by the logics and displayed by the Central circuit to protect against malfunctions of the power
Vehicle Monitoring System (CVMS) located on the circuit.
steer console.
Thermal protection circuits are used on the hydraulic
pump motor, the drive motor and the control panel to
NOTICE prevent permanent damage caused by over heating.
Damage to all motors and control panels will
result. The motors and control panels are 48 volt
unit and must be operated at their designed
voltage. The voltage can not be changed without Logic Unit
changing motors and control panel.
The steering system is activated when the truck is

powered up and the line contactor closes. The truck 1 4 3 2
uses a combined power steering/hydraulic system
where the hydraulic fluid for steering is provided by a
DC series hydraulic motor, pump, and priority valve.
12 5
11
The drive motor and the hydraulic pump motor are 10 6
controlled by pulsing transistors ON and OFF and
controlling contactor operation. 9 7
8
The speed and direction of the drive motor are
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 and drive
transistor pulsing. Components on Logic Unit
(1) Connector P1
The drive circuit pulses transistors to provide travel (2) Connector P2
speed control up to 90% of full speed, after which the (3) Connector P9
bypass contactor closes to provide full speed. The (4) Connector P8
drive circuit includes a failure protection circuit which (5) DIAG/RUN/SETUP
detects malfunctions of the drive power circuit, a (6) Jumper JP1 - 36 V
plugging circuit to provide electrical braking and a (7) Jumper JP2 - 48 V
current limit circuit to prevent excessively high (8) VR1 potentiometer - Drive current limit adjustment
currents during transistor pulsing. (9) VR2 potentiometer - Plugging current limit
adjustment
(10) VR5 potentiometer - BDI adjustment
(11) VR6 potentiometer - Bypass dropout adjustment
(12) VR8 potentiometer - Electrical Assist Brake
adjustment
NOTE: When you change voltage jumper

(JP1 JP2), you should do the default
setting on page 129.

Operational Circuit Elements On Board “Run Time” Diagnostics
(Fault Detection)
Central Vehicle Monitoring System “Run Time” diagnostics use letters and numbers on
the seven segment LCD portion of the CVMS,
The Central Vehicle Monitoring System (CVMS) is International Pictorial Symbols and LCD to signal
located on the steering console. both improper operating sequences and truck circuit
It is a self contained, solidstate instrument panel with defects.
two seven segment liquid crystal displays, warning
and system condition segments. Display = “EE” Static Return to Off (SRO)
The LCD consists of seven segments which are
turned on or off to form numbers and letters. The logics has a Static Return to Off (SRO) circuit
which assures that the direction switch has been
returned to neutral and the accelerator returned to
the full up position after the key and seat switch are
closed. This safeguards against an accidental
actuation of direction and speed when an operator
resumes operation of an idle truck.
If SRO occurs, the direction lever can be moved to
neutral and the accelerator pedal released.
The direction can now be reselected and the
accelerator pedal depressed to start normal lift truck
drive operation.
Display = “EE” (Flashing) Seat Circuit Problem
Anytime the battery is connected, the key is turned to

ON and no one is in the seat longer than 6 seconds
the letter “EE” will flash on and off.
The truck will not operate until the seat switch is
Seven Segment Display Layout
closed.
The Central Vehicle Monitoring System interacts with
Display = “E1” Drive Motor Brush Problem
the logics and failure detection circuits.
It functions as a battery discharge indicator (BDI) and
The logics monitor the length of the brushes in the
provides on-board diagnostic data on the operational
drive motors. As the brushes wear, a wire built into
condition of the truck.
the brushes moves down and makes contact with the
During normal operation it provides “Run Time”
commutator. A wire from each motor brush set is
diagnostics, and during troubleshooting it provides
connected to the logics. If any brushes wear down to
“Self” diagnostics.
a preset limit, an “E1” will display on the LCD.
Display = “E2” Pump Motor Brush Problem
The logics monitor the length of the brushes in the

pump motor. As the brushes wear, a wire built into
the brushes moves down and makes contact with the
commutator. A wire from each motor brush set is
connected to the logics. If any brushes wear down to
a preset limit, an “E2” will display on the LCD.

Display = “EL” Battery Lock-out Display = “F5” Drive System Problem (Left)
When the battery is discharged, the CVMS displays The logics at P9-5 uses wire #L64 from the emitter of
“EL” and pump motor will not operate. If key switch the left drive transistor to detect battery negative. The
turn off and then on, pump will operate for only 3 logics sends a test pulse out to the left drive
seconds. Drive motor speed will not exceed 70% of transistor when power up. This test pulse is detected
the max. regardless of an accelerator’s output at P9-5 also. If battery negative is present or the test
voltage. pulse is not detected, the line contactor will be
deactivated and an “F5” will display on the LCD.
Display = “F2” Drive System Problem (Left)
Display = “F5” (Flashing) Drive System Problem
The logics at P9-5 uses wire #L64 from the emitter of (Right)
the left drive transistor to detect if the left drive
transistor, bypass contactor tips or the driver board The logics at P9-6 uses wire #R64 from the emitter
are shorted. In normal operation P9-5 has battery of the right drive transistor to detect battery negative.
voltage only when the logics is pulsing the left drive The logics sends a test pulse out to the right drive
transistor or the bypass contactor is activated. transistor when power up. This test pulse is detected
When a failure occurs the line contactor will be at P9-6 also. If battery negative is present or the test
deactivated and an “F2” will display on the LCD. pulse is not detected, the line contactor will be
deactivated and an “F5” will flash on the LCD.
Display = “F2” (Flashing) Drive System Problem
(Right) Display = “F6” Pump System Problem
The logics at P9-6 uses wire #R64 from the emitter The logics at P9-7 uses wire #74 from the emitter of
of the right drive transistor to detect if the right drive the pump transistor to detect battery negative.
transistor, bypass contactor tips or the driver board The logics sends a test pulse out to the pump
are shorted. In normal operation P9-6 has battery transistor when power up. This test pulse is detected
voltage only when the logics is pulsing the right drive at P9-7 also. If battery negative is present or the test
transistor or the bypass contactor is activated. When pulse is not detected the line contactor will be
a failure occurs the line contactor will be deactivated deactivated and an “F6” will display on the LCD.
and an “F2” will flash on the LCD.
Display = “F7” Drive and Pump System Problem
Display = “F3” Pump System Problem
The logics will release the line contactor and display
The logics at P9-7 uses wire #74 from the emitter of “F7” on the LCD when BOTH wires #64 and #74
the pump transistor to detect if the pump transistor or detect battery negative or do not detect the proper
the driver board are shorted. pulsing.
In normal operation P9-7 has battery voltage only See “F5”, “F5” (Flashing) and “F6”.
when the logics is pulsing the pump transistor is
activated. When a failure occurs the line contactor Display = “FA” Angle Circuit Problem
will be deactivated and an “F3” will display on the
LCD. Steer angle commands are monitored by the logics.
If steer angle switch has defects or each wires #50,
Display = “F4” Drive and Pump System Problem 51, 52 and 53 is shorted/opened, the line contactor
will be deactivated and an “FA” will display on the
The logics will release the line contactor and display LCD.
“F4” on the LCD when BOTH wires #64 and #74
detect battery voltage when it should not be present.
See “F2”, “F2” (Flashing) and “F3”.

Display = “Fb” Battery Mismatch Central Vehicle Monitoring System
The motors and control panels are 48 volt (or 36 volt)
(CVMS) International Pictorial
units and must be operated at 48 volt(or 36 volt) Symbols
. If battery condition is abnormal, an “Fb” will display
on the LCD. Refer to problem 42 in troubleshooting. Park Brake Symbol
Display = “Fd” Pressure Switch Problem
The logics at P 2-1 uses wire #41 from the pressure

switch to detect if the pressure switch is opened for
more than 10 seconds after the key switch ON. The
“Fd” will be displayed and the truck will be operated
normally.
Park Brake Symbol
If the park brake is applied, the park brake symbol

will turn on to warn the operator that the brake is
applied, and drive operation will be prevented.
Overtemperature Symbol
Normally closed thermal switches are constantly

monitored by the logics and the CVMS. All these
thermal switches are normally closed, so must open
for the LCD to turn on. Truck performance will
automatically be cut back by the logics, and the
CVMS will light the LCD until the component cools.
Control Panel Overtemperature Symbol
Control Panel Overtemperature Symbol
Two thermal switches (HYD and MAIN control

panels) are connected in series to the logics. If any
of the control panels overheat, the thermal switch in
the center of the positive heatsink will open. The
logics will slow lifting speeds and reduce drive speed.
Truck acceleration will decrease.
The overtemperature symbol and “Ec” will display on
until the controller cools. “Ec” will be saved as stored
error code.

Drive Motor Overtemperature Symbol Wait Mode
If the seat switch is closed, key turned to ON and the
direction lever is left in neutral with no other operator
requests, the line contactor will deactivate after
approximately six seconds. The LCD will display
“PP”. The lift truck will remain in this condition until
the operator activates the direction switch,
accelerator pedal or a control valve lever. The line
contactor then reactivates and the truck is ready for
normal operatation.
Drive Motor Overtemperature Symbol
Current Sensor
The drive motor thermal switch, held against the
drive motor field, will open if the motor gets too hot. The left current sensor mounts around the cable that
The logics will reduce drive pulsing and prevent the carries left drive motor current. The logics supplies a
bypass contactor from pulling in. The truck speed constant voltage to one lead of the current sensor at
and acceleration will be reduced. P1-16 wire #25 (12V). A second lead of the current
The overtemperature symbol and “Ed” will display on sensor is connected to battery negative at the
until the motor cools. “Ed” will be saved as stored negative heatsink. When current passes through the
error code. cable, the third current sensor lead wire #L22 causes
the voltage to change at logic P1-12. As the current
Pump Motor Overtemperature Symbol passing through the cable increases, the voltage at
logic P1-12 increases. The logics uses the voltage at
P1-12 to determine the amount of current flowing
through the left drive motor.
The right current sensor, similar to the left current

sensor, mounts around the cable that carries right
drive motor current. A third lead of the right current
sensor is connected to logics at P1-13 #R22. The
logics uses the voltage at P1-13 to determine the
amount of current flowing through the right drive
motor.
Pump Motor Overtemperature Symbol
The pump motor thermal switch, similar to the drive Contactors

motor thermal switch, will open if the motor gets too
hot. The logics will reduce pump motor speeds. The control panel is equipped with intermittent duty
The overtemperature symbol and “EP” will display on contactors. The logics controls the voltage supplied
until the pump motor cools. “EP” will be saved as to the coils. When a contactor is first activated, full
stored error code. battery voltage is supplied to the coil. After the
contactor tips have closed, the logics will pulse the
coil to reduce the voltage across the coil to between
18 and 36 volts.

Battery Discharge Indicator (BDI) BATTERY TERMINAL VOLTAGE
BAR SYMBOLS
The logics monitors the battery voltage during truck TYPE 1 (OPT) : Closed Voltage
DISPLAY
operation and shows the level of battery charge on 36V 48V
the LCD. If the battery voltage is below 40.0V or
6 above 37.2 above 49.1
above 60.0V, this is a battery mismatch or
misconnection. If these voltages are monitored, the 5 36.8 to 37.2 48.6 to 49.1
display will show “Fb” on the LCD and no lift truck 4 36.4 to 36.7 48.0 to 48.5
operate.
3 36.0 to 36.3 47.5 to 47.9
Full 6 bars on the LCD indicates a fully charged 2 35.6 to 35.9 47.0 to 47.4
battery. As the battery discharges, the bars
1 35.2 to 35.5 46.5 to 46.9
decreases to 5, 4 etc, down to 1st bottom bar.
1* 25.8 to 35.1 33.8 to 46.4
When the battery nears the 80% discharge level, the O/EL below 25.8 below 33.8
1st bar continuously flashes. This is a warning that lift
interrupt is near. The operator should complete the 1* = Display is flashing
current lift operation and travel to the battery
replacement or charge area. If the truck is kept in
operation, the display go to a “EL”. The lift, tilt and BATTERY TERMINAL VOLTAGE
auxiliary functions will be vastly reduced in speed, BAR SYMBOLS
TYPE 2 (STD) : Closed Voltage
operating only with steering flows and the vehicle DISPLAY
travel speed will be cut in harf. At this point the 36V 48V
battery is greater than 80% discharged. The logics
will now remember that the battery has been
discharged to lift interrupt and require a fully charged 5 36.8 to 37.2 48.4 to 49.1
battery to reset the remembered interrupt. See 4 36.3 to 36.7 47.7 to 48.3
Programmable Option Features “3”.
3 35.9 to 36.2 47.1 to 47.6
Due to different voltage characteristic of battery 2 35.4 to 35.8 46.4 to 47.0
technologies, it may be necessary to use the battery
1 35.0 to 35.3 45.9 to 46.3
voltage chart as shown below. You can choose a
type in Programmable Option Features “10”. 1* 34.5 to 34.9 45.0 to 45.8
O/EL below 34.5 below 45.0
Descriptions of BDI symbol on the LCD 1* = Display is flashing
Bar Symbols
BATTERY TERMINAL VOLTAGE
BAR SYMBOLS
6 : The highest position : Max. charged status TYPE 3 (OPT) : Closed Voltage
DISPLAY
36V 48V
5:
4: 5 36.9 to 37.2 48.3 to 49.1
3: 4 36.6 to 36.8 47.4 to 48.2

3 36.3 to 36.5 46.6 to 47.3
2:
2 35.9 to 36.2 45.7 to 46.5
1: 1 35.6 to 35.8 44.9 to 45.6
: A) Not flashing
B) Flashing - 80% 1* 35.3 to 35.5 44.0 to 44.8
discharge O/EL below 35.3 below 44.0
warning.
1* = Display is flashing

Accelerator Control Steer Angle Control
Accelerator Table Two drive motors are controlled independently
according to steer wheel position. A direction of drive
motors is determined with wheel angle as shown in
OUTPUT the chart.
REMARKS
VOLTAGE
WHEEL ON - TIME(%)
OVER ACCELERATOR CIRCUIT P2-17 P2-18 P2-19 P2-20
ANGLE LEFT RIGHT
11.00 DEFECT
-90° LOW HIGH HIGH HIGH (-)50 50
BYPASS OPERATION
9.60 DRIVE SPEED (100%) -75° LOW HIGH HIGH LOW 0 75
-45° LOW HIGH LOW LOW 75 100
DRIVE SPEED STEP 14
9.02 DRIVE SPEED STEP 13 L 25° LOW LOW LOW LOW 100 100
8.44 **DEAD ZONE I**
+45° HIGH LOW LOW LOW 100 75
DRIVE SPEED STEP 12
7.86 +75° HIGH HIGH LOW LOW 75 0
DRIVE SPEED STEP 11
7.28 +90° HIGH HIGH LOW HIGH 50 (-)50
DRIVE SPEED STEP 10
6.70 (–) means that the motor will turn opposite direction.
DRIVE SPEED STEP 9
6.12
DRIVE SPEED STEP 8
5.54
DRIVE SPEED STEP 7
4.96
DRIVE SPEED STEP 6
4.38
DRIVE SPEED STEP 5
3.80
DRIVE SPEED STEP 4
3.22
DRIVE SPEED STEP 3
2.64
DRIVE SPEED STEP 2
2.06
DRIVE SPEED STEP 1
1.48
DRIVE SPEED STEP 0
0.90
0.00 **DEAD ZONE II**
i) DEAD ZONE I
In order to eliminate the bypass contactor
chattering, the bypass contactor will be engaged if
the accelerator output voltage is over than 9.6V.
But the bypass contactor should be disengaged if
the accelerator output is less than 9.02V.
ii) DEAD ZONE II

In order to eliminate the direction contactors
chattering, the direction contactors will be
engaged if the accelerator output voltage is over
than 1.48V.
But the direction contactors should be disengaged
if the accelerator output is less than 0.9V.

Accessory Circuits
Horn Circuit
The horn will operate when the battery is connected The 12 volt output of the converter is protected
and the horn button is pushed. Current flows from against short circuits and overloading by an internal
battery positive through horn fuse, horn switch and 15 amp current limit circuit. A fuse on the converter
horn, back to battery negative. protects it from reverse connection of the battery
voltage.
Refer to Problem 31 in Troubleshooting section.

Hour Meter Circuit
The hour meter, dependent on marketplace, can be
NOTICE
wired a number of different ways. Battery voltage is
Do not connect the 12volt negative output of the
always supplied from the key switch to the positive
DC-DC converter to battery negative. Damage to
terminal of the hourmeter. The negative terminal of
system components could occur.
the hourmeter can go to seat switch to record seat
switch hours, or can be wired into the drive motor
armature through a diode assembly to record drive
motor hours.
DC-DC Converter
DC-DC Converter Circuit System
The DC-DC converter changes the lift truck battery

voltage to 12 volts. This 12 volts is used to power
accessories such as floodlights, brakes/side lights
and backup alarms.
The positive of the 12 volt output is common to the

positive of the battery voltage. The negative of the 12
volt output is pulsed to maintain a steady 12 volt
supply.

Actuation Circuit
Actuation Circuit
NOTE: The circuit diagrams have shaded lines for When the battery is connected and the key switch is
illustration of current flow in each circuit. closed, current flows from battery positive
Other circuits can be activated at the same through the key fuse, key switch, wire #5 to the logic
time, but each one is shown separately to connector P1-1 and P1-2.
illustrate current flow in each individual The logic connection to battery negative is at P1-19
circuit. and P1-20. The logic circuits are powered up
to accept voltage inputs and create voltage outputs
This circuit supplies power to the MicroController
whenever the battery is connected and the key is
Control System and the Central Vehicle Monitoring
turned to ON.
System (CVMS). It must be activated before power
steering, hydraulics or drive will operate.

The Central Vehicle Monitoring System (CVMS) is Hydraulic Pump Motor Circuit
also powered at this time. The CVMS first does
a “LCD test” which will light all the warning lights Only one hydraulic pump motor (series winding) is
through 6 shield wires, wire #101(5V) and wire #108 used for all power steering, lift, tilt and auxiliary
(B-) for approximately five seconds. hydraulic functions. To activate the pump circuit, the
seat switch, key switch and line contactor must be
The logics will start to perform a set of “Run Time” closed first as explained in the topic, Actuation
diagnostic checks. The letter “EE” will flash on the Circuit.
CVMS display indicating the key is ON with no
operator in the seat.
When the seat switch is closed, current will flow from Power Steering Circuit
the logic P2-7 through the seat switch to battery
negative. The logics then activates the line contactor The power steering (PS) circuit has two speeds
by allowing current to flow from P1-3 through the line (PS idle and PS boost-up) independent of the lifting
contactor coil and P1-4 back to battery negative. speeds.
With the line contactor tips closed the logics Followings are standard PTR1 pulsing rates of the
continues its checks for any “Run Time” faults. signal at the logics.
If no faults are detected the display will indicate the
battery charge level, the power steering (IDLE)
system operates, the pump and drive power circuits Motor Speed PTR1 Pulsing Rate Logic Pin#
receive battery voltage and the logics receives
IDLE 11% –
battery voltage on wire #4 at P9-9.
POWER STEERING 23% P2-1
TILT 50% P2-2
LIFT1 35%
LIFT2 50% P2-3 & P2-4
LIFT3 95%
AUX1 50% P2-2
AUX2 45% P2-16
The above pulsing rate can be adjustable in

“Programmable Option Features”.
NOTE: The circuit diagrams have shaded lines for

illustration of current flow in each circuit.
Other circuits can be activated at the same
time, but each one is shown separately to
illustrate current flow in each individual circuit.

