Testing And Adjusting To clear all of the faults, wait until the display shows a

solid “-,” then move the DIAG/RUN/SETUP switch to

Accessing Stored Faults
The logics stores the last eight faults or warnings the
truck has experienced. This is useful in case the truck
has an intermittent problem or a thermal condition and
the operator cannot tell the service people exactly
what happened. By analyzing the contents of the
stored faults, one may be able to determine what sort
of application the truck has been in (thermal conditions
or motor overcurrent).
the SETUP position. The display will show a solid “=”
to indicate that all of the faults have been erased. At
this point, it will be necessary to place the DIAG/RUN/
SETUP switch in the desired position and cycle the
key switch.
The following are possible faults stored in memory:
NOTE: The single-digit BDI display will alternate
between the letter “F” and a second letter or number to
indicate two-digit fault codes.

These stored faults are accessed at the end of • FO - Excessive drive motor current in either pulsing
diagnostics by using the following procedure: or bypass modes.

1. Access the self-diagnostics procedure as usual. • Fr - Drive problem; voltage on right drive transistor
emitter (wire 37).
2. Either step through the self-diagnostic procedure or
override each test by moving the DIAG/RUN/SETUP • FL - Drive problem; voltage on left drive transistor
switch from DIAG to RUN and back to DIAG until emitter (wire 41).
the contactor testing is complete.
• F - Drive problem; both an F“r” and an F“L” problem
3. Cycle the DIAG/RUN/SETUP switch once more and
together.
cycle through the contactor testing again. After the
left directional contactor drops out, for the second
• FE - Non-volatile memory problem; try
time the display will indicate a “C.”
reprogramming default values.
The stored faults can now be accessed one at a time
• A - Wheel angle transducer problem.
by moving the DIAG/RUN/SETUP switch to RUN and
then back to DIAG. This will display the most recent
• C - Controller thermal switch open circuit.
fault. By cycling the switch more times, more faults will
appear on the display, up to a total of eight. When the
display shows a solid “-,” it indicates that all of the
faults have been displayed. It is possible that the “-”
will appear immediately, indicating no faults have been
encountered. It is also possible that all faults may be
the same and the display will not change between
switch cycles. If when displaying a “-” the
DIAG/RUN/SETUP switch is cycled to DIAG and RUN,
the faults will start to be displayed again.

