ECB Electric Training

Forklift Electric System

Forklift Electric include 7 systems:

 Power System
 Control System
 Traction System
 Lifting System
 Steering System(Priority valve)
 Low Voltage System
 Harness System
Electric System working Chart

Power
wi
re

wire
Control wire Low Voltage
i re

wi
re
w

Traction Steering
Steering Priority
Lifting
 1
1. Power System
Power system include the following parts:
 Battery Module
Power to the truck.
 Battery Management System (BMS)
Check the state of the battery, and control the charging and
discharging of the battery.
 Charging System
Charging the battery.
 DC/DC Voltage Transfer System
The voltage converter transfer the battery 80V to 12V for the low
voltage system.
 1
2. Control System
Control system include the following parts:
 Controller
Controller is the main part of the truck, it works as a human brain. It receives
the signal of sensors and switches, and turn the driver’s operation command
into the working control of the motor.
 Sensors and Feedback System
The system receives the working state and the operator’s command, and
transfer the signal into Volt or Current signal and send to controller.
 Display System
The display system is the interface for the driver to read the truck information,
and also the driver can do some menu setting in the display system.
 1
3. Traction System
 Traction motor.
Traction motor transfer the electric power to mechanical power,
and power the traction system.

4. Lifting System
 Pump motor.
Pump motor turn the electric power into oil pressure, and push the
mast moving, pressure transfer to kinetic power and potential power.
Provide stable and reliable pressure for the hydraulic system.
 1
5. Steering System
 Steering system is priority steering system, power from the pump
motor.
 Hydraulic oil supply to the steering unit through the priority valve,
then priority valve divide the oil to the steering cylinder.
6. Low Voltage System
The low voltage system include the following parts:
 Lights
Lights include head light and beam light. Use for illumination and
shows driving signal to other people and driver for safety.
 Alarm System
Alarm system include turning light, braking light width light, beacon
and horn. These components use to show the working state to other
person around for safety.

7. Harness
Harness connect all the electric component, is the neural network of
the truck.
2. Electric and control
Power System
 ECB units – 80V Battery
 One battery module with 12 cells, total voltage about 40V;Two battery
modules series to 80V battery system
 Each battery module connect to one Sampling device(BIC),collect the
temperature and voltage information from the battery and send the
information to BMS.(inside one battery pack must pack with one Device 1
and one device 2)
Power System
 BMS: monitor the battery status and control charging and discharging.
 Current Sensor: measure the current from the positive cable and send to
BMS.
 12V main contactor: BMS control the open and close of the contactor.
 12V controller contactor: BMS control the contactor, when the contactor
close, 80V to Pin3(Key) of the controller.
Power System
80V/12V DC/DC control logic:
1. Battery permanent 80V to DC/DC.
2. Ignition on, 80V+ to DC/DC, DC output 12V to
the low voltage system.
3. While charging, charger provide 12V to
Charger Relay(KA2), disconnect battery 80V
to DC/DC.
4. Emergency switch off the 80V+ power to
DC(ON/OFF).
5. DC/DC total capacity 300W, left about 100W.
80V Battery
12+
12-

Charging Pot
Ignition
Fuse
12-
Low
12V Output
Voltage
12+
Ignition
Emergency SW
Power System
Power on procedure
Display send
out 0x384
Ignition 80V/12V message.
on BMS power on, Contactor
DC/DC
monitor battery close
output 12V

Display send
Battery
out 0x384
output
message.
80V

Close Pre-charger
controller output Pre-charger
contactor voltage go up charging
to 65V in 5s.

Controller 80V main Controller receive

power contactor command signal, and
on,enable Close close operation.
 Power System
Power on procedure Pre-charger

Contactor 80V main Contactor Fuse

Controller
Fuse
12V Contactor KA1: Controller Contactor
KA2:Charging Relay
Current Sensor

KA3:BMS Relay
Battery

Fuse

On Relay

On Relay
BMS fuse Switch
BMS

T
BIC

V
CAN
 Ignition on, 80V+ to 80V/12V DC/DC and output 12V.
 DC/DC output 12V to BMS, contactor, display, light, etc.
 BMS supply 12V to BIC, BIC collect battery voltage and temperature information.
 BMS supply 15V to current sensor, measure circuit current.
 BMS analyze the battery information and check if the battery is in good condition or not, also send
battery information to display.
 Display send out 0x384 message, BMS close the controller contactor(KA1) and the 12V main
contactor. So 80V to Pin3, enable the controllers.
Power System
Power on procedure
Power System Fuse
Charging Procedure Box
Contactor
Charging Pot