Power Steering Idle
Transistor PTR1 Pulsing
TR5 Base Input Signal
After the line contactor is closed the logics generates logics is ON at TR5, TR5 will be ON.
a positive pulsing signal (approximately 0.7 volts) on When the base signal is OFF, TR5 will be OFF.
P9-3 to the base of transistor TR5. This is a rapidly
changing signal that can only be viewed on an
oscilloscope. Because TR5 is a NPN type transistor,
the positive signal into the base causes current flow
through the base/emitter junction. When current
flows through the base/emitter junction the transistor
turns ON and main current will flow through the
collector/emitter junction. If the base signal from the

TR6 Base Input Signal, TR5 ON
When TR5 is ON, current flows through the

emitter/base junction of transistor TR6, through PR1
and TR5 to battery negative. Because TR6 is a PNP
type transistor, the current flow to battery negative
through the emitter/base junction causes TR6 to turn
ON. When TR5 is OFF, TR6 is OFF.

PTR1 Base Input Signal, TR5 and TR6 ON
When TR6 is ON, current flows through TR6 into the

base of transistor PTR1. This puts a voltage signal at
the base of PTR1 causing PTR1 to turn ON.
With PTR1 ON, high amperage motor current can
flow through PTR1, motor armature and motor field
to battery negative.
When TR5 and TR6 are OFF, PTR1 is OFF.
The percent “on-time” of the signal at the logics is
also the percent “on-time” of PTR1.
PTR1 is pulsed at 11% “on-time” supplying 11% of
battery voltage to the pump motor (IDLE).

Flyback Circuit
Flyback Circuit
PD is a flyback diode for the power steering and

hydraulic motor circuit. This circuit uses the current
created by the collapsing magnetic field of the field
windings in the pump motor to keep current flowing
when transistor PTR1 is OFF. When PTR1 is OFF all
current from the field goes through P2, PD, P1 and
pump motor armature (ARM) back to the field.
When PTR1 is pulsing the flyback circuit causes the

average pump motor current to be greater than the
average battery current through PTR1.

Lift Control Circuit
Location of Components
(1) Valve control card.
This control panel accept a three speed lift control When the operator pulls the lift lever, magnet (3)
signals and tilt/aux lever signals. The three speed lift moves closer to the lift sensor (2). The sensor
control system is controlled by valve control card (1) detects the increasing magnetic field and sends an
mounted at the top of the control valve. increasing voltage to the valve control card. The
valve control card produces voltage changes which
The valve control card uses a hall-effect transducer input to the logics at P2-3 and P2-4 The logics uses
(LIFT SENSOR) and a magnet to sense lift lever these changing voltages to determine what speed to
movement. The closer the magnet is to the operate the pump motor. The logics then controls the
transducer the greater the hydraulic pump motor pump transistor PTR1. The pump motor lift speed as
speed. shown in the chart.
Motor Pulse
P2-3 P2-4 PTR1
2 Speed Ratio
0 12V 12V Steering Variable
1 0.2V 12V 35% Pulsing Variable
2 0.2V 0.2V 50% Pulsing Variable
3 12V 0.2V 95% Pulsing -
3
Variable : Set by Option Programmbles Feature.
Pump Bypass Contactor (36V only)
The Pump Bypass contactor will close at Lift Speed 3

on 36V system. Also this contactor will activate if the
Aux2 speed was set at 95% pulsing in option
programmable Feature 15.
(2) Lift Sensor. (3) Magnet.

Lift Circuit
Lift Circuit
If the streeing wheel is turned, hydraulic pressure When the lift lever is pulled to lift speed 1 the logics
increases and a pressure switch (PRESSURE SW) will pulse the pump transistors PTR1.
located in the steering gear load sensing hose, will
open. This causes the voltage at logic connector As shown in the chart under Lift Control Circuit, if the
P2-1 to change from a LOW (less than one volt) to a lift lever is pulled to lift speeds 2 through 3 the pump
HIGH (12 volts). When a HIGH is present the logics transistors are pulsed with a higher percent “on-time”.
knows that more hydraulic flow is required and will The pump motor armature will turn faster.
supply a pulse from P9-3 to PTR1 at rate of 23%
“on-time” for 48 volt trucks. The pump motor speed
will increase.

Drive Circuit
Control Circuit
Drive Control Circuit
NOTE: The circuit diagrams have shaded lines for Selecting a direction will change the voltage from
illustration of current flow in each circuit. HIGH to LOW on P2-5 for forward or P2-6 for
reverse. Depressing the accelerator pedal will cause
With the actuation circuit complete the logics the accelerator analog voltage on P1-15.
supplies a HIGH voltage (12volts) to the direction With the forward direction selected current flows from
(F/R) switch at P2-5 and P2-6. A HIGH voltage is the logics P1-3 through forward direction
also supplied to the power of accelerator at P1-16. contactor coil to logics P1-5 and P1-7 back to battery
Releasing the park brake closes the park brake negative. The forward contactors tips close.
switch and provides a path to battery negative.

Power Circuit
TR2 and TR4 Base Input Signal
NOTE: The circuit diagrams have shaded lines for The logics generates a positive pulsing voltage
illustration of current flow in each circuit. (approximately 0.7 volts) on P9-1 and P9-2, to the
Other circuits can be activated at the same base of transistors TR2 and TR4. These pulses turn
time, but each one is shown separately to ON TR2 and TR4 which turn ON TR1 and TR3. A
illustrate current flow in each individual more complete description of this transistor turn on
circuit. circuit can be found in : Hydraulic Pump Motor
Circuit under Power Transistor Pulsing.
The high amperage current, which provides the
power and torque necessary to drive the lift truck,
flows in this circuit. The speed of the drive motor is
controlled separately from the pump motor
circuit by the MicroController Control System.

Power Transistors, TR1, TR2, TR3 and TR4 all ON
When TR1 and TR3 are ON, current flows through The percent “on-time” of the voltage at logics P9-1
TR1 and TR3 emitter/collector into the base of drive and P9-2 is also the percent “on-time” of the power
power transistors (DTR1 and DTR2). This puts a transistors. As the “on-time” increases, the average
HIGH voltage at the base of the power transistors voltage applied to the drive motor increases which
causing them to turn ON. With the power transistors increases the speed of the lift truck. The percent
ON, high amperage motor current can flow through “on-time” out of the logics is determined by how far
them, the field, forward contact tips, armatures, the accelerator is depressed.
forward contact tips and current sensors back to
battery negative. When TR1 and TR3 are OFF,
the power transistors are OFF.

Flyback Circuit
Flyback Circuit
When the drive power transistors (DTR1 and DTR2) Because of this, the average drive motor armature
are ON, battery current flows through the field current will be greater than the average battery
windings of the drive motor and a magnetic field is current. Refer to following Average Current Flow
created around the windings. When the power chart.
transistors are turned OFF battery current through
the windings stops and the magnetic field collapses.
This collapsing magnetic field induces current which
is used to power the drive motor while the power
transistors are OFF (during pulsing). Induced current
flows from the field windings through the forward
contact tips, armature, forward contact tips, current
sensor and diodes DD1, DD3 back to the field
windings.

Average Current Flow
Current Limit
The logics monitors the current that flows through through the sensor and will increase or decrease as
DTR1 and DTR2 and limit this current flow to a current changes. The logics uses this voltage to
preset value. As this current flows through DTR1 and monitor the current in the circult.
DTR2 the drive motor and the current sensors, a When the current has increased too high, the logics
voltage is created by the sensor. decreases the pulse rate to the transistors to prevent
This voltage is proportional to the current flowing current higher than the preset value.

Bypass Circuit
Bypass Circuit Activated
The bypass circuit bypasses DTR1 and DTR2 and

connects 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 DTR1 and DTR2 through 92% “on-time”,
the logics will activate the BYPASS CTR after 1.5
seconds.

Electrical Braking (Plugging)
Plugging Circuit (Transistor DTR1, DTR2 “ON”)
Plugging is an electrical braking mode which permits When DTR1 and DTR2 are ON, battery current flows
the lift truck operator to slow, stop and change the through DTR1 and DTR2, field windings, direction
direction of travel electrically without using the contactor tips, armature, direction contactor tips and
service brake. current sensor back to the battery. Current energizes
Plugging begins when the operator selects a the field and tries to turn the armature opposite the
direction opposite the lift truck’s motion, while rotation caused by the truck’s motion. The current
keeping the accelerator depressed. The logics will acts to electrically brake the truck. With the field
deactivate the bypass contactor (if activated) and energized and momentum of the truck turning the
change the direction contactors to the new direction armature opposite the pulsed direction, the armature
selected. The momentum of the truck causes the generates current.
drive motor to generate current, and the logics will
puise the transistors at a slow rate.

Plugging Circuit (Transistor DTR1, DTR2 ”OFF”)
The generated current flows from the armature back to the field. This current continues the electrical
through the direction contactor, current sensor and braking action. As long as the truck momentum is
diode DD2, DD4, back to the armature. When turning the armature opposite the pulsed direction,
armature generated current flows through DD2, DD4 the motor continues to act as a generator with
wire #1 at P1-20 becomes a more positive voltage armature generated current flowing through DD2,
than plug sensing wire #32 at P1-10, P1-11, due to DD4 back into the armature.
the voltage drop across DD2, DD4. The logics When the truck has come to a stop, the armature no
detects the voltage change at P1-20 and P1-10, P1- longer is turning opposite the pulsed direction. The
11, then reduces the tansistor pulsing to stay below armature stops generating current and DD2, DD4 no
the preset plugging current limit. longer conducts. The logics no longer detects a more
When DTR1 and DTR2 are OFF, flyback current negative voltage on plug sensing wire #32 than on
from the collapsing motor field flows through the wire #1, so normal drive operation begins in the
direction contactor tips, armature, direction contactor opposite direction.
tips, current sensor and diode DD1, DD3,

Thermal Protection Circuits
Control Panel Hydraulic Pump Motor
If the power transistors overheat, a thermal switch If the hydraulic pump motor overheats a thermal
mounted in the transistor heatsink will open at a switch mounted in the pump motor housing will open
predetermined temperature. When it opens, voltage at a predetermined temperature. When it opens,
at logic connection P2-11 will go HIGH (12 volts). voltage at logic connection P2-13 will go HIGH. The
The Central Vehicle Monitoring System will display a Central Vehicle Monitoring System will display a “Run
“Run Time” diagnostic symbol. Time” diagnostic symbol. To decrease the amount of
The logics will decrease the pulsing of the drive current allowed to flow through the pump motor, the
system and restrict the hydraulic circuit pulsing to logics will reduce the hydraulic pump motor to 50%
50%. The amount of current allowed to flow through pulsing. When the hydraulic pump motor cools off
the power transistors is decreased to permit them to and the thermal switch closes, the truck will return to
cool. When the heatsink cools off and the thermal normal operation.
switch closes, the truck will return to normal An “EP” is stored in memory.
operation. Drive system bypass is not affected by an
overheated control panel, but due to the reduced
pulsing acceleration performance will be decreased.
An “Ec” is stored in memory. Failure Protection Circuit
If the logics detects an improper voltage at P9-5 wire
Drive Motor #L64 (left drive circuit) and/or P9-6 wire #R64 (right
drive motor) or P9-7 wire #74 (pump circuit), the line
If the drive motor overheats a thermal switch contactor will be deactivated and a “Run Time”
mounted in the drive motor housing will open at a diagnostic code (display = “F2” through “F7”) will
predetermined temperature. When it opens, voltage display.
at logic connection P2-12 will go HIGH. Current is also monitored in the drive motor, and
The Central Vehicle Monitoring System will display a should it exceed preset limits in either pulsing or
“Run Time” diagnostic symbol. To decrease the bypass the truck will shut down and display an “F0”.
amount of current allowed to flow through the drive The logics will monitor the four steering angle switch
motor, the logics will reduce the pulsing and disable signals, wires #50, 51, 52 and 53 to determine if
the bypass contactor. When the drive motor cools off there is an out of sequence problem.
and the thermal switch closes, the truck will return to An “FA” will be displayed if this should occur.
normal operation. If the battery voltage is mismatched, the “Fb” will
Drive system acceleration performance and top travel display.
speed is affected by an overheated drive motor. The logics will monitor the two current sensor
An “Ed” is stored in memory. signals, wires #L22 and #R22 to determine if there is
an wrong voltage pattern. An “F5” will be displayed.
Once a failure has been detected the truck must be
repaired before normal operation can resume.

Testing And Adjusting
Troubleshooting
NOTICE
The following Troubleshooting Check List is an aid in Damage can be caused to the control panel. Do
troubleshooting MicroController lift trucks. The not switch the direction lever from one direction to
troubleshooting check list, “Run Time” diagnostic the other (plug the lift truck) when the drive wheels
indications, “Self” diagnostic tests, problem list and are off the ground and in rotation at full speed.
problem flow charts will assist in:
1. Defining the problem and verifying a problem

exists. Troubleshooting Check List
2. Performing the checks in a logical order. 1. Perform Preparation Tests and Checks.
3. Making the necessary repairs. 2. Correct any display problems and “Run Time”
diagnostic faults.
4. Verifying the problem has been resolved.
3. Correct the “Self” diagnostic faults.
WARNING 4. Perform Operational Checks.
The lift truck can move suddenly.Battery voltage 5. Correct “Failure Code Problems” in the
and high amperage are present. Injury to Troubleshooting Problem List.
personnel or damage to the lift truck is possible.
Safely lift both drive wheels off the floor. Put blocks 6. Perform Operational Checks to verify repairs.
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 Preparation Tests and Check
battery and discharge HEAD CAP. Ring's,
watches and other metallic objects should be
removed from hands and arms when Battery Tests
troubleshooting, the MicroController Control
System. A weak battery can cause or contribute to problems
in the MicroController and power circuits.
Verify the battery is good before investigating other
possibilities.
NOTICE 1. Verify proper polarity at the battery connector and

Damage can be caused to the test equipment. the MicroController panel. Positive cable should be
Make resistance and continuity checks only after at the line contactor and negative at the negative
the battery is disconnected. heatsink.
2. If the lift truck is operational, perform a battery

load test.
NOTICE 3. If the truck is not operational and the battery is

Damage can be caused to the control panel. Do suspected, perform a cell voltage or specific
not use steam or solvent to clean the controls. Use gravity test.
pressure from an air hose with a maximum
pressure of 205 kPa (30 psi) to clean the control
panel when necessary. Make sure the air pressure
supply is equipped with a water filter.
MicroController Control Systems 43 Testing And Adjusting

Battery Load Test
Cell Voltage Test
1. Turn the range switch on the multimeter to read
battery voltage. With the truck powered up and the power steering
motor running, measure the voltage at each cell.
2. Connect the battery. Normal voltage should be between 1.95V and 2.12V
per cell. If the voltage on each cell is below 1.95V the
48V battery must be charged or repaired before
continuing to troubleshoot.
NOTE : The indication between cells should not differ

more than 0.05 volts. If it does, the battery
2 must have an equalizing charge or be
repaired.
Hydrometer Test
1 Test each cell of the battery with a hydrometer. If the
specific gravity indication is below 1.140, the battery
must be charged. The battery is fully charged if the
indication is 1.265 to 1.285.
Battery Voltage Test.
(1) Positive cable connection. NOTE : The indication between cells should not differ
(2) Negative cable connection. more than .020. If it does, the battery needs
an equalizing charge or needs to be
36V repaired.
Battery Maintenance
NOTE : It is important that all batteries be charged
and maintained according to the battery
manufacturers instructions.
The care and maintenance of batteries is most

important to maximize battery life and efficient truck
1 2 operation. 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
3. Connect the multimeter leads between positive (+) chassis. Tighten all vent plugs, wash the battery
cable connection (1), and negative (-) cable with water and a brush, then dry with an air hose.
connection (2). It may be necessary to use a baking soda solution
if water alone will not clean the top of the battery.
4. In a safe area, operate the hydraulic system, (hold
tilt lever to maximum position momentarily) while 2. Add enough water to cover the plates before
reading the voltage indicated on the multimeter. charging. This will ensure the proper chemical
reaction over the entire plate surface. After
5. If the indication is less than 44.2 volts, the battery charging is complete, add water until it is about
needs to be charged or repaired before continuing 12.7 mm (.50 in) above the plates. Use distilled
to troubleshoot. water or water that has tested free from minerals.