MicroCommand Control System 44 Testing And Adjusting

Troubleshooting
The following Troubleshooting Check List is an aid in
troubleshooting MicroCommand lift trucks. The
troubleshooting check list, “Run Time” diagnostic
indications, “Self” diagnostic tests, problem list and
problem flow charts will assist in:
1. Defining the problem and verifying a problem
exists.
2. Performing the checks in a logical order.
3. Making the necessary repairs.
4. Verifying the problem has been resolved.
NOTICE
Damage can be caused to the test equipment. Make
resistance and continuity checks only after the battery
is disconnected.
NOTICE
Damage can be caused to the control panel. Do not
use steam or solvent to clean the controls. Use
pressure from an air hose with a maximum pressure
of 205 kPa (30 psi) to clean the control panel when
necessary. Make sure the air pressure supply is
equipped with a water filter.
MicroCommand Control System
NOTICE
Damage can be caused to the control panel. Do not
switch the direction lever from one direction to the
other (plug the lift truck) when the drive wheels are off
the around and in rotation at full speed.
NOTICE
Damage to the drive and hydraulic pump motors will
result. The drive and hydraulic pump motors are single
voltage units 36 or 48 volts, and must be operated at
their designed voltage. The voltage of the lift truck
cannot be changed without chancing motors.
Troubleshooting Check List
1. Perform Preparation Tests And Checks.
2. Correct any display problems and “Run Time”
diagnostic faults.
3. Correct the “Self” diagnostic faults.
4. Perform Operational Checks
5. Correct “Other Problems” in the Troubleshooting
Problem List.
6. Perform Operational Checks to verify repairs.
Preparation Tests And Checks
Battery Tests
A weak battery can cause or contribute to problems in
the MicroCommand control and power circuits. Verify
the battery is good before investigating other
possibilities.
1. Verify proper polarity at the battery connector and
the MicroCommand control panel. Positive cable
should be at the line contactor and negative at the
negative heatsink.
2. If the lift truck is operational, perform a battery load
test.
3. If the truck is not operational and the battery is
suspected, perform a cell voltage or specific gravity
test.
45 Testing And Adjusting
Battery Load Test
1. Turn the range switch on the multimeter to read
battery voltage.
2. Connect the battery.
3. Connect the multimeter leads between positive (+)
cable connection (1) on line contactor, and
negative (–) cable connection (2) on 4 diode
heatsink.
4. In a safe area, operate the hydraulic system, (hold
tilt lever to maximum position momentarily) while
reading the voltage indicated on the multimeter.
5. If the indication is less than 33.1 volts for 36 volt
trucks or 44.2 volts for 48 volt trucks, the battery
needs to be charged or repaired before continuing
to troubleshoot.
Cell Voltage Test
With the truck powered up and the power steering
motor running, measure the voltage at each cell.
Normal voltage should be between 1.95V and 2.12V
per cell. If the voltage on each cell is below 1.95 the
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 needs an
equalizing charge or to be repaired.
Hydrometer Test
Test each cell of the battery with 5P0957 or 5P3514
Battery Tester Group. 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.
NOTE: The indication between cells should not differ
more than .020. If it does, the battery needs an
equilizing charge or to be repaired.
MicroCommand Control System
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 maximum battery life and efficient truck
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
chassis. Tighten all vent plugs, wash the battery
with water and a brush, then dry with an air hose. It
may be necessary to use a baking soda solution if
water alone will not clean the top of the battery.
2. Add enough water to cover the plates before
charging. This will ensure the proper chemical
reaction over the entire plate surface. After
charging is complete, add water until it is about
12.7 mm (.50 in) above the plates. Use distilled
water or water that has tested free from minerals.
3. Charge the battery correctly. A battery should be
discharged to 80% of its capacity then fully
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
charge (an extra three or four hour charge at a low
finish rate) once a month to make sure all cells are
in a fully charged condition. Properly charged
batteries should be identified to prevent low
batteries from being installed in trucks.
4. Operation with a low battery must be prevented.
Low battery operation may damage the battery and
will cause higher than normal current in the
electrical system. High current draw due to a low
battery will damage contactor tips and shorten
motor brush life.
5. The battery’s maximum temperature is critical. The
electrolyte temperature should never exceed 43°C
(110°F) either while operating or charging.
Overcharging a battery will cause over heating and
warp the battery plates. Maximum battery life will
result from maintaining 25°C (77°F) electrolyte
temperature. Most of the charging equipment is
fully automatic but should be checked periodically
to assure proper working order.
46 Testing And Adjusting
6. Keep accurate battery records. Regular battery
readings should be taken with a battery tester or
voltmeter and a written record kept. Specific gravity
and voltage of each cell should be checked and
recorded at least once each month. This inspection
should be made after an equalizing 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 wearing
out.
Repairs should be made immediately, otherwise the
battery may become damaged. Batteries stored in a
discharged condition may be difficult to recharge, due
to sulfate formation.
Visual Checks
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 that there is no mechanical binding or
interference in the contactors.
3. Visually check the parking brake switch, the lift
switch and accelerator linkage for adjustment or
interference problems.
Resistance To Chassis Checks
Resistance between any point in the truck wiring and
the chassis should be a minimum of 100 000 ohms.
Many malfunctions are caused by shorts to chassis.
Usually, two shorts must exist before a malfunction will
occur. But, since batteries can have chassis leakage,
only one short to chassis in the truck wiring can cause
problems. To prevent problems because of shorts, do
the following:
1. Disconnect the battery and discharge the HEAD
CAP.
2. Randomly measure any component connection or
wiring connection with respect to the lift truck
chassis for a minimum resistance of 100 000 ohms.
Any test point with low resistance must have the
short to chassis removed.
3. Always keep batteries clean to minimize current
leakage to the chassis.
MicroCommand Control System
4. Routinely clean the brush dust from the motors.
5. Be sure that all attachments, such as horns and
lights, are designed for no chassis connection (a
two wire system).
Removal Of Shore To Chassis
When a short is found, it must be cleared even if the
machine has normal operation. It is necessary to
narrow the field of possible problem areas before
inspection of individual wires and components.
When a low resistance circuit is located, it should be
opened at various points. This will permit the shorted
wire or component to be pin-pointed for repair or
replacement.
Control And Power System
Operational Checks
All operational checks are to begin with the
battery connected, directional switch in neutral,
rear steer wheel straight ahead, drive wheels off
the ground and the accelerator and parking brake
released. All programmable features should be
set to their factory default values before making
any adjustments. See the topic Activating Default
Settings in the Systems Operation section.
NOTE: Perform all operational checks before returning
to the Troubleshooting Check List.
Check 1: Key And Seat Switch
1. Actuate the key and seat switch. The line contactor
activates and the power steering motor turns on.
After the time set in Programmable Feature “3,” the
contactor deactivates and the motor turns off.
Check 2: Hydraulic Performance
1. Slowly pull the lift control lever. The pump contactor
activates and the hydraulic motor turns on at one
speed.
2. Slowly pull and push the tilt and auxiliary levers.
The pump contactor activates and the hydraulic
motor turns on at one speed with each lever
movement.
47 Testing And Adjusting
Check 3: Forward Drive Performance, Steer
Wheel Straight Ahead
1. Engage the parking brake. Select forward direction
and depress the accelerator slightly. The right
contactor will not activate and both drive wheels will
not turn.
2. Release the parking brake, select forward direction
and depress the accelerator slightly. The right
contactor will activate and both drive wheels will
turn forward slowly.
3. Slowly increase the amount of accelerator
depression. The right contactor will remain
activated. Both drive wheels will turn forward and
slowly increase in speed equally.
4. Depress the accelerator fully. The right contactor
will remain activated and bypass contactor will
activate. Both drive wheels will turn forward at full
speed.
Check 4: Reverse Drive Performance, Steer
Wheel Straight Ahead
1. Select reverse direction and depress the
accelerator slightly. The left contactor will activate
and both drive wheels will turn in reverse slowly.
2. Slowly increase the amount of accelerator
depression. The left contactor will remain activated.
Both drive wheels will turn in reverse and slowly
increase in speed equally.
3. Depress the accelerator fully. The left contactor will
remain activated and bypass contactor will activate.
Both drive wheels will turn in reverse at full speed.
Check 5: Right Turn Steer Angle Performance,
Steer Wheel Straight Ahead
1. Select forward direction and depress the
accelerator fully. The right and bypass contactors
will activate. Both drive wheels will turn forward at
full speed.
2. Slowly turn the steering wheel to the right. As the
steering wheel is turned, the following sequence of
events will occur: The bypass contactor will
deactivate, the right drive wheel will begin to slow
down and come to a complete stop. The right
contactor will deactivate and the right drive wheel
will begin rotating in reverse increasing in speed.
When the steering wheel is at maximum right turn,
the right and left drive wheels will rotate at the same
speed but in opposite directions. This should be a
smooth sequencing while turning the steering
wheel.
MicroCommand Control System
Check 6: Left Turn Steer Angle Performance,
Steer Wheel Straight Ahead
1. Select forward direction and depress the
accelerator fully. The right and bypass contactors
will activate.
2. Slowly turn the steering wheel to the left. As the
steering wheel is turned the following sequence of
events will occur: The bypass contactor will
deactivate, the left drive wheel will begin to slow
down and come to a complete stop. The left
contactor will activate and the left drive wheel will
begin rotating in reverse increasing in speed. When
the steering wheel is at maximum left turn, the left
and right drive wheels will rotate at the same speed
but in opposite directions. This should be a smooth
sequencing while turning the steering wheel.
Check 7: Electrical Braking Performance, Steer
Wheel Straight Ahead
NOTICE
Do not perform this check with the lift truck in bypass
mode. Damage to the control panel can result.
1. Select forward direction and depress the
accelerator to the point just before bypass occurs.
While continuing to depress the accelerator,
change the direction switch to reverse. The right
contactor should deactivate and the left contactor
should activate. There should be a smooth
deceleration of forward tire rotation and a smooth
acceleration of reverse tire rotation.
2. While continuing to depress the accelerator in
reverse direction change the direction switch to
forward. The left contactor should deactivate and
the right contactor should activate. There should be
a smooth deceleration of reverse tire rotation and a
smooth acceleration of forward tire rotation.
Built-In Diagnostic Operation
The logics and the display provide built-in diagnostic
analyzer functions. Several diagnostic functions occur
while the lift truck is in operation. These are called
“Run Time” diagnostics. The other diagnostics are
called “Self” diagnostics. They are performed when the
lift truck is not in operation by using a switch located in
the logics.
48 Testing And Adjusting
“Run Time” Diagnostics (Lift Truck In Operation) LED Display = “O”
Lift truck hydraulic lift or tilt will not operate, see
The diagnostic functions that follow would occur
Troubleshooting Problem 15. Possible cause, lift
during normal lift truck operation and are shown on the
lockout caused by low battery.
display. The single digit Battery Discharge Indicator
(BDI) portion of the display is used to indicate these
diagnostic functions.
LED Display = “9 through 2” (Solid Number)
NOTE: Improper lift truck operation with normal battery Lift truck battery above 80% discharge level, normal
indication should be checked with “Self” diagnostics. operation.

LED Display = “A” LED Display = “1, 2, . . . F” (Continuously Changing)

Lift truck moves very slow, see Troubleshooting Lift truck battery is at 80% discharge level, and lift
Problem 6. Possible cause, steer angle sensor lockout is approaching. Possible cause, low battery.
disconnected.

“Self” Diagnostic (Lift Truck Not In Operation)

LED Display = “C”
Lift truck accelerates slower during transistor pulsing,
see Troubleshooting Problem 7. Possible cause, one
transistor left and/or right over temperature.
The diagnostic procedure should be used to aid in
troubleshooting after a problem occurs. It will help to
find the faulty circuit or component. Complete all the
tests before returning to the Troubleshooting Check
List. Before testing, do the steps that follow.

LED Display = “d” 1. Verify that the steer wheel is in the straight ahead
position.
Lift truck will not operate, see T roubleshooting
Problem 8. Possible cause, DIAG/RUN/SETUP switch 2. Turn the key to OFF.
in diagnostic position.
3. Disconnect the battery and discharge the head
capacitor.
LED Display = “E” (Flashing)
Lift truck will not operate, see troubleshooting Problem
9. Possible cause, seat switch open.

LED Display = “E” (Not Flashing)

No lift truck drive operation, see Troubleshooting
Problem 10. Possible cause, static return to off (SRO).

LED Display = “FE”

Lift truck will not operate, See Troubleshooting
Problem 10A. Possible cause, logic board failure.