Battery
BMS

Charging Control ：
1. Connect to charger, charger supply 12V to Coil of BMS Relay(KA3), KA3 NO terminal close, 12V
power to BMS; KA3 NC terminal open, cut off 12V power to display, MFA and light.
2. BMS collect the battery Volt and Temp information, check if the battery is in good condition, then
close the 12V main contactor, charging allow; If not ok, open the contactor, alarm “Connect bat.”
on the display.
3. Charger supply 12V to the coil of the Charging Relay(KA2), KA2(NC Relay) cut off the battery
80V+ to the 80V/12V DC/DC, so during charging if the ignition on, the DC/DC will not working and
no 12V output to the electric device.
Control System
Controller
Controller is the brain of the truck, receive the signal of the sensors and
switches, supply current to the motor, operate the command from the driver.
Node
Model
Left Middle Right

ECB16 Dual 7 （ 220A ） 8(220A) 6(220A)

ECB25 Dual 8 (330A) 6(330A) 7(440A)

ECB35 Dual 8(330A) 6(330A) 7(440A)

ECB25 Single  8(440A) /  7(330A)

ECB35 Single  8(550A) /  7(440A)

Control System
80V main contactor

Main controller close the 80V main contactor, then the controller can perform
the high-power work, supply 53Vac power to the motor.

80V main
contactor
Control System
Pre-Charger
Input cable(Red) and output cable(Yellow) are separately connect to the front
terminal and the rear terminal, the 80V+ from battery box connect to the front
terminal of the contactor, the same point where the pre-charger input cable
connect, 80V+ charge the pre-charger first, if the voltage at pre-charger output
cable(Controller B+) go up higher than 65V in 5s, controller close the 80V main
contactor.
Note: if in 5s, the voltage between B+ and B- lower than 65V, means pre-
charging fail, alarm pre-charging fail on display or red battery light, controller
error code 407 in 0x3011.

Pre-charger
Control System
Pre-charger
Pre-charger help to protect the controllers, when power on, voltage of B+ will go
up smoothly, when higher than 65V in 5s, close the main contactor, not close the
contactor immediately when Pin3 gets 80V+, if not the Spike high voltage will
damage the controllers

Pre-charger

Contactor 80V main Contactor Fuse

Controller
Fuse
12V Contactor KA1: Controller Contactor
KA2:Charging Relay
Current Sensor

KA3:BMS Relay
Battery

Fuse

On Relay

On Relay
BMS fuse Switch
BMS

T
BIC

V
CAN
Control System
Install extra device and get 80V+ from the 80V main contactor, should connect
to the input cable of the pre-charger where connect to the battery output cable.

Note: if connect to the pre-charger output terminal, before the 80V main
contactor close, if the device is already on, the device will get the power
through the pre-charger, if the current high than the capacity of the pre-charger,
it will damage the pre-charger.

Get the
80V+ from
this terminal
Control System
Cooling fans
Controller is high power consumption component, during working generates a lot of
heating, to avoid that the controller stop working because of high temperature, so
cooling fans mounted on top to blow the air from top to bottom to carry the heat
from the controller.

 Fans not working, controller temperature higher than 80℃, limit power output.
 Temperature higher than 95℃, cut off the power output.
 Overheating alarm, red motor light on display.
Control System-Sensor and Feedback
Basic truck seat (OPS function)

Only when the driver on the seat, the OPS is active, traction and pump function
are allowed.
Control System-Sensor and Feedback
Comfort truck seat (OPS function)

Only when the driver on the seat, the OPS is active, traction and pump function
are allowed.

11. MFA
12. Seat
14. OPS
Control System-Sensor and Feedback
Comfort truck-MFA
● 80V/12V DC/DC converter supply 12V to MFA(PIN1 and PIN2)

● Inside the MFA, convert 12V into 5V to the 4 fingertips.

 Control System-Sensor and Feedback
Comfort truck

Coil on the E-valve

Move the fingertip sensor, controller get the analog signal from the fingertip, if
the value is in the active range, the controller running the pump motor and
supply 24V current(0~800mA) to the coil on the E-valve, move the spool and
open the oil-way.