3. Charge the battery correctly. A battery should be switch and accelerator linkage for adjustment or
discharged to 80% of its capacity then fully interference problems.
recharged. It should cool four to eight hours to
allow the voltage to stabilize before being put back
in use. The battery should have an equalizing Resistance to Chassis Checks
charge (an extra three or four hour charge at a low
finish rate) once a month to make sure all cells are Resistance between any point in the truck wiring and
in a fully charged condition. Properly charged the chassis should be a minimum of 10,000 ohms or
batteries should be identified to prevent low more.
batteries from being installed in trucks.
Many malfunctions are caused by shorts to chassis.
4. Operation with a low battery must be prevented. Usually, two shorts must exist before a malfunction
Low battery operation may damage the battery will occur. But, since batteries can have chassis
and will cause higher than normal current in the leakage, only one short to chassis in the truck wiring
electrical system. High current draw due to a low can cause problems. To prevent problems because
battery will damage contactor tips and shorten of shorts, do the following:
motor brush life.
1. Disconnect the battery and discharge the HEAD
5. The battery's maximum temperature is critical. The CAP.
electrolyte temperature should never exceed 43°C
(110˚F) either while operating or charging. 2. Randomly measure any component connection or
Overcharging a battery will cause over heating and wiring connection in respect to the lift truck chassis
warp the battery plates. Maximum battery life will for a minimum resistance of 10,000 ohms. Any test
result from maintaining 25˚C (77˚F) electrolyte point with low resistance must have the short to
temperature. Most of the charging equipment is chassis removed.
fully automatic but should be checked periodically
to assure proper working order. 3. Always keep batteries clean to minimize current
leakage to the chassis.
6. Keep accurate battery records. Regular battery
readings should be taken with a battery tester or 4. Routinely clean the brush dust from the motors.
voltmeter and a written record kept. Specific
gravity and voltage of each cell should be checked 5. Be sure that all attachments, such as horns and
and recorded at least once each month. This lights are designed for no chassis connection (a
inspection should be made after an equalizing two wire system).
charge. Readings should never be taken directly
after water has been added. Records of all battery
maintenance should be made and filed so it will be
known which batteries are being abused or Removal of Shorts to Chassis
wearing out.
When a short is found, it must be cleared even if the
Repairs should be made immediately otherwise machine has normal operation. It is necessary to
the battery may become damaged. Batteries narrow the field of possible problem areas before
stored in a discharged condition may be difficult to inspection of individual wires and components.
recharge due to sulfate formation.
When a low resistance circuit is located, it should be
opened at various points. This will permit the shorted
wire or component to be pin-pointed for repair or
Visual Checks replacement.
1. Verify all components and wires are in their proper

place. Check fuses, components, contactor tips,
wires and connections. Verify that they are not
burned, broken or loose.
2. Verify there is no mechanical binding or

interference in the contactors.
3. Visually check the parking brake switch, the lift

Control and Power System
Operational Checks
All operational checks are to begin with the 4. Depress the accelerator fully. The forward
battery connected, directional switch in neutral, contactors should remain activated. The bypass
drive wheels off the ground and the accelerator contactors should activate. The drive wheels will
and parking brake released. turn forward at full speed.
NOTE: Perform all operational checks before Check 5: Reverse Drive Performance
returning to the Troubleshooting Check List.
1. Select reverse direction and depress the
Check 1: Key Switch, Seat Switch and Power accelerator slightly. The reverse contactors should
Steering activate and the drive wheels should turn in
reverse slowly.
1. Activate the key and seat switch. The line
contactor activate and the hydraulic pump motor 2. Slowly increase the amount of accelerator
should turn on at slow speed (idle). depression. The reverse contactors should remain
activated. The drive wheels should turn in reverse
2. Turning the steering wheel will increase the and slowly increase in speed.
hydraulic pump motor speed (boost-up).
3. Depress the accelerator fully. The reverse
3. After five to ten seconds the line contactor contactors should activated. The bypass
deactivates and the motor turns off. contactors should activate. The drive wheels will
turn in reverse at full speed.
Check 2: Lift Performance
Check 6: Electrical Braking (Plugging)
1. Pull the lift lever half way. The hydraulic pump Performance
motor activates slowly to a preset speed.
2. Pull the lift lever to maximum. The hydraulic pump

motor activates full speed. NOTICE
Do not perform this check with the lift truck in
Check 3: Tilt and Auxiliary Performance bypass mode. Damage to the Drive Train can
result.
1. Slowly pull and push the tilt and auxiliary levers.
The hydraulic pump motor activates to one of the
preset speeds with each lever movement. 1. Select forward direction and depress the
accelerator to the point before bypass occurs.
Check 4: Forward Drive Performance While continuing to depress the accelerator,
change the direction switch to reverse. The
1. Engage the parking brake. Select forward direction forward contactors should deactivate and the
and depress the accelerator slightly. The forward reverse contactors should activate. There should
contactor should NOT activate and the drive be a smooth deceleration of forward tire rotation.
wheels should NOT turn. After the forward tire rotation stops, there is a
smooth acceleration of reverse tire rotation.
2. Release the parking brake, select forward direction
and depress the accelerator slightly. The forward 2. Continue to depress the accelerator while in
contactors should activate and the drive wheels reverse direction. Change the direction switch to
should turn forward slowly. forward. The reverse contactors should deactivate
and the forward contactors should activate. There
3. Slowly increase the amount of accelerator should be a smooth deceleration of reverse tire
depression. The forward contactors should remain rotation. After the reverse tire rotation stops, there
activated. The drive wheels should turn forward is a smooth acceleration forward tire rotation.
and slowly increase in speed.

Built-In Diagnostic Operation
The logics and the display provide built-in diagnostic Display =“Ec” Lift truck will not operate, see
analyzer functions. Several diagnostic functions Troubleshooting Problem 20. Possible cause, control
occur while the lift truck is in operation. These are panel thermal problem.
called “Run Time” diagnostics. The other diagnostics The overtemperature indication will display on LCD.
are called “Self” diagnostics. They are performed
when the lift truck is not in operation by using a Display =“Ed” Lift truck will not operate, see
switch located in the logics. Troubleshooting Problem 21. Possible cause, drive
motor thermal problem. The overtemperature
Central Vehicle Monitoring System (CVMS) indication will display on LCD.
Problems
Display =“EP” Lift truck will not operate, see
If the display does not work, or it’s operation seems Troubleshooting Problem 22. Possible cause, pump
incorrect see Troubleshooting Problems 1, 2, 3 and 4. motor thermal problem.
The overtemperature indication will display on LCD.
Display =“EL” Lift truck will not operate, see

“Run Time” Diagnostics Troubleshooting Problem 23. Possible cause, low
(Lift Truck in Operation) battery voltage.
The diagnostic functions that follow would occur Display =“F0” Lift truck operates, then shuts down
during normal lift truck operation and are shown on during travel. See Troubleshooting Problem 32.
the seven segment display. Possible cause, excessive currents in drive motor.
NOTE: Improper lift truck operation with normal Display =“F2” Lift truck will not operate, see
battery indication, should be checked with “Self” Troubleshooting Problem 33. Possible cause, a failed
diagnostics. left drive power transistor (DTR1).
Display =“F2” (Flashing) Lift truck will not operate,

see Troubleshooting Problem 34.
Possible cause, a failed right drive power transistor
(DTR2).
Display =“F3” Lift truck will not operate, see

Troubleshooting Problem 35. Possible cause, a failed
pump power transistor (PTR1).

Troubleshooting Problem 36. Possible cause, failed
pump and drive power transistors.
Display Layout Display =“F5” Lift truck will not operate, see
Troubleshooting Problem 37. Possible cause, left
Display =“EE” No Lift truck operation, see drive flyback diode DD1 failed.
Troubleshooting Problem 17. Possible cause, static
return to off. Display =“F5” (Flashing) Lift truck will not operate,
see Troubleshooting Problem 38. Possible cause,
Display =“EE” (Flashing) Lift truck will not operate, right drive flyback diode DD3 failed.
see Troubleshooting Problem 18. Possible cause,
seat switch open. Display =“F6” Lift truck will not operate, see
Troubleshooting Problem 39. Possible cause, pump
Display =“E1” or “E2” Lift truck will operate, see flyback diode PD failed.
Troubleshooting Problem 19. Possible cause, pump
or drive brush problem.

Troubleshooting Problem 40. Possible cause,pump
and drive flyback diodes (DD1,DD3 and PD) failed.
Display =“FA” Lift truck will not operate, see

Troubleshooting Problem 41. Possible cause, steer
angle switch failure or harness problem.
Display =“Fb” Lift truck will not operate, see

Troubleshooting Problem 42. Possible cause,
abnormal battery condition.
Display =“Fd” Lift truck will operate, see

Troubleshooting Problem 43. Possible cause,
pressure switch failure or harness problem.

“Self” Diagnostics
WARNING
(Lift Truck not in Operation)
The lift truck can move suddenly. Injury to
The diagnostic procedure should be used to aid in personnel or damage to the lift truck is possible.
troubleshooting after a problem occurs. It will Disconnect the battery and disconnect the line
help to find the faulty circuit or component. fuse to prevent lift truck movement.
Complete all the tests before returning to the
MicroController Troubleshooting Check List.
Before testing, do the steps that follow :
4. Release the parking brake to close the park brake
1. Turn the key to off. switch.
2. Disconnect the battery and discharge the head

capacitor below 5 volts by holding the discharge
resistor in place for 10 seconds.
48V
3
1
Removing Cover from Logic Unit (Logics)
(2) Screws. (3) Cover.
5. Loosen four screws (2) to remove logic cover (3).
Location of Fuse
(1) Line fuse.
36V
DIAG/RUN/SETUP Switch Location

(4) Switch.
1
6. Move switch (4) to “DIAG” position. This places the
controller in diagnostics when the battery is
3. Disconnect line fuse (1) to prevent lift truck connected and key is turned to ON.
movement.

7. Connect the battery and turn key to ON. Test 4 : Lift Switch Circuit
Display = “blank” Pull lift lever slowly.

See Troubleshooting Problems 1 or 2. Display now shows the speed that the lift lever is set
to. As lever is pulled back, 0 through 3 will be shown.
Display = “F”
Logics has a failure. Replace logics. This indicates at what position the lift lever changes
the pump motor speed.
Display = “d”
Line fuse is not disconnected or discharge the head If still “A0” lift switch circuit defect, see
capacitor. Return to step 2. Troubleshooting Problem 10.
Display = “8b” Test 5 : Tilt Switch Circuit

Direction lever is in the reverse position. Move
direction lever to neutral. Pull tilt lever to maximum.
Display = “A6” Tilt switch circuit OK.
NOTE: This test does not check all the logics circuit,
so the logics may pass this test and still have Release tilt lever.
a failure. Display = “A0” Tilt switch circuit OK.
The LCD will display all symbols about 2 seconds. If still “A0” or “A6”, tilt switch circuit defect, see
Display = “A0” Ready for test 1. Troubleshooting Problem 11.
Test 1 : Seat Switch Test 6 : Auxiliary Switch Circuit
Press seat to close seat switch. Pull auxiliary lever to maximum.

Display = “A1” Seat switch circuit OK. Display = “A7” Auxiliary switch circuit OK.
Release seat to open seat switch. Release auxiliary lever.

Display = “A0” Seat switch circuit OK. Display = “A0” Auxiliary switch circuit OK.
If still “A0” or “A1”, see Troubleshooting Problem 8. If still “A0” or “A7”, auxiliary switch circuit defect, see
Troubleshooting Problem 12.
Test 2 : Reverse Direction Switch
Test 7 : Parking Brake Switch
Move direction switch from neutral to reverse.
Display = “A2” Direction switch circuit OK. Pull park brake lever to maximum.
Display = “A9” Park brake circuit OK.
Move direction switch from reverse to neutral.
Display = “A0” Direction switch circuit OK. Release Park brake lever.
Display = “A0” Park brake circuit OK.
If still “A0” or “A1”, see Troubleshooting Problem 9.
If still “A0” or “A9”, Park brake circuit defect, see
Test 3 : Forward Direction Switch Troubleshooting Problem 13.
Move direction switch from neutral to forward.

Display = “A3” Direction switch circuit OK.
Move direction switch from forward to neutral.

Display = “A0” Direction switch circuit OK.
If still “A0” or “A3”, see Troubleshooting Problem 9.

Test 8 : Accelerator Control
Press accelerator pedal to maximum.

Display = The speed symbols will increase from 0 to 6
10 on the LCD, Accelector circuit OK.
Release accelerator pedal. 7

Display = The speed symbols will decrease from 10
to 0 on the LCD, Accelector circuit OK.
If the speed symbols is not full on the LCD, see

Test 1 through 8 may be checked without sequence 8

and there are repeatable checkings to adjust
switches and levers.
Contactor Locations
(6) Bypass contactor. (7) Right direction contactor.
48V (8) Left direction contactor.
Contactor Test
Test 9 through 14 may be activated in regular

sequence by movement of the DIAG/RUN/SETUP (4)
to “Run” then back to “Diagnostic” position, and “AC”
will display on the LCD.
Test 9 : Line Contactor
Test 10 : Bypass contactor

5 Test 11 : Left Forward Direction Contactor
Contactor Locations
Test 12 : Right Forward Direction Contactor
(5) Line contactor.
Test 13 : Left Reverse Direction Contactor

36V
Test 14 : Right Reverse Direction Contactor
Test 15 : Pump Bypass Contactor (36V only)
If the above actions do not occur, see

This completes the built-in diagnostic test.

Contactor test may be repeated contiune by
movement of the DIAG/RUN/SETUP to “Run” then
back to “Diagnostic” position.
5 After running through the contactor testing, pull tilt

lever and then release to netural position will access
the stored error codes. See Accessing Stored Error
Codes.

Accessing Stored Error Codes Saving Service Records
The B18T series of trucks remembers the last 24 To save service records, the following procedures are
error codes. This is useful in case the truck has had used at the end of self diagnostics and service
an intermittent problem, but the operator cannot records are numbered from 1 to 9.
remember which code appeared on the display. Also
by analyzing the contents of the last 24 error codes, 1. Access all of the error codes until display shows
it may be possible to determine what sort of static “E” on the LCD.
application the truck has been working in.
2. Move the direction lever to the forward then
The stored error codes are accessed at the end of display will show static “8d”.
diagnostics by using the following procedure:
3. Move the DIAG/RUN/SETUP switch to “SETUP”
1. Access the self diagnostics procedure as usual. and back to “DIAG” two times.
2. Either step through the self diagnostics procedure, 4. Pull the tilt lever to maximum position and then
or override each test by moving the release.
DIAG/RUN/SETUP switch from DIAG to RUN and
back to DIAG until the contactor testing is 5. A saved service records will show for a few
completed. second.
3. Cycle the DIAG/RUN/SETUP switch once more, 6. Wait until the display will show a flashing “8d”, the
and cycle through the contactor testing again. After display indicates that a service record have been
the right reverse contactor drops out, now the saved.
display will indicate a “AC”.
7. Turn OFF the key switch.
The error codes can now be accessed one at a time
by pulling tilt lever and then release. This will display
the most recent error code. By cycling the tilt lever
more times, more error codes will appear on the Erased Stored Error Codes
display, up to a total of 24.
When the display shows a solid “E”, it will indicate To erase all of the error codes, the following
that all of the stored error codes have been procedures are used at the start of self
displayed. It is possible that the “E” will appear diagnostics.
immediately, indicating no error codes have been
encountered. 1. Move the direction lever to the reverse and the
DIAG/RUN/SETUP switch to the DIAG position.
2. Turn on the key switch and wait until display

shows a solid “8b”, then move the
DIAG/RUN/SETUP switch to the SETUP position
and back to DIAG two times.
3. Move the direction lever to neutral.
4. Wait until the display will show a “A0”, the display

indicates that all error codes have been erased.
5. Turn off the key switch.

Stored Error Codes Quick Diagnostic Procedure
The following are possible error codes stored in An alternative method of entering diagnostics has
memory. Most error codes are identical to the ones been programmed into the logics. This will enable
displayed during RUN. quick diagnostics of some of the components without
removing the controller room, line fuse, or placing the
E1 : Drive motor brush problem. DIAG/RUN/SET switch to the “Diagnostic” position.
E2 : Hydraulic motor brush problem. Contactors and seat circuit will NOT be energized.
Ec : Control panel thermal problem.
Ed : Drive motor thermal problem. To enter quick diagnostics, open the seat switch and
EL : Battery lock out. place the direction lever to forward and ensure that
EP : Pump motor thermal problem. the park brake is released. While depressing the
F0 : Excessive drive motor current in pulsing or accelerator to maximum position other than OFF, and
bypass operation. key switch to ON.
F2 : Left drive problem, voltage on left drive transistor
emitter (wire #L64). Display will go to a solid “A3” and the speed symbols
F2 (Flashing) : Right drive problem, voltage on right will increase from 0 to 10 on the LCD, indicating that
drive transistor emitter (wire #R64). you have entered diagnostics and you are ready for
F3 : Pump problem, voltage on pump transistor Test: You can test the direction control lever, all
emitter (wire #74). hydraulic levers, the park brake switch and the
F4 : Both F2 and F3 problems together. accelerator.
F5 : Left drive problem, no voltage on left drive See Built-In Diagnostic Operation on page 50-52.
transistor emitter (wire #L64).
F5 (Flashing) : Right drive problem, no voltage on NOTE : This test enables a salesman to demonstrate
right drive transistor emitter some of the diagnostic procedure without
(wire #R64). ever having to open up the controller room.
F6 : Pump problem, no voltage on pump transistor
emitter (wire #74).
F7 : Both F5 and F6 problems together.
FA : Steer angle problem.
Fb : Battery mis-match.
Fd : Pressure switch problem.

Troubleshooting Problem List
TROUBLESHOOTING PROBLEM LIST

Problem # CENTRAL VEHICLE MONITORING SYSTEM (CVMS) PROBLEMS
1 CVMS does not work, with no lift truck operation.
2 CVMS does not work at all, lift truck operation normal.
Display portion of CVMS seems random or wrong.
3
Lift truck operation normal.
Display portion of CVMS works until seat switch is closed then blank,
4
no lift truck drive or pump motor operation.
“SELF” DIAGNOSTIC PROBLEMS
5 Display = “d”, no lift truck operation or “Self-diagnostics” operation.
6 Display = “F”, no lift truck operation.
7 Display = “8b”, no lift truck operation.
8 Seat switch circuit defect.
9 Direction switch circuit defect.
10 Lift switches circuit defect.
11 Tilt switch circuit defect.
12 Auxiliary switch circuit defect.
13 Park brake switch circuit defect.
14 Accelerator circuit defect.
15 Incorrect contactor operation.
16 Any contactor closes when key switch is activated.
“RUN TIME” DIAGNOSTIC PROBLEMS
17 Display = “EE”, no lift truck drive operation.
18 Display = “EE” (Flashing), no lift truck drive operation.
19 Display = “E1”, or “E2” lift truck operation normal.
Overtemperature is ON and display = Lift truck accelerates slower than normal. Lifting speed is
20
slower than normal.
Overtemperature is ON and display = Bypass contactor will not close.
21
Pump and steering operation normal. Acceleration slow.
Overtemperature is ON and display = Lifting speed slow.
22
Drive and power steering operation normal.
23 Display = “EL”. No hydraulic (lift and tilt). Steering normal.
24 Hourmeter does not work.
25 Normal hydraulic operations, display is normal and no drive operations.
26 Current limit adjustment cannot be made.
27 Slow steering, but pump motor does turn. Drive system operation normal.
Pump motor runs continously when neutral is selected. Pump motor turns at high power steering
28
speed continuously.
Drive motor does not operate or operates with low power or is erratic.
29
Pump and power steering systems operation normal.
30 Horn does not function correctly. Lift and drive operation normal.
Auxiliary lighting and/or alarm does not function correctly.
31
Lift and drive operation normal.

TROUBLESHOOTING PROBLEM LIST
Problem # FAILURE CODE PROBLEMS
32 Display = “F0”, no lift truck operation.
34 Display = “F2” (Flashing), no lift truck operation.
38 Display = “F5” (Flashing), no lift truck operation.
41 Display = “FA”, no lift truck operation.
42 Display = “Fb”, no lift truck operation.
43 Display = “Fd”, lift truck operation normal.

PROBLEM 1
Central Vehicle Monitoring System (CVMS) does

not work, with no lift truck operation.
POSSIBLE CAUSE
Battery polarity not correct on control panel;

Key fuse open circuit; Key switch defect;
Logics defect.
CHECKS
With battery connected, check control panel battery connections for correct polarity.
Positive battery connected to line contactor and negative battery connected to negative heatsink.
If correct If not correct
Push horn buttton to close horn switch. Make correction to cables.
Horn work Horn does not work
Does CVMS pass self test at actuation of key Disconnnect battery and check the horn
and seat switches. fuse for continuity.
Yes NO Continuity No continuity
See Problem 2, CVMS does not work, Check for shorts and
lift truck operation normal. replace fuse.
Check continuity from horn fuse holder to

Close key switch. Measure voltage on P1-1 control panel battery positive connection at
and P1-2. the line contactor. Also check continuity from
Battery Less than key fuse holder to wire #3 on key switch
voltage Battery voltage Continuity No continuity
Replace key switch or repair broken wire

#5 between key switch and P1-1 and P1-2. Repair horn circuit. Repair or replace
open wire.
Check continuity from negative heatsink

to logics P1-19 and P1-20.
Continuity No continuity
Replace logics. Repair or replace open wire.
MicroController Control System 56 Troubleshooting

PROBLEM 2
CVMS does not work at all, lift truck operation normal.