LED Display = “FO”

Lift truck operates, then shuts down, see 4. Disconnect the drive fuse (2) to prevent lift truck
Troubleshooting Problem 10B. Possible cause, movement. The pump fuse (1) does not need to be
excessive drive motor current or improper adjustment removed.
of logics potentiometers.

LED Display = “F” “Fr” or “FL”

Lift truck will not operate, see Troubleshooting
Problems 11, 12, 13, 14. Possible cause, failed power
transistor.

MicroCommand Control System 49 Testing And Adjusting

5. Release the parking brake to close the parking
brake switch.
6. Loosen two screws (3) to remove the logic unit
(logics) cover (4).
7. Move switch (5) to the DIAG position. This places
the controller in diagnostics when the battery is
connected and the key switch is turned on. If any of
the tests that follow fail (except the drive fuse test
where the LED display = “d”), continue through the
tests that remain. Move switch (5) to RUN and then
back to DIAG. This will bypass the failed test and
allow the next test to be performed.
8. Connect the battery and turn the key to ON.
LED Display = “blank.” See Troubleshooting problems
1, 2, 3 and 4.
LED Display = “d”. Drive fuse is not disconnected.
Return to Step 2. This check cannot be bypassed with
switch (5).
LED Display = “F”. Logics failure. Replace logics.
MicroCommand Control System
NOTE: This test does not check all the logics circuits,
so the logics may pass this test and still have a failure.
LED Display = “1”. Ready for Test 1.
Test 1: Seat Switch
Press and release seat to close and open switch.
LED Display = “1”. Seat switch circuit defect. Move
hand around on seat and try again. If still “1”, see
Troubleshooting Problem 16.
LED Display = “2”, Seat switch circuit OK.
Test 2: Direction Switch
Move direction switch from neutral to reverse to
forward.
LED Display = “2”. Direction switch circuit defect. See
Troubleshooting Problem 17.
LED Display = “3”. Direction switch circuit OK.
Test 3: Lift Switch
Pull lift lever to maximum, then release.
LED Display = “3”. Lift switch circuit defect. See
Troubleshooting Problem 18.
LED Display = “4”. Lift switch circuit OK.
Test 4: Accelerator Control
Push accelerator pedal to the stop and release.
LED Display = “4”. Accelerator circuit defect. See
Troubleshooting Problem 19.
It is possible at this point to obtain information about
the problem by overriding the test. Move the
DIAG/RUN/SETUP switch to RUN and back to DIAG.
The display will begin to flash some digit that indicates
the current accelerator position “0” through “F”. Press
the accelerator slowly. The display should show all
accelerator positions as the pedal moves. Some
speeds may be missing, for example. A missing “F”
suggests the linkage needs adjustment; or if no
speeds are shown, then the parking brake switch may
have an open circuit.
LED Display = Flashing of some digit, “0” through “F”
The flashing digit indicates the current accelerator
position. The accelerator circuit test has passed.
However, the display will not automatically increment
to the next diagnostic number, “5”. To continue, move
the DIAG/RUN/SETUP switch to RUN and then back to
DIAG.
50 Testing And Adjusting
Test 5: Steer Angle Sensor Move switch (5) to DIAG position.

Turn steering wheel clockwise to the right stop, LED Display = “8”. Line contactor reopens in DIAG
counterclockwise to the left stop, then back to the mode if circuit is OK.
straight ahead position.
Test 8: Pump Contactor (9)
LED Display = “5”. Steer angle sensor circuit defect.
See Troubleshooting Problem 6.
Move switch to RUN position.
LED Display = “6”. Steer angle sensor OK. Power
LED Display = “8”. Pump contactor (9) does not close,
steering motor will turn on.
circuit is defective. See Troubleshooting Problem 20.

Test 6: Battery Discharge Indicator (BDI) LED Display = “8”. Pump contactor closes, circuit is
OK.
This test is performed automatically, and “6” will be
shown for one second only if the BDI is OK. Move switch (5) to DIAG position.

LED Display = “6”. Battery discharge indicator circuit LED Display = “9”. Pump contactor reopens in DIAG
defect. See Troubleshooting Problem 15. mode if circuit is OK.

LED Display = “7”. BDI circuit OK.

Test 9: Bypass Contactor (8)
The tests that remain check contactor operation.
Move switch (5) to RUN position.
Switch (5) is cycled between RUN and DIAG to
activate and deactivate the contactors in question. The
LED Display = “9”. Bypass contactor (8) does not
LED display will advance one digit or letter after each
close, circuit is defective. See Troubleshooting
test no matter what the test results. The contactors
Problem 20.
must be visually observed for proper operation during
these tests.
LED Display = “9”. Bypass contactor closes, circuit is
OK.

Move switch (5) to DIAG position.

LED Display = “A”. Bypass contactor reopens in DIAG

mode if circuit is OK.

Test 10: Right Direction Contactor (6)

Move switch (5) to RUN position.

LED Display = “A”. Right direction contactor (6) does

not close, circuit is defective. See Troubleshooting
Problem 20.

LED Display = “A”. Right direction contactor closes,

circuit is OK.

Move switch (5) to DIAG position.

LED Display = “b”. Right direction contactor reopens

Test 7: Line Contactor (10) in DIAG mode if circuit is OK.

Move switch (5) to RUN position.

LED Display = “7”. Line contactor (10) does not close,

circuit is defective. See Troubleshooting Problem 20.

LED Display = “7”. Line contactor (10) closes, circuit

OK.

MicroCommand Control System 51 Testing And Adjusting

Test 11: Left Direction Contactor (7)

Move switch (5) to RUN position.

LED Display = “b”. Left direction contactor (7) does

not close, circuit is defective. See Troubleshooting
Problem 20.

LED Display = “b”. Left direction contactor closes,

circuit is OK.

Move switch (5) to DIAG position.

LED Display = “C”. Left direction contactor reopens in

DIAG mode if circuit is OK.

NOTE: Toggling the diagnostics switch to RUN then

DIAG at this point—first time testing—will repeat the
contactor testing series. Toggling the switch the next
time “C” appears—second time testing—will
automatically display the stored error codes.

That completes the built-in diagnostics test. Tests 7

through 11 may be repeated by the movement of the
DIAG/RUN/SETUP switch to the RUN position then to
the DIAG position.

Disconnect the battery and discharge the head

capacitor before reconnecting the drive fuse. Move the
DIAG/RUN/SETUP switch to the RUN position and
install the logics cover.

MicroCommand Control System 52 Testing And Adjusting

Troubleshooting Problem List

MicroCommand Control System 53 Testing And Adjusting

MicroCommand Control System 54 Testing And Adjusting
MicroCommand Control System 55 Testing And Adjusting
MicroCommand Control System 56 Testing And Adjusting
MicroCommand Control System 57 Testing And Adjusting
MicroCommand Control System 58 Testing And Adjusting
MicroCommand Control System 59 Testing And Adjusting
MicroCommand Control System 60 Testing And Adjusting
MicroCommand Control System 61 Testing And Adjusting
MicroCommand Control System 62 Testing And Adjusting
MicroCommand Control System 63 Testing And Adjusting
MicroCommand Control System 64 Testing And Adjusting
MicroCommand Control System 65 Testing And Adjusting
MicroCommand Control System 66 Testing And Adjusting
MicroCommand Control System 67 Testing And Adjusting
MicroCommand Control System 68 Testing And Adjusting
MicroCommand Control System 69 Testing And Adjusting
MicroCommand Control System 70 Testing And Adjusting
MicroCommand Control System 71 Testing And Adjusting
MicroCommand Control System 72 Testing And Adjusting
MicroCommand Control System 73 Testing And Adjusting
MicroCommand Control System 74 Testing And Adjusting
PROBLEM 24 (continued)

MicroCommand Control System 75 Testing And Adjusting

PROBLEM 24 (continued)

MicroCommand Control System 76 Testing And Adjusting

MicroCommand Control System 77 Testing And Adjusting
MicroCommand Control System 78 Testing And Adjusting
MicroCommand Control System 79 Testing And Adjusting
MicroCommand Control System 80 Testing And Adjusting
PROBLEM 29 (continued)

MicroCommand Control System 81 Testing And Adjusting

PROBLEM 29 (continued)

Problem 29 (continued)

MicroCommand Control System 82 Testing And Adjusting

System Tests And Adjustments
Test Equipment

A 5P0957 or 5P3514 Battery Tester Group may be

used to test the specific gravity of each battery cell.