Lifting coil

2Pin connector

2nd,3rd and 4th

function coil

4Pin connector Lowering coil

2Pin connector
Control System-Sensor and Feedback
Comfort truck

Comfort truck Electric and hydraulic working flow:

Fingertip signal
0.5~4.5V

24V current 53Vac current

(0~800mA)
5
4
3
Control System-Sensor and Feedback
Basic truck – switch on the manual valve

DC/DC supply 12V to these switches, operate the lever and activate the lifting,
tilting or side shift switch, 12V to the controller PIN, active the pump function,
running the pump motor pump the hydraulic oil to the cylinders.
Control System-Sensor and Feedback
Basic truck – switch on the manual valve

Manual valve electric and hydraulic working flow:

12V digital signal

Move the lever,

open the oil-way 53Vac current
4
5
3
Control System-Sensor and Feedback
Basic truck

Lift potential sensor

The sensor mounted on the bottom of the lifting-lowering valve, when pull
the lifting lever, the signal of the sensor will rise, the controller receive the
signal and control the pump motor different speed when the value
change, to lower the consumption.
Control System-Sensor and Feedback
Basic truck

Lowering valve – working when OPS is activated

When OPS is activated, controller close the lowering valve relay(24V),

12V from DC/DC through the relay to the lowering valve, the lowering
valve working and open the oil-way for lowering.

In case that when no driver on the seat and operate the lowering lever, the
mast will lower.

12V lowering
valve
Control System-Sensor and Feedback
Acceleration Sensor – Need Calibration

The acceleration sensor integrate the digital switch and the analog
sensor:

Digital switch: the switch is off in the initial position, press down the pedal, the
switch is activated.
Analog sensor: when the digital switch is on, and the controller will control the
speed of the traction motor depend on the value of the sensor.
Steering Accel
sensor Sensor

Controller
Digital
Switch
Control System-Sensor and Feedback
Steering Sensor – Need Calibration

Steering sensor send the voltage value to the controller, and the controller
calculate the steering angle of the steering axle, and synchronize control the left
and the right traction motors, also limit the maximum speed when in driving in
the corner for safety.

4-wheels truck
3-wheels truck
Control System-Sensor and Feedback
Brake and braking light

 Pedal brake include hydraulic brake

and electric brake, working by the
brake cylinder and the switch
mounted under the brake pedal.

 Press down he brake pedal, the

braking switch is on, and 12V+
power to the controller PIN,
controller supply the reversing
current to the motor to stop the
motor.

 The braking light switch is on, and

12V+ power to the rear braking light.
Control System-Sensor and Feedback
Handbrake Switch

 Pull the lever, the handbrake switch is

on, the braking alarm red “P” shown on
the display, the truck forbid traction.

 Push the lever forward completely, the

switch is off, and the truck is enable
traction function, and the parking on
ramp function also activate.
Control System-Sensor and Feedback
FNR Switch On Basic Truck

Switch forward is F, and backward is R.

Control System-Display
Display – light and button
Display communicate with BMS and controllers through CAN Bus system.

Button1

Button2

Button3

Motor /Controller Overheating

电机过热报警，主接触器 Wrench Light
有故障时，扳手
Main Contactor Off
突然断开也会亮起 亮起
Battery Failure Turtle Light
电池故障报警 龟速指示灯
Button1:Drive
按钮1：驱动模式调节，上移 Mode, roll up
Parking
驻车制动指示灯 Light
Button2:Setting, Return
按钮2：设置，返回
Button3:Turtle,Roll down
按钮3：龟速，下移
 Control System-Display
Display – light and button

Drive Mode
OK Indicate

SOC Direction

Total KM
Speed Mode

Total Hour
Voltage

Interface and menu:

 OK indicate: serious error, main contactor off, OK light off.
 SOC, Voltage: BMS send these information to display.
 Total Hour: also can set to “current Working Hour”.
 Speed: km/h and MPH, shows different value when choose different unit; Error code also shown here.
 Drive Mode: ECB No this function.
 Direction: Controller send the F,R information to display, if it is not F or R, it shows N.
 Speed Mode: H, M and L, long press the turtle button, can choose the M speed mode; the speed mode
choose in red turtle light, will be the default speed mode. The display send the speed mode message
to the controller, the controller will control the maximum speed in different speed mode.
Traction System
Traction motor

ECB use KDS 53Vac motor, traction motor and pump motor, the working logic
is the same, only the specification is different.