If only part of CVMS works, replace the CVMS.
POSSIBLE CAUSE
Disconnected logic connector P8; Open circuit from

P8-1 to CVMS connector PIN 1; Open circuit from P8-
8 to CVMS connector PIN 8; CVMS defect.
CHECKS
Make sure CVMS connector is connected to CVMS.
If connected If not connected
Connect multimeter positive lead to P8-1 Connect CVMS connector.

wire #101 and negative lead to P8-8 wire
#108. Measure the voltage.
5 volts 0 volt
Replace the CVMS module. Repair or replace open circuit between 8 wires
from logics to CVMS.

PROBLEM 3
Display portion of the CVMS module seems random or wrong.

Lift truck operation normal.
POSSIBLE CAUSE
Connection defect; Wiring defect; Logics defect; Display

defect.
CHECKS
Check continuity from logics to CVMS connector (wire

#101/WH/YL/GN/BU/BK/RD/108).
Continuity No Continuity
Check for shorts to battery negative from Repair or replace open wire.
PIN 2 to PIN 7 on CVMS connector.
No shorts found Shorted
Replace logics. Repair or replace shorted wire.

PROBLEM 4
Display portion of CVMS 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 #4

at P9-9 open circuit; Logics defect.
CHECKS
Does the line contactor close and remain closed ?
Yes No
Check voltage at bottom of line fuse See Problem 15. Incorrect

with line contactor activated. contactor operation.
Less than
Battery voltage Battery voltage
Check voltage at top of line fuse Repair or replace line contactor

with line contactor activated. tips or power connections.
Less than
Battery voltage Battery voltage
Check voltage at logic connector Check for possible shorts in the power circuit
P9-9, wire #4 with line contactor (Head Capacitor, diode, shorted cables) and
activated. replace line fuse. If repeat failures occur,
Less than check drive motor current limit and/or lift
Battery voltage Battery voltage truck application.
Replace logics. Repair open circuit between line

fuse and P9-9, wire #4.

PROBLEM 5
Display = “d”, no lift truck or “Self-diagnostics” operation.
POSSIBLE CAUSE
Logic DIAG/RUN/SETUP switch in DIAG position with

line fuse installed; Head capacitor not discharged
below 5 volts; Logics defect.
CHECKS
Trying to run Trying to

“Self-Diagnostics” ? operate lift truck ?
Disconnect battery, discharge head capacitor Disconnect battery, remove logic cover, set
below 5 volts, remove line fuse, set DIAG/RUN/SETUP switch to RUN position,
DIAG/RUN/SETUP switch to DIAG position, reconnect the battery and recycle key switch.
reconnect the battery and recycle key switch.
Lift Truck
“Self-diagnostic” Display remains at “d” Operation OK
Display remains at “d” Operation OK
Measure voltage on P9-9. Continue with “Self- Replace logics. Place lift truck
Diagnostics” operation. into operation.
Below 5V.
Replace logics.

PROBLEM 6
Display = “F”, no lift truck operation.
POSSIBLE CAUSE
Wiring defect; Logics defect.
CHECKS
With the key on, check the voltage at logic P1-1 and
P1-2, wire #5.
Battery voltage No voltage
Check continuity from control panel battery Repair or replace open wire.
negative to logic P1-19 and P1-20.

PROBLEM 7
Display = “8b”, no lift truck operation.
POSSIBLE CAUSE
Wiring defect; Direction switch defect; Logics defect.
CHECKS
Does the DlAG/RUN/SETUP switch in “Diagnostic” position ?
NO YES
Does the direction switch in neutral ? Move switch to “Run” position.
YES NO
Check continuity from logic P2-6 to Move switch to neutral.

battery negative.
No continuity Continuity
Replace logics. Repair or replace short wire

or direction switch.

PROBLEM 8
Seat switch circuit defect.
POSSIBLE CAUSE
Seat switch defect; Wiring to seat defect;

Logics defect.
CHECKS
Disconnect the battery and remove logic cover.

Disconnect P2 connector. Check continuity from P2-7
harness connector to negative heatsink with multimeter in
diode test position. Should be closed circuit when
seat is pressed on and open circuit when seat is
released.
No continuity Constant continuity Check OK
Disconnect seat switch connector. Push Replace logics.

on the seat and check the continuity
across the seat switch.
Disconnect seat switch connector. Check
continuity from logic harness connector
P2-7 to control panel battery negative with
Replace seat switch. multimeter in diode test position.
Check continuity from terminal #1 of seat

switch to control panel battery negative.
Replace seat switch.
Check wiring for short circuits between

Repair or replace open wire harness connector P2-7 and control
panel battery negative.
Repair any short circuit found.
Check continuity from terminal #2 of seat

switch to logic harness connector P2-7
with multimeter in diode test position.
Repair or replace open wire.

PROBLEM 9
Direction switch circuit defect.
POSSIBLE CAUSE
Direction switch defect; Wiring to direction

switch defect; Logics defect.
CHECKS
Release park brake. Disconnect the battery and

remove logic cover. Disconnect P2 connector.
Disconnect service brake switch connector.
Check continuity from control panel battery negative to
P2-5 logic connector; With direction lever in forward
should have a closed circuit, in neutral should be open.
Check OK Check failed
Check continuity from control panel Disconnect direction switch connector.

battery negative to logic connector Check continuity of wire #27.
P2-6. With direction lever in reverse
should have a closed circuit, in neutral Continuity No continuity
should be open.
Check OK Check failed Repair or replace wire.
Replace logics.
Check continuity from terminal #2 of
direction switch harness connector to
control panel battery negative.
Disconnect direction switch connector.
Check continuity of wire #28. Continuity No continuity
Replace direction switch.
Repair or replace wire.

Repair or replace open wire.
Check continuity from terminal #2 of direction

switch harness connector to control panel
battery negative.
Replace direction switch. Repair or replace open wire.

PROBLEM 10
Lift sensor circuit defect.
POSSIBLE CAUSE
Lift sensor not adjusted properly or defective;

Lift sensor wiring defect; Valve control card (board)
defect; Logics defect.
CHECKS
Disconnect the tilt and auxiliary switch connectors.

Retest lift sensor circuit in self diagnostics.
Circuit passes Circuit fails

“Self-Diagnostics” “Self-Diagnostics”
Perform Problem 11,12 Tilt or Disconnect PV connector at the valve control board.
auxiliary circuit defect. Connect multimeter negative lead to PV-5 and the
positive lead to PV-2. Measure the voltage.
Battery Voltage 0 Volt
Measure each voltage from : Repair or replace broken wire

PV-1, PV-3 to battery negative PV-5. between key switch and PV-2
(wire #5) or between PV-5 and
All = 11.5 to 12.5 Any/All = 0V battery negative(-).
Reconnect PV and adjust the lift sensor and Measure each voltage from P2-3, P2-4
valve control card to specifications. to battery negaive.
Display does not Display changes All = 11.5 to 12.5 Any one or all 0V
change 0 to 3 0 to 3
Perform “Self-Diagnostics”. Repair or replace broken wire

Lift circuit should work. between P2 logic connector
and PV connector.
Measure each voltage from P2-3, P2-4 to

battery negative as the lever is pulled.
Remove P2 logic connector. Check P2-3,
P2-4 for shorts to negative.
11.5 to 12.5 and .2v 11.5 to 12.5 and .2V
Measured on each NOT measured on each
If shorted No shorts
Replace logics. Replace valve Control Card.

Replace or replace wire. Replace logics.
NOTE : Before lift truck is placed into service, connect tilt and auxliary switches and verify proper adjustment.

PROBLEM 11
Tilt switch circuit defect.
POSSIBLE CAUSE
Tilt switch defect; Wiring defect; Logics defect.
CHECKS

Disconnect P2 connector. Pull tilt lever to maximum.
Check continuity from P2-2 logic connector to
control panel negative.
Replace logics. Check continuity of wire #49.
Check continuity from tilt switch terminal Repair or replace wire.

of wire #1 to control panel negative.
Replace tilt switch. Repair or replace wire.

PROBLEM 12
Auxiliary switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Auxiliary switch defect; Logics defect.
CHECKS

Disconnect P2 connector. Pull auxiliary lever to
maximum. Check continuity from P2-16 logic
connector to control panel negative.
Replace logics. Check continuity of wire #46.
Check continuity from Aux. switch terminal Repair or replace wire.

of wire #1 to control panel negative.
Replace Aux. switch. Repair or replace wire.

PROBLEM 13
Park brake switch circuit defect.
POSSIBLE CAUSE
Park brake switch defect; Wiring defect; Logics defect.
CHECKS
Disconnect the battery. Check continuity from wire #71

to #1 on the park brake switch; With park brake released
should have a closed circuit; With park brake applied
should have an open circuit. Check park brake switch to
make sure it is activated by the park lever.
Check continuity from wire #1 on the park Replace park brake switch.
brake to control panel battery negative.
Check continuity from wire #71 Repair or replace wire.

on the park brake switch to
logic P2-8
Replace logics. Repair or replace wire.

PROBLEM 14
Accelerator circuit defect.
POSSIBLE CAUSE
Wiring defect; Accelerator defect; Logics defect.
CHECKS
With the key switch on, the seat switch closed,

park brake released and connect multimeter
positive lead to P1-16, negative lead to P1-20.
Measure the voltage.
12 volts Other voltage
Connect multimeter positive lead to P1-15, Replace logics.

negative lead to P1-20. Measure the voltage
accelerator pedal released : 0 volt.
Press accelerator pedal to max. : 9.6 to 11
volts.
Disconnect P1 logic connector. Replace accelerator.

Check continuity of wire #18.
Check continuity from terminal #1 of accelerator Repair or replace wire.

harness connector to logic harness connector P1-16.
Check continuity from terminal #3 of accelerator Repair or replace wire.

harness connector to logic harness connector P1-20.

PROBLEM 15
Incorrect contactor operation.
POSSIBLE CAUSE
Wiring defect; Contactor defect; Logics defect.
CHECKS
During the “Self-Diagnostic” test, which of the following occurs?
Contactor does not activate A contactor activates whenever the key

or does not remain activated. switch is closed through all tests.
Disconnect the battery. Check for free See Problem 16. “Any contactor
mechanical movement of contactor tips closes when key switch is closed”.
Movement OK Movement not free
Remove logic cover. Disconnect P1. Check continuity Replace contactor.

from P1-3 (wire #15) to terminal of the contactor
with incorrect operation.
Measure continuity from the appropriate P1 socket to Repair or replace wire.

the coil terminal of the contactor that has incorrect
operation. Determine the P1 socket with respect to
the contactor that has incorrect operation as follows:
Line ....................................................P1-4, wire #33
Forward direction left .........................P1-5, wire #L34
Reverse direction left .........................P1-6, wire #L35
Forward direction right .......................P1-7, wire #R34
Reverse direction right .......................P1-8, wire #R35
Bypass ..............................................P1-9, wire #36
Pump Bypass Contactor ....................P1-14,wire #37
Check the contactor coil resistance. Repair or replace wire.

See Component Measurements in
Specifications section.
Check OK Check not OK
Connect P1 and run “Self-Diagnostics” Replace contactor.

again. If contactor does not close,
replace logics.

PROBLEM 16
Any contactor closes when key switch is activated.
POSSIBLE CAUSE
Wiring defect; Logics defect.
CHECKS
Connect the battery. Does the line contactor close

when the key switch is closed ?
Yes No
Did the seat switch pass

“Self-Diagnostics”?
No Yes
See Problem 8 Seat

Switch Circuit Defect. With contactor closed ? Disconnect the battery. Remove
logic cover and disconnect logic P1 connector.
Check for a short circuit from control panel battery
negative to P1 harness connector socket.
Determine the P1 socket with respect to the contactor
that closed as follows:
Line................................................................P1-4
Forward direction left.....................................P1-5
Reverse direction left ....................................P1-6
Forward direction right ..................................P1-7
Reverse direction right ..................................P1-8
Bypass...........................................................P1-9
Pump Bypass Contactor ...............................P1-14
Short circuit Open circuit
Repair or replace shorted wire. Replace logics.

PROBLEM 17
Display = “EE”, no lift truck drive operation.
POSSIBLE CAUSE
Static Return to Off (SRO) circuit activated by

improper operation sequence; Direction switch defect;
Accelerator linkage not fully released;
Accelerator control defect; Logics defect.
CHECKS
Check for SRO by release of accelerator, release

park brake move, the direction lever to neutral,
reselect direction and press the accelerator.
No change Lift Truck Operation OK
Run “Self-Diagnostics” to find Inform operator of correct start–up procedure.

faulty circuit or component. Also, that the direction lever must be left
in neutral when leaving the truck.
If no faulty component is found,

replace logics.

PROBLEM 18
Display = “EE” (Flashing),

no lift truck drive operation.
POSSIBLE CAUSE
No opterator in seat; Seat switch defect;

Open wiring; Logics defect.
CHECKS
See Problem 8, seat switch circuit defect.

PROBLEM 19
Display = “E1”, or “E2” lift truck operation normal.
POSSIBLE CAUSE
Worn brushes; Short wiring; Display defect.
CHECKS
If “E1” displays, drive motor brush wear.

If “E2” displays, hydraulic motor brush wear.
Disconnect the respective wire from the motor.
Wire #31 for drive motor or wire #72 for pump motor.
Connect the battery and close the key switch and
seat switch.
Does the LCD go out ?
No Yes
Disconnect the battery. Check continuity of Check the brushes and replace
the respective wires to the logics. as necessary.
Replace or repair wires.
Disconnect logic P2 and check for shorts from

logic P2-14 and P2-15 to battery negative.
Shorted Opened
Repair wires. Replace logics.

PROBLEM 20
Overtemperature is ON and Display = . Lift truck

accelerates slower than normal. Lifting speed is
slower than normal. Power steering operation normal.
POSSIBLE CAUSE
Control panel overheated; Control thermostat (thermal

switch) defect; Open wiring; Display defect;
Logics defect.
CHECKS
Let the truck cool for 15 minutes.
Overtemperature indicator ON Normal display
Disconnect the battery. With the controller Control panel was overheated, resume normal
at close to room temperature, disconnect the operation. If repeats occur, check
control thermal switch connectors P10 and PP. drive and pump motors current draw or
Check continuity of thermal switches. operating cycle for excessive ramp
Should have continuity below 69°C (156°F) climbing, towing or excessive lifting.
Check continuity of wire #69 between themostat Replace thermal switch.

connector P10 and PP.
Check continuity of wire #1 at HYD. thermostat Repair or replace wire.

to negative heatsink (control panel negative).
Remove logic cover. Check continuity of wire Repair or replace wire.

#69 at P10-7 to logic P2-11.

PROBLEM 21
Overtemperature is ON and Display = . Bypass

contactor will not close. Pump and power steering
operation normal. Acceleration slow.
POSSIBLE CAUSE
Drive motor overheated; Drive motor thermostat (thermal

Logics defect.
CHECKS
Disconnect the battery. With the drive motor Drive motor was overheated, resume normal
at close to room temperature, disconnect the operation. If repeats occur, check drive motors
drive motor thermal switch connector. current draw or operating cycle for excessive
Check continuity of thermal switch. ramp climbing or towing.
Should have continuity below 123°C (253°F)
Check continuity of wire #43 between left and Replace thermal switch.
right drive motor thermal switch.
Check continuity of wire #1 at left drive motor Repair or replace wire.

thermal switch to negative heatsink.

#43 at right drive motor thermal switch to
logic P2-12.

PROBLEM 22
Overtemperature is ON and Display = . Lifting

performance slow. Drive and power steering operation
normal.
POSSIBLE CAUSE
Pump motor overheated; Pump motor thermostat (thermal

Logics defect.
CHECKS
Disconnect the battery. With the pump motor Pump motor was overheated, resume normal
at close to room temperature, disconnect the operation. If repeats occur, check
pump motor thermal switch connector. Check pump motor current draw or operating
continuity of thermal switch. cycle for excessive lifting and tilting.
Should have continuity below 123°C (253°F).
Check continuity of wire #1 at pump motor Repair or replace switch.

thermal switch to negative heatsink.

#42 at pump motor thermal switch connector to
logic P2-13.

PROBLEM 23
Display = “EL”. No hydraulic (lift and tilt).

Steering normal.
Battery discharge indicator (BDI) circuit defect.
POSSIBLE CAUSE
Battery discharged or has a defect; Logics defect.
CHECKS
Connect battery, turn on key switch, close seat

switch and measure voltage from line contactor to
negative heatsink. Voltage must be greater than
45 volts.
Voltage OK Voltage low
With key ON, seat switch and line contactor Check battery connections;
closed, measure voltage at P9-9. Charge or replace battery.
Battery voltage Less than battery
Replace logics. Repair shorted wire or high resistance

connection causing the improper voltage.

PROBLEM 24
Hourmeter does not work.
POSSIBLE CAUSE
The hourmeter requires battery voltage to run.

Measure voltage at hourmeter to ensure that it is
battery voltage.
No voltage Battery voltage
Check continuity from key switch to Replace hourmeter.

hourmeter positive (+) terminal.
Check continuity from hourmeter negative (-) Repair or replace wire.

to seat switch wire #45.
Check continuity from seat switch to battery

negative wire #1.
No continuity

PROBLEM 25
Normal hydraulic operations, display is normal

and no drive operations.
POSSIBLE CAUSE
Service brake switch shorted.

Short wires (#27, #28).
Charged head capacitor.
CHECKS
Disconnect the battery connector and

discharge the head capacitor fully.
Check continuity from wire #27 (logic P2-5)

to wire #28 (logic P2-6).
Check service brake switch and wires #27, #28 Replace logics.
from logics to service brake switch.
Check direction switch.
All checks OK Any checks failed
Replace logics. Repair or replace wire or switches.

PROBLEM 26
Current limit adjustment cannot be made.
POSSIBLE CAUSE
Current sensor defect; Wiring defect; Logics defect.
CHECKS
Perform current sensor component check.
Replace logics. Repair wiring or replace current sensor.

PROBLEM 27
Slow steering, but pump motor does turn. Drive

system operation normal.
POSSIBLE CAUSE
Steering pressure switch defect; Wiring defect;

Logics defect.
CHECKS
Check the battery, close the seat and key switches.

Put the direction lever in forward.
Disconnect pressure switch connector.
Pump motor speed Pump motor speed

remains the same increases
Disconnect pressure switch connector. Replace the pressure switch.

Check for a continuity between P2-1
and battery negative.
Replace logics. Repair the wiring.

PROBLEM 28
Pump motor runs continuously when neutral is

selected (no wait mode). Pump motor turns at
high power steering speed continuously.
POSSIBLE CAUSE
Steering pressure switch defect; Pressure switch

connector disconnected; Wiring defect; Logics defect.
CHECKS
Check steering pressure switch connector for

proper connection.
Connected Disconnected
Disconnect the pressure switch connector. Place jumper Connect connector.

wire between both pressure switch connector terminals.
With the key 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 Replace the pressure switch.
capacitor. Check continuity from terminal #1
of pressure switch connector to the control
panel negative. Also check continuity from
terminal #2 of pressure switch connector to
logic connector P2-1.