Current Limit Test Switch

The current limit can be checked and adjusted with

6V7070 Heavy Duty Digital Multimeter (1) can be used
to measure voltage, resistance or current. When used
to troubleshoot MicroCommand control panels, 8T3224
Needle Tips (5) should be attached to the meter leads.
These needle tips have a smaller diameter and are
less likely to cause damage to connectors. See
Special Instructions SEHS7734 for the correct
operation of 6V7070.
greater accuracy by using a fabricated switch and
wire assembly. With the use of the switch and wire
assembly, the accelerator pedal does not have to be
pushed. Instead, the switch sends the exact signal to
the logics. This electrically locates the correct pedal
position to give an accurate adjustment of the current
limit.

8T0900 Clamp-On Ammeter (2) may be used to

measure current. When using ammeter (2) with the
6V7070 Digital Multimeter (1) as a remote readout,
6V6014 Cable (4) should be used to connect ammeter
(2) to multimeter (1). See Special Instructions
SEHS8420 for the correct operation of 8T0900.

358280 Resistor (3) is a 150 ohm, 25 watt resistor used

to discharge the head capacitor before contact is
made with the control panel.

4C4029 Trimmer Adjust Tool (6) allows easier

adjustment of the adjusting screw found on
potentiometers. The insulated body has a blade on
each end. One blade is recessed to provide a captive 1. Cut the wire into 1.2 m (4 ft) lengths for wires (2)
screwdriver for adjustments that are difficult to see. and (6), and into 0.3 m (1 ft) length for wire (4).
The other end has an exposed blade to reach
adjustment screws that are behind panels which have
small access holes.

MicroCommand Control System 83 Testing And Adjusting

 Discharging Head Capacitor
(HEAD CAP)

2. Install a 5P2766 terminal on one end of wires (2)

and (6). Install a 7N7780 Pin on the other end of
wire (6). Install a 7N7779 socket on the other end of
wire (2).

3. Install a 7N7779 socket on one end of wire (4).

Connect (splice) wire (4) to wire (2).

4. Install wires (2), (4) and (6) into the number 2, 4 and
6 openings in the 9G3671 housing.
5. Connect wire (2) with the 5P2766 terminal to the
normally open, “NO” contact of the switch.
6. Connect wire (6) with the 5P2766 terminal to the
common, “COM” contact of the switch.
1. Disconnect the battery.
2. Put a 150 ohm, 25 watt resistor (1), Part No.
358280, in position between the terminals of head
capacitor (2). Hold the resistor in position for 8 to 10
seconds. This will discharge the capacitor.

MicroCommand Control System 84 Testing And Adjusting

Logics Removal

1. Disconnect the battery and discharge the head

capacitor.

5. Remove screws (7) which hold logics (6) to control

panel.

6. Remove logics and replace logics cover to prevent

damage.

“Run Time”Tests

2. Loosen screws (1) that hold logics cover (2).

3. Tilt top of cover in (toward center of lift truck) and lift

up and out.

4. Disconnect connectors P1 (3), P2 (5) and P3 (4).

When disconnecting connectors pull on plastic
connector housing, not on the wires.

MicroCommand Control System 85 Testing And Adjusting


Logic Board Layout
Key To ON, No Operator Warning, Display = “E”
(Flashing)
1. Connect the battery.
2. Turn key to ON with no one on the seat.
3. The display should show the letter “E” flashing on
and off.
4. With an operator on the seat or by pressing on the
seat the letter “E” should stop flashing.
Static Return To Off (SRO)
1. Connect the battery and sit on the seat.
2. Select a direction before turning key to ON.
3. Turn key to ON. An “E” (not flashing) should appear
on the display and the drive system should not
operate.
4. Return the directional lever to neutral, then back to
forward or reverse. The “E” should disappear from
the display and the drive system should operate.
5. Turn key to OFF. Depress and hold the accelerator
pedal.
6. Turn the key to ON. An “E” (not flashing) should
appear on the display and the drive system should
not operate.
7. Release the accelerator pedal. The “E” should
disappear from the display and the drive system
should operate.
MicroCommand Control System
Failure Protection
1. With blocks safely under the frame so the drive
wheels are free to turn, connect the battery. Close
the seat switch and turn the key to ON.
2. Use an insulated object and manually push and
hold the bypass contactor (BYP CTR) closed.
3. The line contactor should deactivate. The letter “F,”
“FL,” or “Fr” should appear on the display.
4. Release the bypass contactor. Turn key to OFF then
back to ON. The lift truck should operate normally.
Control Panel Overtemperature Protection
NOTE: If Programmable Feature “6” or “9” is selected,
control panel overtemperature protection will no longer
function.
1. Disconnect the battery and discharge the head
capacitor.
2. Disconnect the control panel thermal switch
connector P8. Place the direction lever in neutral.
3. Connect the battery, close seat switch and turn key
to ON. The letter “C” should appear on the display.
If current limit is checked, it will be reduced.
4. Disconnect the battery and discharge the head
capacitor. Connect P8 connector.
Steer Angle Sensing
1. Disconnect the battery and discharge the head
capacitor.
2. Remove the logics cover and disconnect steer
angle connector P3 from the logics.
3. Connect the battery, close seat switch and turn key
to ON. The letter “A” should appear on the display.
The drive system will only operate at creep speed.
4. Disconnect the battery and discharge the head
capacitor. Connect P3 connector to the logics. The
truck should operate normally.
86 Testing And Adjusting
Component Tests
To clean the control panel, use air pressure to blow off
dust and dirt. Do not use steam or solvent.
NOTICE
Do not use steam or solvent to clean the controls.
Damage can be caused to the control panel. Use
pressure from an air hose with a maximum pressure of
205 kPa (30 psi) to clean the control panel when neces-
sary. The air supply must be equipped with a water
filter.
NOTE: When control wires and power cables or bus
bars are to be connected to the same bolt or stud,
place all control wires together on the top of the bus
bar or power cable.
Use the wiring diagram and electrical schematic
(located inside top battery cover) to locate
components referred to by name and number in the
procedures that follow. All wires must be located as
shown on the wiring diagram and schematic.
MicroCommand Control System
Logic Unit Quick Reference Voltage Check
The chart that follows is a quick reference of the
expected voltages at the logics card pin connectors.
All voltage measurements are made with respect to
battery negatives. Voltages will have minor variations.
Refer to Systems Operation to clarify any major voltage
variations.
1. Put blocks of wood under the frame so both drive
wheels are free to turn.
2. Disconnect the battery and discharge the head
capacitor.
3. Remove the logics cover.
4. Connect the multimeter negative lead to control
panel battery negative.
5. Select the appropriate voltage range for the voltage
to be measured.
6. Use the multimeter positive lead and measure the
voltages under normal and activated conditions as
shown in the Logic Voltage Reference chart.
87 Testing And Adjusting
MicroCommand Control System 88 Testing And Adjusting
Conductor And Switch Continuity
NOTICE
Damage can be caused to the head capacitor. Do not
1. Set the multimeter to the 200 Ω range.
remove screws from capacitors to perform tests.
Remove capacitor connecting cables at heatsink
2. Use the multimeter to perform the continuity test. If
connections.
continuity exists, the measurement will be less than
1 ohm. If the measurement is more than this,
continuity does not exist and the problem will have
to be repaired. 1. Disconnect the battery and discharge the head
capacitor.