Encoder
Temp. Sensor

Encoder Wheel
Rotator
Stator
Traction System
Motor and controller connection

U,V,W 3-phase cable (53Vac)

Temp. sensor (Pin26 and Pin6)
Encoder (Pin5,Pin6,Pin7 and Pin8)

Steering Accel
Sensor Sensor

Controller

Accel enable
switch
 Traction System
Sensor Measurement

Controller
12V

A
B 0V

Error code
• Encoder:
800 、 801 、 802 、 803 、 804 、
805 、 810 、 811 Ω V
• Temp.
sensor:800 、 801 、 810 、 811
、 600 、 601 、 602 、 603 、 604 Multimeter
万用表
Traction System
Motor Tem. Sensor R-T conversion table (KTY84-150)
Traction System
Encoder – speed sensor
Encoder function:
● feedback the motor speed and direction to the controller.
● two output signals, 90° phase difference.
 
AC motor encoder is an incremental encoder, commonly used external
plug-in and built-in. it can output two signals with 90° phase difference.
controller counting the motor feedback pulse signal, and calculate the
motor speed; determine the direction of the rotation of the motor by the phase
sequence the two pulse signals.
Lifting System-Steering System
Pump motor

Pump motor connect to pump controller, pump controller running

the pump motor, pump the high pressure oil to the cylinder.

Encoder
Temp. Sensor

Encoder Wheel

Stator Rotator
Low Voltage System – Light and Alarm
Light Switch

Front Light(LED

Tail Light (LED)

Low Voltage System – Light and Alarm
Horn and Horn Switch
Low Voltage System – Light and Alarm
Back-up Alarm

 Basic Truck:

Switch inside the reverse

gear.

 Comfort Truck:

When switch to reversing

direction, controller close
the reversing relay (24V),
12V from DC/DC to back-
u alarm.
Low Voltage System – Light and Alarm
Charging Gate Switch

 When the switch is

activate, alarm shown
on the display, traction
forbidden.

 Protect the charger

when the charger
connect to the truck.
Low Voltage System – Fuse box

Relays and Fuse

 Low Voltage System – Fuse box
Fuse box for Basic Truck
 Low Voltage System – Fuse box
Fuse box for Basic Truck

Fuse 6(10A) = Switch fuse. Relay 1(24V) = Lower valve relay

Fuse 7(5A) = Tail light fuse
Fuse 10(15A) = Back up light fuse
Fuse 11(15A) = Controller Contact fuse
Fuse 12(10A) = Tilt fuse
Fuse 13(10A) = Lower fuse
Fuse 14(5A) = Display fuse
Fuse 15(25A) = Front marker light fuse
Fuse 16(15A) = Wiper switch fuse
Fuse 18(10A) = BMS fuse
Fuse 19(10A) = Horn fuse
Fuse 20(10A) = Controller fans fuse
Fuse 21(15A) = Fan fuse
Fuse 23(15A) = Brake light fuse
Relay 2(12V) = Front light relay  
Relay 3(12V) = ON relay
Relay 4(12V) = Horn relay
Relay 5(24V) = Tilt valve relay
Relay 6(12V) = BMS relay KA3
Relay 7(12V) = Charge relay KA2
Relay 8(12 V) = Flasher relay for the
directional lights
 Low Voltage System – Fuse box
Fuse box for Comfort Truck
 Low Voltage System – Fuse box
Fuse box for Comfort Truck

Fuse 6(10A) = Switch fuse  Relay 1(24V) = Backup valve relay

Fuse 7(5A) = Tail light fuse Relay 2(12V) = Front light relay
Fuse 10(15A) = Back up light fuse Relay 3(12V) = ON relay
Fuse 11(15A) = Controller Contact fuse Relay 4(12V) = Horn relay
Fuse 14(5A) = Display fuse Relay 6(12V) = BMS relay KA3
Fuse 15(25A) = Front marker light fuse Relay 7(12V) = Charge relay KA2
Fuse 16(15A) = Seat heat fuse Relay 8(12 V) = Flasher relay for the
Fuse 17(15A) = MFA fuse directional lights
Fuse 18(10A) = BMS fuse
Fuse 19(10A) = Horn fuse
Fuse 20(10A) = Controller fans fuse
Fuse 21(15A) = Fan fuse
Fuse 22(15A) = Wiper switch fuse
Fuse 23(15A) = Brake light fuse
Harness
80V Ignition Fuse and Controller Contactor Fuse

Fuse 4 ： 80V Ignition Fuse

Fuse5 ： 80V Controller
Contactor Fuse