PROBLEM 29
Drive motor does not operate or operates with

low power or is erratic. Pump and power steering
systems operation normal.
POSSIBLE CAUSE
Accelerator defect; Direction control circuit defect ;

Current limit set too low; Wiring defect ;
Logics defect.
CHECKS
Perform self-diagnostics.
Passed Does not pass
Readjust current limit to specifications. See respective problem for

Check DR1 and DR2 for correct resistance. defective circuit.
Resistance is 90Ω I 5%.
In specification Not in specification
Check wire #L67, #L68, #R67 and #R68 for a good connection on DR1 Replace resistor.
and DR2.
Check wires #L63 and #R63 to base of transistors DTR1 and DTR2.
Check continuity of wire #L64 and #R64 from emitter of power
transistors to logics P9-5 and P9-6.
All OK Defective wiring
Check diode DD1, DD2, DD3 and Repair or replace defective wiring
DD4 for shorts or open circuit. or connection.
Diode OK Defective diode
Check drive motor, cables and contactor for open circuits. Replace defective diode.
Check OK Open circuit
Replace logics. Repair open circuit or replace drive motor.

PROBLEM 30
Horn does not function correctly. Lift and drive

operation normal.
POSSIBLE CAUSE
Open fuse; Faulty wiring; Defective switch;

Horn defect.
CHECKS
With the faulty horn circuit activated, check for

voltage on the load side of the horn fuse.
Battery voltage No voltage
Check for voltage on the load side of Check for short circuits;
the horn switch. Replace horn fuse.
Battery voltage 0 volt
Check for voltage at the negative Repair or replace open wire from fuse
connection of the load. or replace defective switch.
0 volt Battery voltage
Repair or replace open wire from Repair or replace open wire going to battery
the horn switch or replace horn. negative.

PROBLEM 31
Auxiliary lighting and/or alarm does not function

correctly. Lift and drive operation normal.
POSSIBLE CAUSE
Open fuse; Faulty wiring; Defective switch; Shorted

load; Open load; Loss of input voltage to DC-DC
converter; Defective DC-DC converter.
CHECKS
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 Voltage

output above 13V below 11V 11 to 13V
Con’d Con’d Con’d With the faulty auxiliary circuit

Next Next Next activated, check for voltage on
Page Page Page load side of the auxiliary fuse.
11 to 13 volts No voltage
Check for voltage on the load Check for short

side of the auxiliary switch. circuits; Replace
auxiliary fuse.
11 to 13 volts 0 volt
Check for voltage at the negative connection Repair or replace open wire from
of the load. fuse or replace detective switch.
0 volt 11 to 13 volts
Repair or replace open wire from the Repair or replace open wire going
auxiliary switch or replace the to battery negative.
defective auxiliary component.

Problem 31 (continued) No voltage output.
Measure the voltage from (POS INPUT) to (NEG INPUT).
Measure the voltage from (12V POS) terminal Measure the voltage from the battery positive
of the DC-DC converter to battery negative. cable at the line contactor to the (NEG INPUT)
terminal of the DC-DC converter.
Measure the voltage from Replace

(ENABLE) terminal of the the DC-DC Check for open fuse or Repair open
DC-DC converter to converter. wiring between the line negative
battery negative. contactor and the (POS connection from
INPUT) terminal of the converter (NEG
Battery voltage 0 volt DC-DC converter. INPUT) to battery
negative.
Open fuse Open wiring
Repair or replace open wiring

from the key sw to the (ENABLE)
Replace fuse and check Repair or replace
terminal of the DC-DC converter.
wiring for shorts. If no faulty wiring.
shorts are found and the
fuse continues to fail,
replace the DC-DC converter.
Test the fuse at the DC-DC converter for continuity.
Fuse good Fuse open
Remove the load connections at the (12V POS) and (12V NEG) Replace fuse. If fuse
terminals of the DC-DC converter. Measure the voltage from continues to fail, replace
the (12V POS) to the (12V NEG) terminals of the DC-DC converter. the DC-DC converter.
11 to 13 volts <11 or >13 volts
Check for a short circuit in each auxiary circuit. Replace the DC-DC
converter.
No shorts found Shorts found
Replace the DC-DC converter. Repair or replace faulty

wiring or components.

Problem 31 (continued) Voltage bellow 11 volts.
Measure the voltage from (POS INPUT) or (+IN) terminal

to the (NEG INPUT) or (-IN) terminal of the DC-DC
converter.
36 volts or above Below 35 volts
Remove all connections at the (12V POS) and(12V Check the battery and DC-DC converter
NEG) or the (+OUT) and (-OUT) terminals input connections from the battery.
of the DC-DC converter. Measure the voltage
from (12V POS) to (12V NEG) or (+OUT) to Battery low Poor connection
(-OUT).
11 to 13 volts Below 11 volts

Charge or replace battery.
Repair or replace faulty wiring or

Check for a short or low resistance connections.
in the auxiliary circuits and loads.
NOTE : Excessive loading places the

DC-DC converter faulty.
converter into current limit
Replace converter.
(12A maximum).
Voltage above 13 volts.
Remove all connections at the (12V POS) and (12V NEG)

or the (+OUT) and (-OUT) terminals of the DC-DC
converter. Measure the voltage from (12V POS) to
(12V NEG) or (+OUT) to (-OUT).
11 to 13 volts Above 13 volts
Check the output load circuits for DC-DC converter faulty.

incorrect wiring or shorts to battery Replace converter.
negative.

PROBLEM 32
Display = “F0”, no lift truck operation.
POSSIBLE CAUSE
Logic potentiometers VR1 and VR6 out of adjustment.

Excessive drive motor currents due to pushing or ramp
application. Failed drive motor. Failed logics.
Weak or discharged battery.
CHECKS
Adjust current limit to specification :

48 V - 250 amps
OK Still “F0”
Place lift truck into operation. Determine when the “F0” occurs.
Before bypass During bypass
Is there a steep ramp that the truck must stop on ? Determine if there is a steep ramp in the
If so the Excessive Drive Motor Current option may not application. Adjust VR6 so that current is
be applicable in this application. greater than maximum drive motor current
Set option Programmable Feature 9 to Data Codes 3. going up the ramp.
No ramp, or continues “F0” No ramp, or continues “F0”
Does the “F0” occur due to excessive pushing or abuse. Ensure that the battery is not being deep
discharged, causing high currents. Inspect the battery for poor maintenance or bad cells.
Explain situation to the customer. If abuse continues, any drive failure will not be warranted.
Discussion : The logic card monitors the current in the drive motors, and prevents high currents that may
damage the drive motor, or possibly blow the line fuse. It uses two current limits settings for this purpose.
Potentiomenter VR1 sets current limit for transistor pulsing, and if drive motor current exceeds the VR1
current setting for longer than 3 seconds, it will failsafe and display an “F0”. Similary, if the bypass contactor
is closed, and the current exceeds the potentiometer VR6 setting for longer than 3 seconds, the truck will
failsafe in a similar manner. In addition, the bypass operation will be prevented if the drive motor currents
exceed the VR1 current limit.

PROBLEM 33
Display = “F2”, no lift truck operation,

line contactor closes and opens.
POSSIBLE CAUSE
Shorted DTR1; Welded bypass contactor tips ;

Open wiring; Driver board defect; Logics defect;
Frame voltage on LS1 drive motor cable.
CHECKS
Disconnect the battery, check bypass contactor for

welded tips. Check contactor for free tip movement.
Not welded Welded
Disconnect battery, remove logic cover, check Repair or replace contactor tips.
continuity and connections of wire #L64 at DTR1 Check BDI adjustment and battery
emitter to P9-5 on logics. Check current limit adjustment.
Disconnect LS1 cable at Repair or replace

panel and retry. wiring or connection.
Still “F2” OK
Investigate voltage Check DTR1 for failure

present on LS1 cable.
Test OK Failed
Test driver board Replace transistor.

(drive side only).
Test OK Failed
Replace logics. Replace driver board.

PROBLEM 34
Display = “F2” (Flashing), no lift truck operation,

line contactor closes and opens.
POSSIBLE CAUSE
Shorted DTR2; Welded bypass contactor tips ;

Open wiring; Driver board defect; Logics defect;
Frame voltage on RS1 drive motor cable.
CHECKS
Disconnect the battery, check bypass contactor for

welded tips. Check contactor for free tip movement.
Not welded Welded
Disconnect battery, remove logic cover, check Repair or replace contactor tips.
continuity and connections of wire #R64 at DTR2 Check BDI adjustment and battery.
emitter to P9-6 on logics. Check current limit adjustment.
Disconnect RS1 cable at Repair or replace

panel and retry. wiring or connection.
Still “F2” (Flashing) OK
Investigate voltage Check DTR2 for failure

present on RS1 cable.
Test OK failed
Test driver board Replace transistor.

(drive side only).
Test OK Failed
Replace logics. Replace driver board.

PROBLEM 35
Display = “F3”, no lift truck operation, line

contactor closes and opens.
POSSIBLE CAUSE
Shorted PTR1; Open wiring; Driver board (HYD.)

defect; Open circuit pump motor or P1, P2 cables ;
Logics defect.
CHECKS
Connect the battery, close the seat and key switches.
Line contactor closes then Line contactor closes then

opens, pump motor does opens, pump motor turns a
not turn. Display = “F3” small amount. Display = “F3”
Disconnect battery, remove logic cover, check Check PTR1 for a short circuit.
continuity of wire #74 at emitter connector of
PTR1 to P9-7 on logics. Not failed Failed
Replace transistor.
*
Repair or replace Check continuity from P1 to
wiring P2 at panel. Check driver board (HYD.).
Continuity No continuity Not failed Failed
Replace logics. Check motor and Replace logics. Replace driver

cables and repair. board (HYD.) *
* See Notice
NOTICE
Damage to the control panel could result. To prevent further damage, before PTR1 or driver
board are replaced, complete the following checks:
1. Check the diode PD for a failure.

2. Check Head capacitor for a failure.
3. Check PTR1 for a failure.
4. Check Driver board for a failure.
5. Check for continuity from PTR1 emitter (wire #74) to logics P9-7.

PROBLEM 36

POSSIBLE CAUSE
Bypass contactor tips shorted; Shorted DTR1, DTR2

and PTR1. Poor connection at logic P9 connector ;
Driver board defect.
CHECKS
See Problems 33, 34 and 35, Display = “F2” or “F2”

(Flashing) and “F3”. Do both procedures.

PROBLEM 37
Display = “F5”, no lift truck operation, line contactor closes and opens.
POSSIBLE CAUSE
Faulty wire connections; DTR1 failed; Current limit set to low; Failed DD1
or DD2; Failed driver board; Failed current sensor; 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 #L65 at P9-1.
Wire #L64 at P9-5 and emitter bus bar of left drive power transistors. Wire #L67 and #L68 at resistor
DR1. Wires #L63 at DTR1. Wire #4 from driver board to positive heatsink. Wire #1 from driver board to
negative heatsink. Wire #L22 from logics P1-12 to current sensor. Wire #25 from logics P1-16 to current
sensor. Current sensor PIN3 to negative heatsink. Repair any defects then reconnect the wires.
Display = “F5” Display normal
Test DTR1 for a failure. Return truck to operation.

Not failed Failed
Replace transistor.
Make sure that the connecter of current sensor is
connected. Measure the voltage at P1-12 with
*
the key switch closed. If the voltage is over than
10V, replace the current sensor.
Test diodes DD1 and DD2 for a failure.
Not failed Failed
Measure voltage at P1-16 with the key switch closed. Replace failed components.
Recalibrate current limit
Voltage = 11 to 12V Any other voltage to specifications. *
Perform Rapid Turn-Up procedure for current limit (VR1). Replace logics.
*
Display “F5” Display normal
Test driver board (drive) for a failure. Recalibrate current limit

adjustments to specifications.
Not failed Failed
Replace logics. Replace failed components. Recalibrate current limit to specifications.

*
* See Notice #1
PROBLEM 38
Display = “F5” (Flashing), no lift truck operation, line contactor closes and opens.
POSSIBLE CAUSE
Faulty wire connections; DTR2 failed; Current limit set to low; Failed DD3 or
DD4; Failed driver board; Failed current sensor; 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 #R65 at P9-2.
Wire #R64 at P9-6 and emitter bus bar of right drive power transistors. Wire #R67 and #R68 at resistor
DR2. Wires #R63 at DTR2. Wire #4 from driver board to positive heatsink. Wire #1 from driver board to
negative heatsink. Wire #R22 from logics P1-13 to current sensor. Wire #25 from logics P1-16 to
current sensor. Current sensor PIN3 to negative heatsink. Repair any defects then reconnect the wires.
Display = “F5” (Flashing) Display normal
Test DTR2 for a failure. Return truck to operation.
Not failed Failed
Replace transistor.
Make sure that the connecter of current sensor is
connected. Measure the voltage at P1-13 with
*
the key switch closed. If the voltage is over than
10V, replace the current sensor.
Test diodes DD3 and DD4 for a failure.
Not failed Failed
Measure voltage at P1-16 with the key switch closed. Replace failed components.
Recalibrate current limit
Voltage = 11 to 12V Any other voltage to specifications. *
Perform Rapid Turn-Up Procedure for current limit (VR1). Replace logics.
*
Display “F5” (Flashing) Display normal
Test driver board (drive) for a failure. Recalibrate current limit

adjustments to specifications.
Not failed Failed
Replace logics. Replace failed components. Recalibrate current limit to specifications.

*
* See Notice #2
NOTICE #1
Damage to the control panel could result. To prevent further damage, before DTR1 or driver
1. Check the diode DD1 and DD2 for a failure.

2. Check DTR1 for a failure.
5. Check for continuity from DTR1 emitter (wire #L64) to logics P9-5.
6. Check Current sensor for a failure.
NOTICE #2
Damage to the control panel could result. To prevent further damage, before DTR2 or driver
1. Check the diode DD3 and DD4 for a failure.

2. Check DTR2 for a failure.
5. Check for continuity from DTR2 emitter (wire #R64) to logics P9-6.
6. Check Current sensor for a failure.

PROBLEM 39

POSSIBLE CAUSE
Failed Fuse - Hydraulic;

Faulty wire connections; PD, PTR1 failed;
Failed driver board (HYD.); Failed logics.
CHECKS
Check the continuity of Fuse - Hydraulic.

Disconnect the following wires, visually inspect them for burnt or discolored terminals,
loose connections, smashed or compressed connectors, corrosion or foreign material.
Wire #75 at P9-3. Wire #77 and #78 at resistor PR1.
Wire from driver board (HYD.) to positive heatsink.
Wire #1 from driver board (HYD.) to negative heatsink.
Wire #73 at base of transistor PTR1.
Repair any defects then reconnect the wires.
Display = “F6” Display normal
Check diode PD for a failure. Return truck to operation.
Not failed Failed
Check transistor PTR1 for Replace failed diode.

a failure. *
OK Failed
Check driver board (HYD.). Replace transistor.

*
Not failed Failed
Replace logics. Replace driver board (HYD.).

*
* See Notice
NOTICE
Damage to the control panel could result. To prevent further damage, before PTR1 or driver
1. Check the diode PD for a failure. 3. Check PTR1 for a failure.

2. Check Head capacitor for a failure. 4. Check Driver board for a failure.
5. Check for continuity from PTR1 emitter (wire #74) to logics P9-7.

PROBLEM 40

POSSIBLE CAUSE
Failure in both the drive and pump circuits.

Incorrect wiring of wires #L67, #L68, #R67, #R68,
#77 and #78.
CHECKS
See Problem 37, 38 and 39, Display = “F5” or “F5”

(Flashing) and Display = “F6”. Do both procedures.

PROBLEM 41
Display = “FA”, no lift truck operation, line

POSSIBLE CAUSE
Faulty wire connections; Failed steer angle

switch; Failed logics.
CHECKS
Disconnect steer angle switch connector.

Check continuity of wires #50, #51, #52 and #53
from logic P2-17 ~ 20 to steer angle switch connector.
Continuity Not continuity
Check continuity wire #1 at steer angle Repair or replace wires.

switch connector to negative heatsink.
Put steer wheel in straight position. Repair or replace wires.

Remove steer angle switch assembly
cover. Check continuity of steer angle
switches.
Continuity Not continuity
Check steer angle switch operation by Replace failed switches.

steer wheel position. (See steer angle
control - page 24)
Check OK Failed
Replace logics. Adjust steer angle switches.

PROBLEM 42
Display = “Fb”, no lift truck operation, line

POSSIBLE CAUSE
Battery defect; Logics defect.
CHECKS
Disconnect battery, measure voltage at battery

connector terminal. Voltage must be higher
than 30 volts on 48V system and 20 volts on 36V
system.
Voltage OK Wrong voltage
With key on, seat switch and line Check battery connections;
contactor closed, measure voltage at logic Replace battery.
P9–9.
Battery voltage No battery voltage

PROBLEM 43
Display = “Fd”, lift truck operation normal.
POSSIBLE CAUSE
Pressure switch defect; Wiring defect; Logics defect.
CHECKS
Disconnect the battery. Check continuity from wire

#41 to #1 on the pressure switch.
Check continuity from wire #1 on the pressure Repair or replace wires.

switch to control panel battery negative.
continuity No Continuity
Check continuity from wire #41 on Repair or replace wires.

the pressure switch to logic P 2-1
continuity No Continuity
Replace logics. Repair or replace wires.

System Tests and Adjustments Potentiometer Adjustment Tool -Trimmer
Available from most electronic suppliers, this

Test Equipment insulated tool allows for fast and easy adjustments of
potentiometers.
Hydrometer
Hydrometers are usually available from any battery

supplier. Battery maintenance is a crucial part of
maintaining the electric vehicle. The ability to
measure specific gravity and adjust the battery
discharge indicator to match battery manufacturers
specifications is an important part in the total
maintenance of the electric vehicle.
There are various pieces of electric truck test Discharging Head Capacitor
equipment that Daewoo recommends for all service (HEAD CAP)
personnel. This equipment is available from a
number of world wide manufacturers and local
electronic suppliers. Contact your Daewoo dealer or
the factory for further recommendations.
WARNING
Battery voltage and high amperage are present.

Handheld Multimeter Injury to personnel is possible. Disconnect the
battery and discharge the head capacitor (HEAD
A digital multimeter that measures DC voltage, CAP) before any contact is made with the control
resistance, and has a diode tester, is required. It is panel.
recommended that a high quality meter that is drop
protected, or comes with a drop proof case, be
purchased. Autoranging features, fast becoming an
industry standard, are convenient for the service
personnel, but are not required for servicing the lift
truck. A variety of miniature test leads, alligator clips,
and needle probes are also useful, and some of
these usually come with the multimeter.
Clamp-on Current Probe
The electric lift truck testing and adjusting procedures

require the measurement of average DC currents. 2 1 3
Currents in excess of 600 amps may be present, so
a clamp-on meter that will exceed this level is Discharging Head Capacitor (HEAD CAP)
(1) Resistor. (2) Positive heatsinks.
required. It is also highly recommeded that a device (3) Negative heatsinks.
that has a voltage output, as well as a visible display,
be used. This makes viewing and adjusting currents
from the operator's seat possible. The jaws of the 1. Disconnect the battery and discharge the head
current probe should be able to accept at least a capacitor.
19mm (.75 inch) cable diameter.
2. Put a 82 ohm, 80 watt resistor (1) Part No.
929315, in position between the positive (2) and
negative (3) heatsinks. Hold the resistor in position
for 10 seconds. This will discharge the capacitor
below 5 volts.