Accelerator Control 2. Visually inspect the capacitor for bulges at the

terminals.

3. Verify the plastic top is not melted around the

terminals and that the blow plug is not leaking.

Refer to “Self Diagnostics” Test 4: Accelerator Control

in Troubleshooting section.

Capacitor (Head)

4. Disconnect positive cable (2) from the bypass

contactor terminal.

MicroCommand Control System 89 Testing And Adjusting


5. Set the multimeter to the 20K Ω range. Connect the
multimeter positive lead to positive side (6) of head
capacitor (5). Connect the multimeter negative lead
to negative side (7) of head capacitor (5).
6. The meter must increment to above 10 000 ohms.
Replace the capacitor if the indication is not
correct.
See Head Capacitor in Specifications section for proper
assembly order of the head capacitor connections.
Tighten both capacitor terminal screws to a torque of
2.3 to 2.8 N • m (19 to 25 lb in).
Contactor (Bypass Activation)
NOTICE
Damage can be caused to the control panel. Do not switch
the direction lever from one direction to the other (plug the
lift truck) when the drive wheels are off the ground and in
rotation at full speed.
1. Connect the battery and close the seat switch.
2. Turn the key to ON and release the parking brake.
3. Verify the steer wheel is in straight ahead position.
4. Select a direction and rapidly depress the
accelerator pedal all the way to the floor.
MicroCommand Control System
5. Measure and record the time it takes the bypass
contactor to close. This should be 1.0 to 5.0
seconds after the accelerator is fully depressed,
depending on how Programmable Feature “7” is
set. This also affects steps 6 and 7, below.
6. If the recorded value from Step 5 is less than 1.0
seconds, the logics may need to be replaced.
7. If the recorded value from Step 5 is more than 5.0
seconds, check the bypass contactor tips for free
movement. Check wiring for bad connections.
NOTE: The bypass contactor will not close if the
accelerator linkage is not adjusted correctly or the
steer wheel is not in the straight ahead position. It also
may not close if Programmable Feature “1” is not set to
maximum.
Contactor
1. Disconnect the battery and discharge the head
capacitor.
Coil Suppression Assembly
2. Disconnect wire (6) that goes to suppression
assembly (4) from terminal Y (3)
3. Set the multimeter to the diode test position.
4. Connect positive multimeter lead (5) to wire (6), and
the negative multimeter lead (1) to coil terminal X
(2).
90 Testing And Adjusting
5. The multimeter must indicate .3 to .9 volts. DC-DC Converter

6. Reverse the leads, positive multimeter lead (5) to Refer to Problem #29 in Troubleshooting section.
coil terminal X (2), negative multimeter lead (1) to
wire (6). The meter must indicate OL.
Diodes
7. If either test fails, the suppression assembly (4)
must be replaced.

Coil Resistance

2. Disconnect all leads to the X and Y terminals of the

coil.

3. Set the multimeter to the 200 Ω range.

4. Measure the resistance of the coil at the X and Y
terminals. It must be within specifications. See
Component Measurements in Specifications
section.
NOTE: The following test procedure can be applied to
diode 4DL, 4DR, 5DL, or 5DR. Diode 4DL will be used
in the following examples.

5. If the coil is not within specifications, the contactor

assembly will have to be replaced.

Contactor Tips

2. Visually inspect the tips to verify they are not

welded, melted, burned, or pitted.

3. Press and release the tips quickly to verify there is

no binding.

4. Visually inspect the contactor assembly. Verify

foreign objects don’t interfere with normal contactor
operation.

1. Disconnect the battery and discharge the head

capacitor.

2. Disconnect 4DL cathode lead wire (1).

3. Set the multimeter to the diode test position.

4. Connect the negative multimeter lead on 4DL

cathode lead wire (1). Connect the positive
multimeter lead to battery negative (3). 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.
5. Check contactor tip gap with a feeler gauge as
shown. Refer to Specifications section for correct
settings. If the gap is not correct refer to the
Disassembly And Assembly Module, Form No.
SENB8279.

MicroCommand Control System 91 Testing And Adjusting

Diode Replacement Display (LED)

1. Disconnect the battery and discharge the head

capacitor.

2. Disconnect the anode or cathode as described in

Diode Testing. Remove the diode.

1. Disconnect the battery and discharge the head

capacitor.

2. Disconnect connector P6 (1) from LED display

board (2). The front cover must be removed from
the console to access connector P6 (1) and display
board (2).

3. Wipe clean contact surface (1) of the diode. Put a

small amount of 5P8937 or 5P9210 Thermal Joint
Compound on contact surfaces (1), but not on the
threads.

4. Install the diode and tighten to a torque of 11.4 to

15.4 N • m (100 to 135 lb in).

5. Connect all wires that were removed.

3. If necessary for testing, remove screws (3) and

remove board assembly (2).

MicroCommand Control System 92 Testing And Adjusting

 Driver Board (On Vehicle)

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the bat-
tery and discharge the head capacitor (HEAD CAP)
before any contact with the control panel is made.

NOTICE
Damage to the control panel could result. To prevent
further damage before the Driver Board is replaced,
complete the check list that follows:
1. Check 4 Diode for a failure on failed side.
2. Check 5 Diode for a failure on failed side.
3. Check continuity from 1 TRN R emitter (wire #37)
to logic connector P2-9 if the right side failed.
4. Check continuity from 1 TRN L emitter (wire #41)
to logic connector P2-10 if the left side failed.
5. Check 1 TRN for a failure on failed side.
6. Check Head Capacitor for a failure.
7. Check for continuity of shunt wires on failed side.

NOTE: Visually inspect the following connections to

ensure proper connection and the lack of corrosion.
1. Wire #36 to the base of 1 TRN R.
4. Set the multimeter to the diode test position. 2. Wire #39 to the base of 1 TRN L.
Connect the negative lead to instrument panel 3. Wire #4 to the positive heatsink.
board assembly pin 6 (5) or pin 8 on later style 4. Wire #1 to the negative heatsink.
displays. Connect the positive lead to each of the 5. Wires #31 and #32 to R312.
other pins (one at a time). Watch each segment (4) 6. Wires #27 and #28 to R302.
for light. If a segment does not light, the board 7. Wires #52 and #47 to connector P12 and
assembly will have to be replaced. logics P2-4 and P2-5.

NOTE: Driver board components are soldered parallel

to each other. The tests that follow may not be typical
of individual component tests. The driver board must
be replaced if any incorrect test results are obtained.