Logics Removal
8
WARNING

Injury to personnel is possible. Disconnect the 7
CAP) before any contact is made with the control
panel.
Logics Removal
(7) Nuts. (8) Logics.
capacitor.
5. Remove screws (7) which hold logics (8) to control
panel.
6. Remove logics and replace logic cover to prevent

2 damage.
1
“Run Time” Tests
WARNING
Battery voltage and high amperage are present. Injury

Component Location
(1) Screws. (2) Logic Cover.
to personnel is possible. Disconnect the battery and
discharge the head capacitor (HEAD CAP) before any
contact is made with the control panel.
2. Loosen screws (1) that hold logic cover (2).
3. Remove the logic cover.

WARNING
The lift truck can move suddenly. Battery voltage

and high amperage are present. Injury to
3 5 6 4 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.
Key ON, No Operator Warning, Display =“EE”

(Flashing)
1. Connect the battery.
Connector Re4moval 2. Turn key to ON with no one on the seat.

(3) Connector P1. (4) Connector P2. (5) Connector P8.
(6) Connector P9. 3. The display should show the letter “EE” flashing on
and off.
4. Disconnect connectors P1(3), P2 (4), P8 (5) and
P9 (6). When disconnecting connectors pull on 4. With an operator on the seat or by pressing on the
plastic connector housing, not on the wires. seat the letter “EE” should stop flashing.

Static Return to Off (SRO), Display = “EE” Overtemperature Protection
1. Connect the battery and sit on the seat.
2. Select a direction before turning key to ON.
3. Turn key to ON. An “EE” should appear on the

display and the drive system should not operate.
4. Return the direction lever to neutral, then back to

forward or reverse. The “EE” should disappear
from the display and the drive system should
operate.
5. Turn key to OFF. Depress and hold the accelerator

pedal. To turn on overtemperature indicator.
6. Turn the key to ON. An “EE” should appear on the 1. Disconnect the battery and discharge the head
display and the drive system should not operate. capacitor.
7. Release the accelerator padal. The “EE” should 2. Disconnect the control panel thermal switch
disappear from the display and the drive system connector.
should operate.
3. Connect the battery, close the seat switch and turn
the key ON. The overtemperature indicator and
“Ec” should be truned on. The drive and hydraulic
speed will be reduced. “Ec” stored.
Steps 1 through 3 can be repeated for the drive and

pump motor thermal switches, the results should be:
Drive – Drive pulse ratio reduced, bypass operation

prevented, and “Ed” stored.
Pump – Lifting performance reduced, and “EP”

stored.

Component Tests Logic Unit Quick Reference Voltage
Check
WARNING The chart that follows is a quick reference of the

expected voltages at the logic pin connectors. All
Battery voltage and high amperage are present. voltage measurements are made with respect to
Injury to personnel is possible. Disconnect the battery negative.
panel. WARNING

Safely lift the drive wheels off the floor. Put blocks
NOTICE of wood under the frame so both drive wheels are
Do not use steam or solvent to clean the controls. free to turn. Keep away from drive wheels.
Damage can be caused to the control panel. Use
pressure from an air hose with a maximum
pressure of 205 kPa (30 psi) to clean the control
panel when necessary. The air supply must be 1. Put blocks of wood under the frame so both drive
equipped with a water filter. wheels are free to turn.

capacitor.
NOTE: When control wires and power cables or bus
bars are to be connected to the same bolt or 3. Remove the logic cover.
stud, place all control wires together on the
top of the bus bar or power cable. 4. Set the multimeter to the 200 volt DC range.
Use the electrical schematic (located in left side 5. Connect the multimeter negative lead to control
panel) to locate components referred to by name and panel battery negative.
number in the procedures that follow. All wires must
be located as shown on the schematic. 6. Use the multimeter positive lead with an Needle
Refer to SB2082E02 schematic(A154764) as Tip to measure the voltages under normal and
attached. activated conditions as shown in the Logic Voltage
Reference chart.
Make sure the chart matches the control

system being tested.
1 3 4 2
Connector Layout
(1) Connector P1.(2) Connector P2. (3)Connector P8.
(4) Connector P9.

LOGIC VOLTAGE CHECKS
Logic Wire Normal Activated Test Function
Function
Terminal No. Voltage Voltage Procedure
P1-1 Battery (+) from 0V: key switch OFF,
5 B (+) B (+)
P1-2 key switch B (+): key switch ON.
P1-3 Battery (+) to all B (+) to all coils with key ON,
15 B (+) B (+)
CTR coils 0V key OFF.
P1-4 33 Line CTR coil B (+) Low B (+): Line CTR open, 0V: closed
P1-5 L34 Left-FWD coil B (+) Low B (+): Left FWD open, 0V: closed
P1-6 L35 Left-REV coil B (+) Low B (+): Left REV open, 0V: closed
P1-7 R34 Right-FWD coil B (+) Low B (+): Right FWD open, 0V: closed
P1-8 R35 Right-REV coil B (+) Low B (+): Right REV open, 0V: closed
P1-9 36 Bypass CTR coil B (+) Low B (+): Byp. CTR open, 0V: closed
P1-10 L32 Left Plug sensor 0 -0.8 to -0.2 Voltage exchanges 0 to negative
P1-11 R32 Right Plug sensor 0 -0.8 to -0.2 Voltage exchanges 0 to negative
P1-12 L22 Left drive CT 0 to 0.03 0.03 to 12 Voltage increases with current
P1-13 R22 Right drive CT 0 to 0.03 0.03 to 12 Voltage increases with current
P1-14 Not used
P1-15 18 Accelerator 0 to 0.89 0.9 to 12 Activate pedal from full up to full down
0V = key switch OFF,
P1-16 25 12 Voltage (+) 11 to 13 11 to 13
12V = key switch ON
P1-17 – Not used
P1-18 – Not used
P1-19
1 Battery Negative 0 0 Logic board negative
P1-20
P2-1 41 Pressure switch Low High Activate steering wheel

Tilt switch
P2-2 49 High Low Activate lever from OFF to ON
AUX1. switch
P2-3 47 Lift 1 switch High Low Activate lever from OFF to ON
P2-4 48 Lift 2 switch High Low Activate lever from OFF to ON
P2-5 27 FWD switch High Low Activate lever from OFF to ON
P2-6 28 REV switch High Low Activate lever from OFF to ON
P2-7 45 Seat switch High Low High: switch open, Low: closed
Low: Park brake activated
P2-8 71 Park brake switch Low High
High: Park brake released
P2-9 20 Height 1 switch High Low Activate lever from OFF to ON
P2-10 24 Height 2 switch High Low Activate lever from OFF to ON
Control thermal Activated by overtemperature of
P2-11 69 Low High
switch control panel
Drive motor Activated by overtemperature of
P2-12 43 Low High
thermal switch drive motor
Pump motor Activated by overtemperature of
P2-13 42 Low High
thermal switch pump motor
Drive brush wear Activated by brush wear of
P2-14 31 High Low
indicator sensor drive motor
Pump brush wear Activated by brush wear of
P2-15 72 High Low
indicator sensor pump motor

LOGIC VOLTAGE CHECKS
Logic Wire Normal Activated Test Function
Function
Terminal No. Voltage Voltage Procedure
P2-16 46 AUX2 switch High Low Activate lever from OFF to ON
P2-17 50 ANGLE SWITCH 1 High/Low High/Low Turn steer wheel lock to lock
P8-1 101 LCD: DC 5 Volt (+) 4.5 to 5.5 4.5 to 5.5 Key switch OFF: 0V, ON: 5V
P8-2 WH LCD: DATA 0 High / Low 0V: segment OFF, High: On
P8-3 YL LCD: DATA-bar 0 High / Low 0V: segment ON, High: OFF
P8-4 GN LCD: CLOCK 0 High / Low 0V: segment OFF, High: On
P8-5 BU LCD: CLOCK-bar 0 High / Low 0V: segment ON, High: OFF
P8-6 BK LCD: LOAD 0 High / Low 0V: segment OFF, High: On
P8-7 RD LCD: LOAD-bar 0 High / Low 0V: segment ON, High: OFF
P8-8 108 Battery negative 0 0V Logic board negative
Pulse drive TR
P9-1 L65 0 0.1 to 1.3 Activated as drive TR pulses (Left TR)
base (Left motor)
Pulse drive TR 0 0.1 to 1.3 Activated as drive TR pulses
P9-2 R65
base (Right motor) (Right TR)
Pulse pump main
P9-3 75 0 0.1 to 1.3 Activated as pump TR pulses
TR base
P9-4 – Not used
Drive TR emitter Voltage increases as drive TR pulses
P9-5 L64 0 1.5 to B (+)
sensor (Left) faster (Left TR)
Drive TR emitter Voltage increases as drive TR
P9-6 R64 0 1.5 to B (+)
sensor (Right) pulses faster (Right TR)
Pump main TR Voltage increases as pump TR
P9-7 74 0 1.5 to B (+)
emitter pulses faster
P9-8 – Not used 0
B(+) from positive
P9-9 4 0 B (+) B (+) with line CTR closed
heatsink
NOTE : “Normal” ; battery connected, key switch and park switch closed.
High voltage signal should be 9 to 12 volts. Low voltage signal should be 0 to 0.9 volt.

Conductor and Switch Continuity
1. Set the multimeter to the 200 Ω range.
2. Use the multimeter to perform the continuity test. lf

continuity exists, the measurement will be less
than 1 ohm. lf the measurement is more than this,
continuity does not exist and the problem will have
to be repaired.
Capacitor (Head)
5 2 1 4 3
WARNING
(1) Positive connection point. (2) Positive cable.
Battery voltage and high amperage are present. (3) Negative connection point. (4) Negative cable.
Injury to personnel is possible. Disconnect the (5) Capacitor.
4. Disconnect positive cable (2) from the positive
panel.
connection point (1).
5. Disconnect negative cable (4) from the negative

connection point (3).
NOTICE
6. Set the multimeter to the 20 KΩ range. Connect
Damage can be caused to the head capacitor. Do
the multimeter positive lead to positive cable (2) of
not remove bolts from capacitor to perform tests.
head capacitor (5). Connect the multimeter
Remove capacitor connecting cables at heatsink
negative lead to negative cable (4) of head
connections.
capacitor (5).
7. The meter must increment to above 10 KΩ.

lf the capacitor fails the Head Capacitor Test, then
replace capacitor. 8. If the head capacitor fails this test, then capacitor
should be replaced.
capacitor. See Head Capacitor in Specifications section for
proper assembly order of the head capacitor
2. Visually inspect the capacitor for bulges at the connections and bolt torque specifications.
terminals.
3. Verify the plastic top is not melted around the

terminals and that the blow plug is not leaking.
WARNING
Head Capacitor “blow plug” will rupture with

reverse polarity. Vapors and contents of Head
Capacitors are toxic, flammable and corrosive.
Personal injury can be caused from breathing the
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.

Contactors Contactor Components
WARNING WARNING
The lift truck can move suddenly. Injury to Battery voltage and high amperage are present.
personnel or damage to the lift truck is possible. Injury to personnel is possible. Disconnect the
Safely lift the drive wheels off the floor. Put blocks battery and discharge the head capacitor (HEAD
of wood under the frame so both drive wheels are CAP) before any contact is made with the control
free to turn. Keep away from drive wheels that panel.
turn.

capacitor.
NOTICE
Damage can be caused to the control panel. Do
not switch the direction lever from one direction to
Coil Suppression Diodes
the other (plug the lift truck) when the drive wheels
are off the ground and in rotation at full speed.
1. Connect the battery and close the seat switch. 1 35

2. Turn the key to ON and release the parking brake.
The line contactor will close.
3. Select a direction and rapidly depress the

accelerator pedal all the way to the floor.
246
4. Measure and record the time it takes the bypass
contactor to close. This should be 1.5 to 2.5
seconds after the accelerator is fully depressed.
5. If the recorded value from Step 5 is less than 1.0

seconds, the logics may need to be replaced.
(During normal operation this time will vary with Suppression Diodes
(1) D3-Line. (2) D4-Left Forward. (3) D5-Left Reverse.
the load on the truck). (4) D6-Right Forward. (5) D7-Right Reverse.
(6) D8-Bypass.
6. If the recorded value from Step 5 is more than 2.5
seconds, check the bypass contactor tips for free
2. Disconnect the logic connector P1.
movement. Check wiring for bad connections, and
check current limit.
3. Set the multimeter to the diode test position.
NOTE : The bypass contactor will not close if the
4. Connect positive multimeter lead to anode, and
accelerator linkage is not adjusted correctly.
the negative multimeter lead to cathode of diode in
the logics.
5. The multimeter must indicate .3 to .9 volts.
6. Reverse the leads (positive multimeter lead to

cathode and negative multimeter lead to anode).
The meter must indicate OL.

Coil Resistance Contactor Tips
2. Disconnect all leads to both terminals of the coil.
3. Set the multimeter to the 200Ω range.
4. Measure the resistance of the coil at both

teminals. If must be within specifications. See
Component Measurements in Specifications
section.
5. If the coil is not within specifications, the contactor

assembly will be replaced.
Coil Pulsing Checking Contactor Tip Gap
2. With the contactor coil leads and suppression 2. Visually inspect the tips to verify they are not
assembly leads connected, set the multimeter to welded, melted, burned, or pitted.
the 200 volts DC range.
3. Pull and release the tips quickly to verify there is
3. Connect the multimeter negative lead to the no binding.
negative coil terminal wire #33 and the meter
positive lead to the coil positive terminal wire #15. 4. Visually inspect the contactor assembly.
Verify foreign objects don't interfere with normal
4. Connect the battery and activate the controls contactor operation.
necessary for the contactor to be activated.
5. Check contactor tip gap with a feeler gauge as
5. After the contactor activates the multimeter must shown. Refer to Specifications section for correct
indicate 24 to 36 volts. If the voltage is not correct settings.
and the contactor passed the Coil Suppression
Diodes test and the Coil Resistance test, the logics
must be replaced.

Current Sensor
4. Check continuity from harness connector PIN2

WARNING wire #L22 to logic P1-12 (3) and connector PIN2
wire #R22 to logic P1-13 (4). Repair or replace
Battery voltage and high amperage are present. any defective wires.
Injury to personnel is possible. Disconnect the
battery. The head capacitor (HEAD CAP) must be
discharged before any contact with the control 5. Set the multimeter to the 200V DC range. With
panel is made. Disconnect the battery and connector P1 disconnected, connect the
discharge HEAD CAP. multimeter positive lead to logic P1-16 (5).
Connect the multimeter negative lead to control
panel battery negative.
1. Disconnect the battery, discharge the head
capacitor, and remove the logic cover. 6. Connect the battery and turn the key to ON. The
measurement must be 11 to 13 volts. If the
measurement is not correct replace the logics.

capacitor. Connect P1.
WARNING

of wood under the frame so both drive wheels are
free to turn. Keep away from drive wheels that
turn.
2 1
Location Of Components 8. Set the multimeter to the 200V DC range and

(1) Current Sensor - Right. (2) Current Sensor - Left. connect the positive lead to logic P1-12 (3) or P1-
13(4)
2. Disconnect current sensor connector.
9. Connect the battery and turn the key to ON. The
3. Make sure wire #1 from current sensors is measurement must be 0 volts.
connected to the negative heatsink.
10. Move the direction lever to forward and depress
the accelerator. The voltage being measured
should increase. If there is no voltage measured
3 4 5 or the voltage being measured does not change,
the current sensor must be replaced.
NOTE: If the current sensor is replaced current limit

must be adjusted.
P1 Connector Locations
(3) P1-12. (4) P1-13. (5) P1-16.

Diodes Diode Replacement
WARNING WARNING
Battery voltage and high amperage are present. Battery voltage and high amperage are present.
Injury to personnel is possible. Disconnect the Injury to personnel is possible. Disconnect the
battery and discharge the head capacitor (HEAD battery and discharge the head capacitor (HEAD
CAP) before any contact is made with the control CAP) before any contact is made with the control
panel. panel.

capacitor.
1 5 6
2. Remove the logics.
3. Disconnect the lead wire and remove the diode.
2 7 9 3 4 8
Location of Comporrents
(1) DD1. (2) DD1cathode lead wire. (3) DD2.
(4) DD2 cathode lead wire. (5) DD3.
(6) DD3 cathode lead wire.(7) DD4.
(8) DD4 cathode lead wire. (9) Battery negative heatsink. Diode installation
(1) Contact surfaces.
DD1 (1) is shown in the procedure that follows. 4. Wipe clean contact surfaces (1). Put a small
Use a similar procedure for the other diodes. DD1 amount of D557047 Thermal Joint Compound on
(1), DD2 (3), DD3 (5) and DD4 (7) have a cathode contact surfaces (1), but not on the threads.
lead wire.
5. lnstall the diode and tighten to the specification
1. Disconnect the battery and discharge the head listed in the chart that follows.
capacitor.
Diode Torque
2. Disconnect DD1 cathode lead wire (2).
DD1, DD2, DD3, DD4 9 to 11 N•m (81 to 99 lb•in)
3. Set the multimeter to the diode test position.
6. Connect all wires that were removed.
4. Connect the negative multimeter lead on DD1
cathode lead wire (2). Connect the positive
multimeter lead to battery negative (9). 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.

Driver Board (On Vehicle)
NOTE: Driver board components are soldered

WARNING parallel to each other. The tests that follow
may not be typical of individual components
Battery voltage and high amperage are present. tests. The driver board must be replaced if
Injury to personnel is possible. Disconnect the any incorrect test results are obtained.
CAP) before any contact is made with the control Drive Side Tests
panel.
Refer to Driver Board Components and Connections.
If any of the measurements that follow are incorrect
the driver board must be replaced.
NOTICE
Damage to the control panel could result. To 1. Disconnect the battery, discharge the head
prevent further damage before the Driver Board is capacitor.
replaced, complete the check list that follow;
2. Disconnect CONN A from driver board - main.
1. Check head capacitor for a failure. 3. Resistor R2 test.