MicroCommand Control System 93 Testing And Adjusting

Right Side Tests
1. Disconnect the battery and discharge the head
capacitor.
2. Disconnect wire #36 (2) from the base of 1 TRN R
(1).
3. Disconnect wire #37 (3) from the emitter of 1 TRN R
(1).
4. Resistor R313 and diode D311 test.
Set the multimeter to the 200 Ω range. Connect
the positive meter lead to wire #36 (2). Connect
the negative meter lead to wire #37 (3). The
measurement must be 6 to 9 ohms.
5. Resistor R315 test.
Set the multimeter to the 2K Ω range. Measure the
resistance between wire #37 (3) and battery
negative. The measurement must be 900 to 1100
ohms.
MicroCommand Control System
6. Disconnect wire #4 (6) that goes to the driver board
from the positive heatsink (4).
7. Disconnect wire #32 (7) from R312 (8).
8. 2 TRN R (collector/emitter) and Z312 test.
Set the multimeter to the diode test position.
Connect the positive lead to wire #36 (2).Connect
the negative lead to wire #4 (6). The measurement
must be .3 to .9 volts.
Reverse the test leads (positive lead to wire #4,
negative lead to wire #36). The measurement must
be OL.
9. 2 TRN R (collector/base) test.
Set the multimeter to the diode test position.
Connect the positive lead to wire #36 (2). Connect
the negative lead to wire #32 (7). The
measurement must be .3 to .9 volts.
Reverse the test leads (positive lead to wire #32,
negative lead to wire #36). The measurement must
be OL.
10. 2 TRN R (emitter/base) and R311 test.
Set the multimeter to the 200 Ω range. Connect
the positive lead to wire #4 (6). Connect the
negative lead to wire #32 (7). The measurement
must be 10 to 14 ohms.
94 Testing And Adjusting
 14. 3 TRN R (emitter/base) test.
Set the multimeter to the diode test position.
Connect the positive lead to the negative heatsink
(10). Connect the negative lead to P12-1, wire
#52 (12). The measurement must be .3 to .9 volts.
Record the meter reading.
Reverse the test leads (positive to P12-1 wire #52,
negative to negative heatsink). Record the meter
reading. This second recorded reading must be
.3 to .9 volts.

15. Resistor R314 test.

Set the multimeter to the 2K Ω range. Connect the
positive lead to P12-1, wire #52 (12). Connect the
negative lead to negative heatsink (10). The
measurement must be 350 to 430 ohms.

16. Replace the driver board if any of the above

11. Disconnect wire #31 (9) from R312 (8). measurements were incorrect.
12. 3 TRN R (collector/emitter) tests. 17. Connect all disconnected wires.
Set the multimeter to the diode test position.
Connect the positive lead to negative heatsink
(10). Connect the negative lead to wire #31 (9). Left Side Tests
The measurement must be .3 to .9 volts.
Reverse the test leads (positive lead to wire #31, 1. Disconnect the battery and discharge the head
negative led to the negative heatsink). The capacitor.
measurement must be OL.

13. 3 TRN R (collector/base) test.

Disconnect P12 (11) connector. Set the
multimeter to the diode test position. Connect the
positive lead to P12-1, wire #52. Connect the
negative lead to wire #31 (9). The measurement
must be .3 to .9 volts.
Reverse the test leads (positive to wire #31,
negative to P12-1 wire #52). The measurement
must be OL.

MicroCommand Control System 95 Testing And Adjusting

2. Disconnect wire #39 (2) from the base of 1 TRN L
(1).
3. Disconnect wire #41 (3) from the emitter of 1 TRN L
(1).
NOTE: On panels with 907014 or 977263 a connector
is used on 1 TRN. To disconnect the wires from 1 TRN,
unplug the connector.
10. 2 TRN L (emitter/base) and R301 test.
4. Resistor R303 and diode D301 test.
Set the multimeter to the 200 Ω range. Connect
the positive meter lead to wire #39 (2). Connect
the negative meter lead to wire )41 (3). The
measurement must be 6 to 9 ohms.
9. 2 TRN L (collector/base) test.
Set the multimeter to the diode test position.
Connect the positive lead to wire #39 (2). Connect
the negative lead to wire #28 (7). The
measurement must be .3 to .9 volts.
Reverse the test leads (positive lead to wire #28,
negative lead to wire #39). The measurement
must be OL.
Set the multimeter to the 200 Ω range. Connect
the positive lead to wire #4 (6). Connect the
negative lead to wire #28 (7). The measurement
must be 10 to 14 ohms.

5. Resistor R305 test.

Set the multimeter to the 2K Ω range, measure the
resistance between wire #41 (3) and battery
negative. The measurement must be 900 to 1100
ohms.

11. Disconnect wire #27 (9) from R302 (8).

12. 3 TRN L (collector/emitter) test.

6. Disconnect wire #4 (6) that goes to the driver board
from the positive heatsink (4).
7. Disconnect wire 28 (7) from R302 (8).
Set the multimeter to the diode test position.
Connect the positive lead to the negative heatsink
(10). Connect the negative lead to the wire #27
(9). The measurement must be .3 to .9 volts.
Reverse the test leads (positive lead to wire #27,
negative lead to the negative heatsink). The
measurement must be OL.

8. 2 TRN L (collector/emitter) and Z302 test.

Set the multimeter to the diode test position.
Connect the positive lead to wire #39 (2). Connect
the negative lead to wire #4 (6). The
measurement must be .3 to .9 volts.
Reverse the test leads (positive lead to wire #4,
negative lead to wire #39). The measurement
must be OL.

MicroCommand Control System 96 Testing And Adjusting

13. 3 TRN R (collector/base)test.
Disconnect P12 (11) connector. Set the
multimeter to the diode test position. Connect the
positive lead to P12-2, wire #47. Connect the
negative lead to wire #27 (9). The measurement
must be .3 to .9 volts.
Reverse the test leads (positive to wire #27,
negative to P12-2 wire #47). The measurement
must be OL.

14. 3 TRN L (emitter/base) test.

Set the multimeter to the diode test position.
Connect the positive lead to the negative heatsink
(10). Connect the negative lead to P12-2, wire
#47 (12). The measurement must be .3 to .9 volts.
Record the meter reading.
Reverse the test leads (positive to P12-2 wire #47,
negative to negative heatsink). Record the meter
reading. This second recorded reading must be
.3 to .9 volts.

15. Resistor R304 test.

Set the multimeter to the 2K Ω range. Connect the
positive lead to P12-2, wire#47 (12). Connect the
negative lead to negative heatsink (10). The
measurement must be 350 to 430 ohms.

16. Replace the driver board if any of the above

measurements were incorrect.

17. Connect all disconnected wires.

MicroCommand Control System 97 Testing And Adjusting

Driver Board (Off Vehicle)

Use the chart that follows for testing the driver board:

MicroCommand Control System 98 Testing And Adjusting

MicroCommand Control System 99 Testing And Adjusting
Transistor (1 TRN) Use the following chart to test the transistors. If any
measurements are incorrect the transistor must be
replaced.

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the bat-
tery and discharge the head capacitor (HEAD CAP)
before any contact is made with the control panel.

NOTICE
Damage to the control panel could result. To prevent
further damage before 1 TRN is replaced, complete
the check list that follows:
1. Check 4 Diode for a failure on failed side.

2. Check 5 Diode for a failure on failed side.

3. Check Driver Board for a failure on failed side.

4. Check Head Capacitor for a failure.

5. Check for continuity of shunt wires on failed side.

1. Disconnect the battery and discharge the head

capacitor.

2. Remove wires from base and emitter terminals of 1

TRN R and 1 TRN L.

3. Determine which transistor is used in this

application.

MicroCommand Control System 100 Testing And Adjusting

Transistor Replacement (1 TRN)
Battery voltage and high amperage are present.
Injury to personnel is possible. Disconnect the bat-
tery and discharge the head capacitor (HEAD CAP)
before any contact is made with the control panel.
Both 1 TRN L and 1 TRN R (1) are replaced in the
same way. 1 TRN R (1) is shown in the procedure that
follows.
1. Disconnect the battery and discharge the head
capacitor.
2. Remove emitter screw (5), bar (6) and emitter
wire#37 (7)
3. Remove base screw (2) and base wire #36 (3).
4. Remove mounting screws (4).
MicroCommand Control System
5. The heatsink contact surface (8) and the transistor
contact surface (9) is coated with 5P8739 or
5P9210 Thermal Joint Compound. Carefully remove
the transistor.
6. To replace the transistor, wipe clean contact
surfaces (8) and (9). Put a small amount of 5P8937
or 5P9210 Thermal Joint Compound on the contact
surfaces (8) and (9). Coat heatsink and transistor so
that compound will only contact transistor in area to
be coated (9).
7. Install transistor (1) with mounting screws (4).
Tighten screws (4) to a torque of 4 to 6 N • m (35 to
53 lb in).
8. Install base wire #36 (3) with screw (2). Tighten
screw (2) to a torque of 1.3 to 1.7 N • m (11 to 15 lb
in).
9. Install bar (6) and emitter wire #37 (7) with emitter
screw (5). Tighten screw (5) to a torque of 4 to 6
N • m (35 to 53 lb in).
101 Testing And Adjusting
Lift Switch

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the bat-
tery and discharge the head capacitor (HEAD CAP)
before any contact is made with the control panel.

2. Disconnect wire#28 (2) from resistor R302 (1) and

wire #32 (4) from resistor R312 (3).

Refer to “Self Diagnostics” Test 3: Lift Switch in

Troubleshooting section.

Resistors (R302 and R312)

Battery voltage and high amperage are present.

Injury to personnel is possible. Disconnect the bat-
tery and discharge the head capacitor (HEAD CAP)
before any contact is made with the control panel.
NOTE: Look for visual breaks or cracks on resistors.
1. Disconnect the battery and discharge the head
capacitor.
3. Set the multimeter to the 200 Ω range. Connect the
multimeter leads to terminals (5) and (6) to check
resistance of R302 (1). Connect the multimeter
leads to terminal (6) and (7) to check resistance of
R312 (3).
4. The measurement for each resistor must be 37 to
41 ohms on panels with 927566 Transistors and 19
to 21 ohms on panels with 907014 or 977263
Transistors. If the measurement is not correct, the
resistor must be replaced.

MicroCommand Control System 102 Testing And Adjusting

Thermal Switch Steer Angle Sensor

Battery voltage and high amperage are present. Battery voltage and high amperage are present.
Injury to personnel is possible. Disconnect the bat- Injury to personnel is possible. Disconnect the bat-
tery and discharge the head capacitor (HEAD CAP) tery and discharge the head capacitor (HEAD CAP)
before any contact is made with the control panel. before any contact is made with the control panel.

NOTE: If the thermal switch is removed from the

heatsink, it can be tested in an oven. Switch (1) will
open circuit if the temperature is 76° to 84°C (169° to
183°F) and close (short circuit) at 64° to 72°C (147° to
162°F).

Refer to “Self Diagnostics” Test 5: Steer Angle Sensor

NOTICE in Troubleshooting section.
Damage to the thermal switch will occur. Do not heat
the thermal switch over an open flame.

Refer to “Run Time” Diagnostics, Display = “C” in

Troubleshooting section.

MicroCommand Control System 103 Testing And Adjusting

Electrical System Adjustments Method B (Electrical)

Accelerator Control Linkage

Method A (Mechanical) The lift truck can move suddenly. Injury to person-
nel or damage to the lift truck is possible. Safely lift
the drive wheels off the floor. Put blocks of wood
under the frame so both drive wheels are free to
turn. Keep away from drive wheels that turn.

1. Put blocks of wood under the frame so both drive

wheels are free to turn.

2. Turn lever setscrew (2) clockwise to its maximum

position.

3. Close the seat switch and turn key to ON. “E” not
flashing will show on the display.

4. Turn lever setscrew (2) counterclockwise until the

“E” not flashing disappears from the display.

5. Continue to turn lever setscrew (2)

counterclockwise one full turn. Tighten the locknut.

6. Turn steer wheel to straight ahead position.

7. Put truck in forward and depress accelerator pedal

(1) fully.

8. Adjust length of rod (4) so bypass contactor just

activates.
1. Disconnect the battery and discharge the head
capacitor. 9. Turn rod (4) clockwise one full turn (lengthen) and
tighten the locknuts.
2. Fully depress accelerator pedal (1) (lever assembly
stopped on cowl). Adjust length of rod (4) so that
groove (5) on the accelerator control shaft is even
with face (6) of accelerator control (7). The groove
should not reach the shaft wiper.

3. Release accelerator pedal (1). Adjust lever setscrew

(2) so that dimension (A) is 48 mm (1.89 in).

The linkage should operate freely without binding or

sticking.

MicroCommand Control System 104 Testing And Adjusting

Parking Brake Switch Lift Switch

The lift truck can move suddenly. Injury to person-

nel or damage to the lift truck is possible. Safely lift
the drive wheels off the floor. Put blocks of wood
under the frame so both drive wheels are free to
turn. Keep away from drive wheels that turn.

The hydraulic control valve linkage and lift switch must

be adjusted so the hydraulic pump motor will start to
operate just as the tilt spool is put into a work position
(metering range). The time period when the pump
operates, with valve spool in neutral, should be at a
minimum.

1. Disconnect the battery and discharge the head

capacitor.

2. Loosen setscrews (11) in all cams (12) and (14).

1. Put blocks of wood under the frame so both drive
wheels are free to turn.
2. Close the seat switch and turn the key to ON.
Loosen bolt (10) and adjust the inboard end of cam
plate (9) so the plate is parallel to cams (12) and
(14) horizontally. Each cam should be centered on
the cam plate contact bar. Tighten bolt (10).

3. Release the parking brake and put the truck in

forward.

4. Depress the accelerator. With the tires in rotation,

slowly depress the parking brake.

5. The tire rotation should stop as the parking brake is

depressed to the second click.

6. If tire rotation did not stop, loosen hex screws (4) so

bracket assembly is free to move.

7. Reposition bracket (3) so the switch actuator is

against cam (1) and the tire rotation stops. Tighten
hex screws (4).

8. Release the parking brake and repeat the

procedure until adjustment is correct.
3. Make sure lift spool cam (14) is in position with flat
side (15) on cam toward the contact bar of cam
plate (9). This will prevent pump motor operation
when mast is lowered. All other cams (12) have flat
side turned 90° from cam plate (9).