Set the multimeter to the 200Ω range. Connect the
If the drive circuit failed: positive lead to CONN A-8. Connect the negative
lead to CONN A-9. The measurement must be 7.1
2. Check diodes DD1, DD2. to 7.9 ohms.
3. Check diodes DD3, DD4.
4. Check transistors DTR1, DTR2. 4. Resistor R5 test.
5. Check continuity of current sensor wires. Set the multimeter to the 200Ω range. Connect the
6. Check continuity from DTR1 emitter (wire #L64) positive lead to CONN A-2. Connect the negative
to logic connector P9-5 and DTR2 emitter (wire lead to CONN A-3. The measurement must be 7.1
#R64) to logic connector P9-6. to 7.9 ohms.
If the hydraulic pump circuit failed: 5. Transistor TR1 (collector/emitter) and ZD1 test.
Set the multimeter to the diode test position.
2. Check diode PD. Connect the positive lead to CONN A-9. Connect
3. Check transistor PTR1. the negative lead to CONN A-1.
4. Check continuity from PTR1 emitter (wire #74) The measurement must be .3 to .9 volts.
to logic connector P9-7.
Reverse the test leads.
NOTE: Visually inspect the following connections to The measurement must be OL.
ensure proper connection and lack of
corrosion. 6. Transistor TR3 (collector/emitter) and ZD2 test.
1. Wire #L63 to the base of DTR1. Connect the positive lead to CONN A-2. Connect
2. Wire #R63 to the base of DTR2. the negative lead to CONN A-1.
3. Wire #73 to the base of PTR1. The measurement must be .3 to .9 volts.
4. Wire #74 to the emitter of PTR1.
5. Wire #4 to the positive heatsink. Reverse the test leads.
6. Wire #1 to the negative heatsink. The measurement must be OL.
7. Wires #L67 and #L68 to DR1.
8. Wires #R67 and #R68 to DR2. 7. Transistor TR1 (collector/base) test.
9. Wires #77 and #78 to PR1. Set the multimeter to the diode test position.
10. Wires #L65, #R65 and #75 to connector P9–1, Connect the positive lead to CONN A-9. Connect
P9-2 and P9-3. the negative lead to CONN A-10.
The measurement must be .3 to .9 volts.

The measurement must be OL.

8. Transistor TR3 (collector/base) test. 15. Transistor TR2 (emitter/base) and R3 test.
Set the multimeter to the diode test position. Set the multimeter to the diode test position.
Connect the positive lead to CONN A-2. Connect Connect the positive lead to CONN A-12.
the negative lead to CONN A-4. Connect the negative lead to CONN A-7.
The measurement must be .3 to .9 volts. The measurement must be .3 to .9 volts as
above
The measurement must be OL. Reverse the test leads.
The measurement must be almost same as
9. Transistor TR1 (emitter/base) and R1 test. above.
Set the multimeter to the 200Ω range.
Connect the positive lead to CONN A-1. Connect 16. Resistor R3 test.
the negative lead to CONN A-10. Set the multimeter to the 2 KΩ range. Connect
The measurement must be 3.5 to 4.3 ohms. the positive lead to CONN A-7. Connect the
negative lead to CONN A-12. The measurement
10. Transistor TR3 (emitter/base) and R4 test. must be 1000 to 1400 ohms.
Connect the positive lead to CONN A-1. 17. Transistor TR4 (emitter/base) and R6 test.
Connect the negative lead to CONN A-4. Set the multimeter to the diode test position.
The measurement must be 3.5 to 4.3 ohms. Connect the positive lead to CONN A-6. Connect
the negative lead to CONN A-7.
11. Transistor TR2 (collector/emitter) test. The measurement must be .3 to .9 volts.
Connect the positive lead to CONN A-7. Connect Reverse the test leads.
the negative lead to CONN A-11. The measurement must be almost same as
The measurement must be .3 to .9 volts. above.
Reverse the test leads. 18. Resistor R6 test.

The measurement must be OL. Set the multimeter to the 2 KΩ range. Connect
the positive lead to CONN A-7. Connect the
12. Transistor TR4 (collector/emitter) test. negative lead to CONN A-6. The measurement
Set the multimeter to the diode test position. must be 1000 to 1400 ohms.
Connect the positive lead to CONN A-7. Connect
the negative lead to CONN A-5. 19. Connect all disconnected connectors.

13. Transistor TR2 (collector/base) test.

Connect the positive lead to CONN A-12.
Connect the negative lead to CONN A-11.

14. Transistor TR4 (collector/base) test.



Hydraulic Pump Side Tests 8. Transistor TR6 (collector/base) test.
Refer to Driver Board Components and Connections. Connect the positive lead to CONN P-3. Connect
If any of the measurements that follow are incorrect the negative lead to CONN P-5.
the driver board must be replaced. The measurement must be .3 to .9 volts.
1. Disconnect the battery, discharge the head Reverse the test leads.
capacitor. The measurement must be OL.
2. Disconnect CONN A, CONN B from driver board - 9. Transistor TR6 (emitter/base) and R11 test.
main and CONN P from driver board - hydraulic. Set the multimeter to the 200 Ω range.
Connect the positive lead to positive heatsink.
3. Transistor TR5 (collector/emitter) test. Connect the negative lead to CONN P-5.
Set the multimeter to the diode test position. The measurement must be 3.5 to 4.3 ohms.
the negative lead to CONN B-4. 10. Resistor R9 test.
The measurement must be .3 to .9 volts. Set the multimeter to the 200 Ω range.
Connect the positive lead to CONN P-3. Connect
Reverse the test leads. the negative lead to CONN P-4.
The measurement must be OL. The measurement must be 7.1 to 7.9 ohms.
4. Transistor TR5 (collector/base) test. 11. Connect all disconnected connectors.

Connect the positive lead to CONN B-6. Connect
the negative lead to CONN B-4.

5. Transistor TR5 (emitter/base) and R7 test.


The measurement must be almost same as
above.
6. Resistor R7 test.
The measurement must be 1000 to 1400 ohms.
7. Transistor TR6 (collector/emitter) and ZD3 test.

Connect the positive lead to CONN P-3. Connect
the negative lead to positive heatsink. The
measurement must be .3 to .9 volts.


Driver Board (Off Vehicle)
Driver Board – Main
2 1
1 6 1 12
7 5 6 3 4
10
Driver Board – Hydraulic
1 8
9
10
Driver Board Components and Connections

(1) CONN A. (2) CONN B. (3) TR1. (4) TR2. (5) TR3. (6) TR4. (7) TR5. (8) CONN P. (9) TR6.
(10) Positive heatsink.

DRIVER BOARD TEST (OFF VEHICLE)
Component Multimeter Range + Lead - Lead Result
DRIVE SIDE
TR1 (C to E) Diode #R63-A9 #4-A1 0.3 to 0.9 volts
TR1 (C to E) Diode #4-A1 #R63-A9 OL
TR1 (C to B) Diode #R63-A9 #R67-A10 0.3 to 0.9 volts
TR1 (C to B) Diode #R67-A10 #R63-A9 OL
TR1 (E to B) AND R1 200Ω #4-A1 #R67-A10 3.5 to 4.5 ohms
R2 200Ω #R64-A8 #R63-A9 7.1 to 7.9 ohms
TR2 (C to E) Diode #1-A7 #R68-A11 0.3 to 0.9 volts
TR2 (C to E) Diode #R68-A11 #1-A7 OL
TR2 (C to E) Diode #R65-A12 #R68-A11 0.3 to 0.9 volts
TR2 (C to B) Diode #R68-A11 #R65-A12 OL
TR2 (E to B) AND R3 Diode #R65-A12 #1-A7 0.3 to 0.9 ohms
R3 200Ω #R65-A12 #1-A7 1000 to 1400 ohms
TR3 (C to E) Diode #L63-A2 #4-A1 0.3 to 0.9 volts
TR3 (C to E) Diode #4-A1 #L63-A2 OL
TR3 (C to B) Diode #L63-A2 #L67-A4 0.3 to 0.9 volts
TR3 (C to B) Diode #L67-A4 #L63-A2 OL
TR3 (E to B) AND R4 200Ω #4-A1 #L67-A4 3.5 to 4.3 ohms
R5 200Ω #L63-A2 #L64-A3 7.1 to 7.9 ohms
TR4 (C to E) Diode #1-A7 #L68-A5 0.3 to 0.9 volts
TR4 (C to E) Diode #L68-A5 #1-A7 OL
TR4 (C to B) Diode #L65-A6 #L68-A5 0.3 to 0.9 volts
TR4 (C to B) Diode #L68-A5 #L65-A6 OL
TR4 (E to B) AND R6 Diode #L65-A6 #1-A7 0.3 to 0.9 ohms
R6 200kΩ #1-A7 #1-A7 1000 to 1400 ohms
PUMP SIDE
TR5 (C to E) Diode #1-A7 #78-B4 0.3 to 0.9 volts
TR5 (C to E) Diode #78-B4 #1-A7 OL
TR5 (C to B) Diode #75-B6 #78-B4 0.3 to 0.9 volts
TR5 (C to B) Diode #78-B4 #75-B6 OL
TR5 (E to B) AND R7 Diode #1-A7 #75-B6 0.3 to 0.9 ohms
R7 200kΩ #1-A7 #75-B6 1000 to 1400 ohms
TR6 (C to E) Diode #73-P3 + HEATSINK 0.3 to 0.9 volts
TR6 (C to C) Diode + HEATSINK #73-P3 OL
TR6 (C to B) Diode #73-P3 #77-P5 0.3 to 0.9 volts
TR6 (C to B) Diode #77-P5 #73-P3 OL
TR6 (E to B) AND R11 200Ω #77-P5 + HEATSINK 3.5 to 4.3 ohms
R9 200Ω #73-P3 #74-P4 7.1 to 7.9 ohms

Transistors DTR1,DTR2 and PTR1 1. Check head capacitor for a failure.
If drive circuit failed:
WARNING 2. Check DD1,DD2 for a failure.

3. Check DD3,DD4 for a failure.
Battery voltage and high amperage are present. 4. Check DTR1,DTR2 for a failure.
Injury to personnel is possible. Disconnect the 5. Check driver board (drive side) for a failure.
battery and discharge the head capacitor 6. Check continuity from DTR1,DTR2 emitter bus
(HEAD CAP) before any contact is made with the bar (wire #L64, #R64) to logic P9-5, P9-6.
control panel. 7. Perform Current Sensor test.
If the pump circuit failed:

capacitor and remove the logics. 2. Check PD for a failure.
3. Check PTR1 for a failure.
2. Remove wires and bus bars from base and emitter 4. Check driver board (pump side) for a failure.
terminals of the transistors to be tested. 5. Check continuity from PTR1 emitter (wire #74)
to logic P9-7.
1 2
Transistor Replacement DTR1,
DTR2 and PTR1
WARNING

Injury to personnel is possible. Disconnect the
3 panel.
D557003 (927566) Transistor

(1) Emitter. (2) Base. (3) Collectror.
TRANSISTOR SPECIFICATIONS
Multimeter (+) (-) D557003
Setting Test Lead Test Results
Resistance Emitter Base 45 to 135Ω
Diode Base Collector 3 to .9 V
Diode Collector Base OL
Diode Emitter Collector .3 to.9V
Diode Collector Emitter OL 7 6 4 5 31 2
(1) Bolt. (2) Bar. (3) Emitter wire #L64.
(4) Base wire #L63. (5) Transistor DTR1. (6) Screw.
NOTICE (7) Bolts.
Damage to the control panel could result.
To prevent further damage before a power transistor DTR1,DTR2 and PTR1 are all replaced in the same
is replaced, complete the check list that follows: way. DTR1(5) is shown in the procedure that follows.

1. Disconnect the battery, discharge the head Resistors (DR1, DR2 and PR1)
capacitor, and remove the logics.
2. Remove bolt (1), bar (2) and emitter wire #L64 (3).
WARNING
3. Remove screw (6) and base wire #L63 (4).
4. Remove mounting bolts (7). Injury to personnel is possible. Disconnect the
panel.
NOTE : Look for visual breaks or cracks on resistors.

capacitor, and remove the logics.
8
2 1
Transistor Removal
(8) Contact surface. 4
3
6
5
Transistor Removal (1) DR1. (2) Wire #L67. (3) DR2.
(5) DTR1 transistor. (8) Contact surface. (4) Wire #R67. (5) PR1. (6) Wire #77.
5. The contact surface (8) of transistor (5) is coated 2. Disconnect wire #L67 (2) from resistor DR1 (1)
with D557047 Thermal Joint Compound. Carefully and disconnect wire #R67 from resistor DR2 (3).
remove the transistor.
3. Set the multimeter to the 200Ω range. Connect the
6. To Replace the transistor, wipe clean contact multimeter leads to terminals on resistor (1) to
surfaces. Put a small amount of D557047 Thermal check the resistance of DR1. Connect the
Joint Compound on the contact surface (8). Coat multimeter leads to terminals on resistor (3) to
transistor so that compound covers only the check the resistance of DR2. Connect the
contact area. multimeter leads to terminals on resistor (5) to
check the resistance of PR1.
7. Install transistor (5) with mounting bolts (7). See
Specifications section for proper torques. 4. The measurement for each resistor must be: 85 to
95 ohms.
8. Install base wire #L63 (4) with screw (6). See
Specifications section for proper torques. 5. If the measurement is not correct, the resistor
must be
9. Install bar (2) and emitter wire #L64 (3) with bolts
(1). See Specifications section for proper torques.

Thermal Switch
The Thermal Switch (1) will open circuit if the

WARNING temperature is 81 to 89°C (178 to 192°F) and close
circuit at 69 to 77°C (156 to 171°F).
Injury to personnel is possible. Disconnect the If the thermal switch is removed from the heatsink, it
battery and discharge the head capacitor (HEAD can be tested in an oven.
panel. See Troubleshooting Problem 20. Possible cause,
pump or drive transistors overtemperature.
NOTICE
Pump Motor and Drive Motor
Damage to the thermal switch will occur. Do not
heat the thermal switch over an open flame.
The Thermal Switch (1) will open circuit if the
temperature is 144 to 156°C (291 to 313°F)
and close circuit at 123 to 137°C (253 to 279°F).
Control Panel If the thermal switch is removed from the motor, it

can be tested in an oven.
See Troubleshooting Problems 21 and 22. Possible

cause, drive or pump motors overtemperature.
1
5
(1) Thermal switch-Drive. (5) Thermal switch-Hydraulic.

Electrical System Adjustments Method B (Electrical)
1. Enter diagnostics, through the specified procedure,

Accelerator Control Linkage the display is an “A0”.
Method A (Mechanical) 2. Depress the accelerator slowly to stop. The speed

symbols will increase from 0 to 10 on LCD.
3. Release the accelerator, the display will be “A0”,

disconnect the battery, and place the
DIAG/RUN/SETUP switch back to RUN, and
4 1 reinstall the line fuse.
Parking Brake Switch

2
63
WARNING

turn.
3

capacitor.
2. Adjust length of lever (1) to 63 L 2 mm and

tighten the nut (2). Fully depress accelerator pedal
(4) until stopped by accelerator stopper (3).
3. Release accelerator pedal (4). Check for

dimension. 3
2
Parking Brake Switch Adjustment

(1) Switch. (2) Plate. (3) Bolts.
1. Close the seat switch and turn the key to ON.
2. Release the parking brake and put the truck in

forward.

3. Reposition plate (2) so the switch (1) actuator is Valve Control Card Adjustment
against the bracket. Tighten bolts (3).
4. Engage the parking brake and the park brake

symbol will be displayed. Repeat the procedure
WARNING
until adjustment is correct.
Safety lift the drive wheels off the floor. Put blocks
Lift Sensor of wood under the frame so both drive wheels are
free to turn. Keep away from drive wheels that turn.
capacitor.
1. Verify the lift sensor clearance is adjusted
correctly.
2. Disconnect all tilt and auxiliary switch connectors.

1
3
3. Place the lift truck in “Quick” or “Self” diagnostics
so that the display is flashing the lift speed.
4
2
Lift Sensor Adjustment

(1) Lift Sensor(transducer) (2) Magnet. (3) Screw.
(4) Setscrew. (A) 1.0 mm (.039 in) Clearance.
1
2
NOTICE
Lift sensor may be damaged. Do not allow the magnet Valve Control Card Adjustment
(2) to make contact with the plastic bracket when the (1) P1 Potentiometer. (2) P2 Potentiometer.
lift lever is activated.
4. Turn potentiometer P1 (1) fully counterclockwise
unitl a clicking sound is heard (roughly 20 turns).
2. Loosen setscrew (4).
5. Turn potentiometer P2 (2) fully counterclockwise
3. Adjust screw (3) to make clearance (A) 1.0mm until a clicking sound is heard (roughly 20 turns).
(.039 in) between lift sensor (1) and magnet (2)
when the lift lever is activated fully (pulled all the 6. Turn potentiometer P2 (1) 15 full turns clockwise.
way back).
7. Position the lift lever just prior to the hydraulic
4. Tighten setscrew (4). Check lift sensor circuit. The valve opening. Adjust P1(1) clockwise until a
valve control card may need adjusting. flashing “1” is obtained on the display.

8. Pull the lift lever all the way back. A flashing “3” Tilt and Auxiliary Switches
must be displayed.
Because each tilt and auxiliary switch can turn on the
9. If a flashing “3” is not displayed, adjust P2 (2) pump motor, it is recommended that only one be
clockwise until it is. connected to start with. After adjusting the first switch
proceed with the next one.
10. Release the lift lever and adjust P1
counterclockwise until a “0” is displayed. 1. Disconnect the battery and discharge the head
capacitor. Disconnect all but one switch connector.
11. Repeat steps 9 and 10 until “0” to “3” speeds
correct.
12. Put the lift truck back in the run mode so the
actual hydraulics can be tested.
13. Connect the battery, close the seat switch and

turn the key to ON.
14. Pull the lift lever back until the pump motor turns
on. The forks must not move. Adjust P1 so the
motor starts just before the valve opens.
1
If the valve opens before the motor turns on, adjust

P1 (1) clockwise.
If the motor turns on too far in advance of the valve

2
opening, adjust P1 (1) counterclockwise.
Tilt and Auxiliary Switch Adjustment

(1) Screw. (2) Screws.
2. With valve spool in neutral position, loosen screws

(2) and adjust screw (1) to center the switch roller
on cam.
3. After adjusting switch in or out to obtain correct

switch point, tighten screws (1) and (2) to lock
switch into position.
4. Connect the battery, close the seat switch and turn

the key to on. Readjust switch if needed, so that
the pump motor turns on before the control valve
opens.
This must be adjusted for each lever direction
(pushed or pulled).
5. Connect the next switch and repeat this proccdure.

Rapid Tune-Up Procedure
3) VR6 : Bypass Dropout Current Potentiometer
Fully counterclockwise (CCW) and then

5 slowly turn VR6 (20 full turns) clockwise
4
3 (430A).
2
4. Make the final adjustments as specified in each of
1 the Testing And Adjusting procedures before
putting the truck into service. Perform these
procedures in the order listed below:
Lacation of Potentiometers 1) Battery Discharge Indicator (BDI)

(1) Current limit potentiometer VR1.
(2) Plugging Current limit potentiometer VR2.
(3) BDI adjustment potentiometer VR5. 2) Current Limit
(4) Bypass drop out adjustment potentiometer VR6.
(5) Electric Assist Brake adjustment potentiometer VR8. 3) Plugging Current Limit
The rapid tune-up procedure establishes a starting 5. Turn off the key switch.
point for logic card adjustments. The following
procedure allows the truck to run without damage to
the truck or its components.
Battery Discharge Indicator (BDI)
Adjustment
WARNING

of wood under the frame so both drive wheels are 1
free to turn. Keep away from drive wheels that turn. 3
2
1. Turn off the key switch.
2. Place direction lever to reverse or forward or seat

switch open. Logic Board Layout
(1) Jumper JP1. (2) Jumper JP2. (3) Potentiometer VR5
3. Turn on the key switch and then wait until display
“EE” (SRO) or “EE” flashing shows on the LCD
and the line contactor will be opened. Accurate adjustment of the BDI is only possible with
a battery of the same voltage that the truck is going
1) VRI : Drive Motor Current Limit to operate at, and at a voltage within the range of the
Potentiometer display. If a lift interrupt has occurred, with a “EL” on
the display, it may be necessary to reprogram
Fully counterclockwise (CCW) and then Feature “10” to select TYPE1, and then make the
slowly turn VR1 (8 full turns) clockwise necessary adjustments.
(250A). If 48 volt European tubular batteries are used, it is
recommended that logic board is programmed
2) VR2 : Plugging Current Limit Potentiometer TYPE1 on Programmable Feature “10”.
Fully counterclockwise (CCW) and then

slowly trun VR2 (8 full turns) clockwise
(250A).