MicroCommand Control System 105 Testing And Adjusting

4. Adjust tilt spool cam vertically to equalize the
backlash with cam plate (9) and tighten setscrew
(11). Make sure the tilt cam is symmetrically
oriented and the other cams have not interfered
with the adjustment.
5. Connect the battery. Close the seat switch and turn
the key to ON. With all the valve spools in NEUTRAL
position, loosen locknut (8) and adjust bolt (12) so
that the hydraulic pump motor will start to operate
just as the tilt spool is put into a work position
(metering range). Secure in place with locknut (8).
6. Repeat Steps 4 and 5 for each additional cam.
Rapid Tune-Up Procedure
The rapid tune-up procedure establishes a starting
point for logic board adjustments. The procedure
allows the truck to run without damage to the truck or
its components. Alter the rapid tune-up procedure,
final potentiometer adjustments are still required for
optimum performance.
Always verify that the battery voltage jumper on the
logic board is properly selected (J1 for 36 volt
operation, J2 for 48 volt operation).
The lift truck can move suddenly. Injury to personnel
or damage to the lift truck is possible. Safely lift the
drive wheels off the floor. Put blocks of wood under
the frame so both drive wheels are free to turn. Keep
away from drive wheels that turn.
MicroCommand Control System
Service exchange logic boards do not need this
procedure performed on them. These boards are
preadjusted and programmable features are set to the
default values.
NOTE: All programmable features should be set to
their default values before making any adjustments.
See the topic Activating Default Settings in the
Systems Operation section.
1. Turn left motor current limit potentiometer P3 fully
counterclockwise.
2. Turn potentiometer P3 15 full turns clockwise.
3. Turn right motor current limit potentiometer P4 fully
counterclockwise.
4. Turn potentiometer P4 15 full turns clockwise.
5. Turn plugging current limit potentiometer P5 fully
clockwise.
6. Turn potentiometer P5 4 full turns counterclockwise.
7. This completes the rapid tune-up. Make the Final
Logic Board Adjustments as specified in each of
the procedures that follow.
Perform these procedures in the order listed below:
1. Battery Discharge Indicator (BDI) - (P2)
2. Current Limit - (P3, P4)
3. Bypass Dropout - (P3, P4)
4. Electrical Braking (Plugging) - (P5)
Final Logic Board Adjustments
Battery Discharge Indicator (BDI) Adjustment
Before adjusting BDI remove battery surface charge
by operating hydraulic system against tilt pressure
relief for five seconds.
1. Disconnect the battery and discharge the head
capacitor. Remove logics cover and verify the
DIAG/RUN/SETUP switch is in the RUN position.
2. Make sure the battery voltage jumper is properly
selected (J1 for 36 volt battery, J2 for 48 volt
battery).
3. Set the multimeter to measure battery voltage.
Connect the multimeter positive lead to logic
terminal P1-20. Connect the multimeter negative
lead to control panel battery negative (4 diode
heatsink).
4. Put the direction lever in neutral and connect the
battery.
106 Testing And Adjusting
5. Close the seat switch and turn the key to ON. The
NOTICE
measurement should be battery voltage, The LED
Damage can be caused to the control panel. Do not
display must show the correct number for the
switch the direction lever from one direction to the other
voltage measured. The correct values are shown in
(plug the truck) when the drive wheels are off the ground
the chart that follows. For European tubular batteries,
and in rotation at full speed.
see the chart under Reduced Voltage BDI range –
Feature “b” in the Programmable Features section
of this manual.
NOTE: Current limit is preset and sealed at the factory
and should only be adjusted by certified mechanics
with calibrated equipment.

NOTE: All programmable features should be set to

their factory default values before making any
adjustments. See the topic Activating Default Settings
in the Systems Operation section.

1. Put blocks of wood under the frame so both drive

wheels are free to turn.

EXAMPLE: If the measurement is 36.8 volts for a 36

volt battery, the display should be at 6.

6. If the display is not correct, turn the key to OFF and

make an adjustment to potentiometer P2. Adjust
potentiometer P2 a small amount. Turn it clockwise
to increase and counterclockwise to decrease the
display number. Repeat step 5. Turn the key to OFF
between each adjustment.

7. If the voltage was 36.8, the potentiometer should be

turned to find the transition point between 7 and 6
2. Connect 8T0900 Digital Ammeter (2) around cable
on the display. This will ensure that the logics is
A1L to check the left drive motor current limit or
calibrated at a high 6.
A1R to check right drive motor current limit.
NOTE: Approximately 1/2 turn of potentiometer P2
NOTE: The arrow on ammeter points in the direction
changes the display one number.
of current flow for a positive indication.

Current Limit Test and Adjustment
The lift truck can move suddenly. Injury to personnel
or damage to the lift truck is possible. Safely lift the
drive wheels off the floor. Put blocks of wood under
the frame so both drive wheels are free to turn. Keep
away from drive wheels that turn.
3. For ease in reading current, a 6V7070 Digital
Multimeter may be set to the 2V DC range and
connected to the 8T0900 Digital Ammeter using a
6V6014 Cable. Refer to Special Instruction
SEHS8030 for more information.
4. Disconnect the battery and discharge the head
capacitor.
5. Make sure programmable option “8” (80% bypass)
is set to 1. See the topic Programmable Features in
the Systems Operation section.

MicroCommand Control System 107 Testing And Adjusting

6. Connect the battery. Close the seat switch and turn
the key to ON.
7. Release the parking brake.
8. With 8T0900 Digital Ammeter in place around either
A1L or AIR, select a direction and push down on
the brake pedal.
9. Push down fully on the accelerator pedal (the
wheels must not turn). The current measurement
must be 255A ± 5%. During this step the bypass
contactor must not activate.
10. If current measurement is not correct, disconnect
the battery and remove the logics cover. Make an
adjustment to potentiometer P3 for the left drive
motor or P4 for the right drive motor. Turn the
potentiometer adjustment screw clockwise to
increase the current limit setting or counter-
clockwise to decrease the current setting.
11. Repeat Steps 8, 9, and 10 of the adjusting
procedure until settings are correct.
12. Repeat the entire procedure for the opposite drive
motor.

NOTICE
Do not stall the drive motors for more than 5 seconds at
a time. Damage to the drive motors will result. Allow
time for the motors to become cool between stalls by
allowing the motor to turn with the tires off the floor. If
the motor remains stalled for more than the time set
by Programmable Feature “4”, the line contactor will
deactivate and “FO” will show on the LED display.

MicroCommand Control System 108 Testing And Adjusting

Electrical Braking (Plugging) Current Test
and Adjustment
NOTE: The electrical braking (plugging) test is made
with the truck drive wheels on the ground and the truck
in motion. Do not place the truck on wooden blocks
with the wheels off the floor for this test. Damage to the
control panel will result.
NOTE: Plugging current can be checked using the
right or left drive motor. For this example, the left drive
motor will be used.
1. Connect 8T0900 Digital Ammeter (1) around cable
A1L to check plugging motor current. Check the
jaws of the meter to make sure they are fully closed.
MicroCommand Control System
NOTE: The arrow on ammeter points in the direction
of current flow for a positive indication.
2. For ease in reading current, a 6V7070 Digital
Multimeter may be set to the 2 VDC range and
connected to the 8T0900 using a 6V6014 Cable.
Refer to Special Instruction SEHS8030 for more
Information.
3. Move the lift truck FORWARD at full speed. Keep
the accelerator pedal fully depressed and change
the direction control to REVERSE.
4. The current measured during the electrical braking
(plugging) must be 300 amps ± 5%.
5. If the correct current is not measured, disconnect
the battery and discharge the head capacitor.
Remove the logics cover and adjust potentiometer
P5. Turn the potentiometer adjustment screw
counterclockwise to decrease plugging current.
NOTE: Though the plugging distance is an
application adjustment, plugging current should not
exceed 315 amps. If recommended setting produces
a short stopping distance for a particular application,
the current may be reduced by turning potentiometer
P5 counterclockwise to give a longer stopping
distance.
109 Testing And Adjusting