BDI Adjustment Battery Table of the Closed Circuits
1. Disconnect the battery and discharge the head Battery Terminal Voltage
capacitor. Remove logic cover and verify the Bar Symbols
Type 1(OPT) : Closed Voltage
DIAG/RUN/SETUP switch is in the RUN position. Display
36V 48V
2. Make sure the jumper connector is in the correct 6 above 37.2 above 49.1
place for the lift truck battery used. Place the
jumper on the following. 5 36.8 to 37.2 48.6 to 49.1
JP1=36V, JP2=48V 4 36.4 to 36.7 48.0 to 48.5
3 36.0 to 36.3 47.5 to 47.9
3. Set the multimeter to measure battery voltage.
Connect the multimeter positive lead to the battery 2 35.6 to 35.9 47.0 to 47.4
positive cable at the line contactor. Connect the 1 35.2 to 35.5 46.5 to 46.9
multimeter negative lead to the battery negative
cable. 1* 25.8 to 35.1 33.8 to 46.4
0/EL below 25.8 below 33.8
4. Put the direction lever in neutral and connect the
battery. 1*=Display is flashing
5. Close the seat switch and turn the key to ON. The
BDI display must show the correct bar for the Battery Terminal Voltage
voltage measured. To correct values are shown in Bar Symbols
Type 1(STD) : Closed Voltage
the charts that follow. Display
36V 48V
EXAMPLE: If the measurement is 49.1 volts for a 48 6 above 37.2 above 49.1
volt battery, the bar display should be at “5”. 5 36.8 to 37.2 48.4 to 49.1
6. If the display is not correct, turn the key to OFF 4 36.4 to 36.7 47.7 to 48.3
and make an adjustment to potentiometer VR5. 3 35.9 to 36.2 47.1 to 47.6
Turn VR5 clockwise to increase and
2 35.4 to 35.8 46.4 to 47.0
counterclockwise to decrease the bar display.
Approximately a 1/2 turn of VR5 will change the 1 35.0 to 35.3 45.9 to 46.3
display one bar. Turn the key to OFF between 1* 34.5 to 34.9 45.0 to 45.8
adjustments otherwise the display WILL NOT
CHANGE. 0/EL below 34.5 below 45.0
1* = Display is flashing
7. If the voltage was 49.1V, VR5 should be turned to
find the transition point between 6 and 5 on the
bar display. This will assure that the BDI is Battery Terminal Voltage
calibrated at a high 5. Bar Symbols
Type 1(OPT) : Closed Voltage
Display
36V 48V
6 : The highest position : Max. Charged Status 6 above 37.2 above 49.1
5 36.9 to 37.2 48.3 to 49.1
5:
4 36.6 to 36.8 47.4 to 48.2
4:
3 35.3 to 36.5 46.6 to 47.3
3: 2 35.9 to 36.2 45.7 to 46.5
1 35.6 to 35.8 44.9 to 45.6
2:
1* 35.3 to 35.5 44.0 to 44.8
1:
: (A) Not flashing 0/EL below 35.3 below 44.0
(B) Flashing - 80%
discharge warning

NOTE: Closed Voltage means that line contactor
close and idle operation in hydraulic system.
7. If the voltage is higher than 49.1V, adjust the BDI

as example.
EXAMPLE: If the measurement is 50.7V, adjust bar

display at a low 6 and then turn VR5 to 1
TURN CW. (1 TURN CW = 1.6V
increase)
BDI Adjustment with display at “EL”
If the logics has already gone into lift interrupt

(display = “EL”) it is not possible to adjust the BDI
until a battery above a certain programmed voltage is
connected to the vehicle.
The factory default setting to reset the lift interrupt is

any voltage equivalent to a bar display of 3 or higher.
This level can be adjusted.
See Program Feature “3”.
By reprogramming Feature “3”, from the factory

default code of 3, to a temporary code of 0, it will
become possible to adjust the BDI with a battery with
a voltage less than a 3 on the bar display .
After adjustment of the BDI, reprogram Feature “3”

back to the default setting of 3.

Current Limit Test and Adjustment
4. Engage the park brake. Connect the park brake

connector of harness to hold the closed circuit.
5. Connect the battery. Close the seat switch and

turn the key to ON.
6. Select a direction and depress the service brake

so that the wheels do not turn. Depress the
1
accelerator to 80% pulsing.
To prevent bypass operation ensure that the
accelerator is not depressed all the way down. To
get an accurate current reading the wheels must
not slip.
Ammeter Connection
(1) Digital Ammeter.
NOTICE
WARNING Damage to the drive motor will result. Do not stall
the drive motor for longer than absolutely
The lift truck can move suddenly. Injury to necessary. To protect the drive motor from
personnel or damage to the lift truck is possible. excessive currents, and “F0” can occur during
Safely lift the drive wheels off the floor. Put blocks current limit setting. Allow for the motors to cool
of wood under the frame so both drive wheels are between stalls, and let the motor run between
free to turn. Keep away from drive wheels that stalls.
turn.
7. The current measurement must be within

NOTE : Current limit is preset at the factory and specification. Adjust logic potentiometer VR1
should not be adjusted unless the truck clockwise to increase the current and
malfunctions, or the logic board is replaced. counterclockwise to decrease the current.
Only qualified service personnel with the 48V between 240 and 260 amps.
correct instrumentation should adjust current
limits. 8. Repeat steps 6 and 7 until setting is correct.
1. Put blocks of wood under the frame so both drive 9. Don’t forget to re-engage the service brake switch
wheels are free to turn. and park brake switch prior to putting the vehicle
back into operation.
2. Connect clamp-on ammeter (1) around the LA1
cable to measure drive motor current. Use
multimeter to read current remotely from the
operator’s seat. Ensure that option feature “9” is
default setting to prevent bypass operation.
3. Remove the floor plate, and disconnect the service

brake switch connector.

Electrical Braking (Plugging) Bypass Dropout Adjustment - Stall
Current Test and Adjustment Protection
WARNING

1
turn.
The stall protection feature helps protect the drive

Ammeter Connection motor from abuse, and can also prevent unnecessary
(1) Digital Ammeter.
line fuse failures. Adjustment or checking of this
current setting is not recommended unless drive
1. Make sure current limit is adjusted to specification motor or fuse failures have occurred, or an “F0”
before adjusting Electrical Braking current. occurs during bypass operation. Factory settings are
as follows:
2. Connect clamp-on current probe (1) around LA1
cable to measure drive motor current. Use 48V between 420 and 440 amps
multimeter to read current remotely from the
operator’s seat. Fully counterclockwise (CCW) and then slowly turn
VR6 (20 full turns) clockwise (430A).
3. Move the lift truck FORWARD at full speed. Keep
the accelerator pedal fully depressed and change If “F0” occurs during bypass operation, the
the direction to REVERSE. application should be investigated for incorrect
operation, and maximum currents should be
4. The current measured during the electircal braking measured. Adjusting VR6 clockwise will increase the
(plugging )must be 250 amps L 5%. maximum current allowed in bypass. For maximum
motor protection, VR6 can be adjusted
5. If the correct current is not measured, disconnect counterclockwise, until a “F0” occurs in bypass, then
the battery and discharge the head capacitor. adjust the potentiometer clockwise 1 turn.
Remove the logic cover and adjust potentiometer
VR2. Turn the potentiometer adjustment screw
counterclockwise to decrease the plugging current.
NOTE : Though the plugging distance

(Recommended plugging distance is
approximately 5 meters) is an application
specific adjustment, plugging current should
not exceed 250 amps. If the recommended
current produces a short stopping distance,
the distance may be lengthened by turning
potentiometer VR2 counterclockwise to
reduce plugging current.

Programmable Features
There are 17 programmable features that effect the With the desired Feature Number being shown, move
operation of the lift truck. A table of these features, the direction lever to forward or reverse and then
the default setting, the minimum setting and the neutral. The display will flash the preset data value.
maximum setting are shown below:
To increase the value, cycle the direction lever to
Default forward and then back to neutral. The display will
Feature Minimum Maximum Setting increment number. Repeat this cycle until the
Description
Number Setting Setting 36(V) 48(V) desired value for this feature is flashed.
0 1 5 4 4 Creep Speed
To save a new setting, pull the tilt lever to
1 1 6 4 2 Maximum Steering Speed
maximum position and then release slowly while
2 1 2 0 1 Electrically Assisted Braking holding a wanted setting.
3 0 6 3 3 Discharged Battery Reset Value The display will show the next feature number.
4 0 6 0 0 Top Travel Speed Limit
5 P P Auto Plugging 3. Repeat again on the above NO.2 until static
6 0 4 2 2 Wait Timer (seconds)
display, 16 will show.
A “PE” indicates the end of the feature list and can
7 1 2 1 1 Discharged Battery Drive Speed
be cycled to return to the beginning of the feature
8 1 5 4 4 Acceleration Travel Speed Time list.
9 1 3 1 1 Excessive Drive Motor Current
10 1 3 2 2 Battery Type Selection
11 1 6 3 3 Maximum Idle Speed
12 1 6 3 3 Maximum Lift1 Speed
Activating Default Settings
13 1 6 1 1 Maximum Lift2 Speed
All of the programmable features can be set to
14 1 6 3 3 Maximum Tilt Speed the factory default settings by the following
15 1 9 4 4 Maximum Auxiliary Speed procedure.
16 1 5 3 3 Hydraulic Ramp Timer
1. Turn the key switch to OFF.
Setting Procedure Option Features 2. Seat switch must be open.
The programming procedures are described on the 3. Move the direction lever to reverse.
following.
4. Place the DIAG/RUN/SETUP switch to SETUP.
1. Initial conditions
5. Park brake must be released.
Move the DIAG/RUN/SETUP switch to “SETUP”
and then turn on the key switch. 6. Depress the accelerator pedal to maximum.
Wait until display “0” shows on the LCD. This code 7. Turn the key switch to ON.
indicates that truck is in the SETUP mode.
8. After the display performs the LCD test, a “d”
2. Programming methods (Flashing) will be displayed. This indicates that the
default settings have been programmed.
To change the Programmable Feature Numbers,
pull the tilt lever to maximum position and then NOTE: When you change voltage jumper
release once. The display will show Feature (JP1 JP2), you should do the default
Number 1. setting on page 129
Cycling the tilt switch advances the display to the

next Feature Number. Cycle the tilt switch until the
Feature Number of the parameter to be
programmed is shown on the display.

Programmable or Settable Option Features
The logics contains a number of features which are either settable or programmable.
The following is a list of the features, however the “Service Manual” or your Daewoo Dealer should be consulted
in determing which options may be beneficial to the application.
Note : Marked means default setting.
FEATURE NO. DESCRIPTIONS

• • Creep Speed
•B
•
Creep Speed Selection provides for slower creep speed control, especially at high mast
application. Depending on truck chassis configuration and customer preference, the
creep speed can be selected. The default setting of 2 gives improved creep speed
0 control, especially at higher mast. The higher “number” makes more faster creep speed.
Data Codes 1 2 3 4 5
On-Duty (%) 20 23 26 29 32
• • Maximum Steering Speed
•B
•
This can be used to limit the maximum steering speed of the truck.
These values are on-duty ratio of the pump main transistor base.
36(V) 1 2 3 4 5 6
Data Codes
48(V) 1 2 3 4 5 6
On-Duty (%) 17 20 23 26 29 32
• • Electrically Assisted Braking
B
•
To automatically activate plugging braking when the service brake is depressed and
accelerator pedal is released.
2
36(V) 0 1
Data Codes
48(V) 0 1
Comments Not used Used
•
•B
• • Discharged Battery Reset Value
This feature sets the level of battery charge required to enable the hydraulics after
a lift interrupt occurs. The battery discharge indicator (BDI) must read a level
greater than the value set in this feature to enable the hydraulics after a lift interrupt
3
occurs. (1* = Display is flashing)
Data Codes 0 1 2 3 4 5 6
On-Duty (%) 1* 1 2 3 4 5 6
•
•B
• • Top Travel Speed Limit
The value of this feature is set to select the drive motor top speed.
Values between 1 and 5 allow for varying speeds, 1 being the slowest and 5 being
the fastest without using the bypass contactor.
4 0 being the normal travel and bypass operation.
Data Codes 0 1 2 3 4 5
Speed(%) 100 : Bypass operation 43 50 60 75 90

• • Auto Plugging
•B
•
If selected, this feature will automatically activate auto plugging braking when the
5 accelerator is released during driving.
Data Codes P
Time (Sec) Pass
• • Wait Timer
•B
•
This feature varies the time before the line contactor drops out after the truck has
been inactive (wait mode-no operator requests, and direction lever in neutral).
The delay may be set in 6 second increments between 0 and 12 seconds.
6
Time (Sec) 0 3 6 9 12
• • Discharged Battery Drive Speed
•B
•
This feature sets the drive motor top speed during lift interrupt, battery lock-out. If
the display shows “EL”, the logics limits the drive motor top speed to the value set
7 in this feature.
Data Codes 1 2
1. Max.speed=70% 1. Normal operation.
Comments
2. No bypass operation. 2. Bypass operation.
• • Acceleration Travel Speed Time
•B
•
This feature allows for varying amounts of time until the bypass contactor close
when accelerator pedal has been depressed from zero to max. position.
8
Time (Sec) Slowest Slower Normal Faster Fastest
• • Excessive Drive Motor Current

•B
•
This prevents the truck from entering bypass when the truck is in current limit, thus
extending the life of the bypass contactor tips, reducing line fuse failures, and
extending drive motor brush life.
If the motor is stalled for longer than the timer is set for, the vehicle will failsafe to
9 prevent motor damage and an “F0” will be displayed.
Data Codes 1 2 3
This is to protect drive This is to protect drive

Comments motor from excessive motor from excessive
Not used
current in either pulsing current in only bypass
or bypass modes. modes.
• • Battery Type Selection
•B
•
Due to different voltage characteristics of battery technologies, specifically
european tubular designs, it may be necessary to use a battery voltage chart with a
10 reduced voltage range.
Data Codes 1 2 3
Battery Voltage (Volt) Max.49.1/Min.33.8 Max.49.1/Min.45.0 Max.49.1/Min.44.0

• • Maximum Idle Speed
•B
•
This can be used to limit the maximum idle speed of the truck.
11 These values are on-duty ratio of the pump main transistor base.
On-Duty (%) 7 9 11 13 15 17
• • Maximum Lift 1 Speed
•B
•
This can be used to limit the maximum lift 1 speed of the truck.
On-Duty (%) 25 30 35 40 45 50
• • Maximum LIft 2 Speed
•B
•
This can be used to limit the maximum lift 2 speed of the truck.
On-Duty (%) 50 60 70 80 90 95
• • Maximum Tilt Speed
•B
•
This can be used to limit the maximum tilt speed of the truck.
On-Duty (%) 30 40 50 60 70 80
•
•B
• • Maximum Auxiliary Speed
This can be used to limit the maximum aux. speed of the truck.
Data Codes 1 2 3 4 5 6 7 8 9
Time (Sec) 30 35 40 45 55 65 75 85 95
• • Hydraulic Ramp Timer
•B
•
When the hydraulic switches are activated, the time which is to take to maximum
pulsing can be adjusted.
16
On-Duty (%) Slowest Slower Normal Faster Faster
Quick Procedure for Programmable Features

An alternative method of entering option programmable features has been programmed into the logics. This will
enable quick option programmable features without removing the controller room, line fuse, or placing the
DIAG/RUN/SET switch to the “Set Up” position.
To enter quick option programmable features, open the seat switch and place the direction lever to reverse and
ensure that the park brake is released. While depressing the accelerator to maximum position other than OFF,
and key switch to ON.
Display will go to a solid “O”, indicating that you have entered option programmable features and you are ready
for setting: Place the direction lever to neutral and release accelerator pedal.You can set the option
programmable features.
See programmable or Settable Option Features on page 129-132.

Specifications Systems Operation Testing & Adjusting: Microcontroller Control System

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Specifications Systems Operation Testing & Adjusting: Microcontroller Control System

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SB2077E03

for Electric Lift Trucks

The meaning of this safety alert symbol is as follows :

Attention! Become Alert! Your Safety is Involved.

MicroController Control Systems 1 Specifications

Testing And Adjusting

MicroController Control Systems 3 Index

Electrical System Adjustments ...............................121

Preparation Tests and Checks .................................43

Programmable Features ........................................129

System Tests and Adjustments ..............................102

Troubshooting Problem List ....................................54

MicroController Control Systems 4 Index

Meter Meter Positive Meter Negative

CURRENT VALUES (AMPS)

MicroController Control Systems 5 Specifications

D557003 (927566)-for Pump(48V) D557065 - for Pump(36V)

(1) Emitter connection

(2) Base connection

(3) Collector connection

MicroController Control Systems 6 Specifications

(1) Tighten screws that fasten the instrument panel to

(1) Torque bolts that hold bracket to steering

(2) Torque bolts that hold bracket to switch to

MicroController Control Systems 7 Specifications

(2) Spring washer D917069.

(3) Ring terminal of wire assembly.

(4) Lockwasher D917071.

(5) Head capacitor terminal.

MicroController Control Systems 8 Specifications

Control Panel - Drive

Control Panel - Pump (48V)

MicroController Control Systems 9 Specifications

(6) Tighten screws that fasten wires to the base of

MicroController Control Systems 10 Specifications

Ammeter An electric meter used to measure current flow in amperes.

Anode The positive (+) side of a diode.

Armature The rotating portion of an electric motor or generator.

Cathode The negative (-) side of a diode.

CVMS Central Vehicle Monitoring System.

Conduct To allow the flow of current.

Conductor A material that provides a path for current flow.

MicroController Control Systems 11 Systems Operation

Continuity Having the ability to allow current flow.

Current The movement or flow of electricity through a conductor. A circuit must be

Display An electrical device that converts voltage inputs to a visual output.

Filter An electrical device or component for restriction or suppression of undesired

Heat Sink A mounting frame used for semiconductor cooling.

MicroController Control Systems 12 Systems Operation

Input A voltage change at the incoming connection of a component.

LCD Liquid Crystal Display.

ON-Time The amount of time current flows through a transistor.

Open Circuit Wiring or components of a circuit that have no continuity.

Potentiometer An adjustable resistor to preset electronic controls for proper specifications.

Pulsing Current flow in a circuit being turned on and off.

MicroController Control Systems 13 Systems Operation

Relay An electrical component consisting of an electromagnetic coil and a set of small

Solid State Reference to semiconductor components or circuits that use semiconductor

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

Turn ON When an electrical component conducts current.

MicroController Control Systems 14 Systems Operation