SENB8604-02

Systems Operation Capacitor

Device used to store electrical energy for short
Glossary periods of time.
Cathode
Accelerator The negative (-) side of a diode.
A device that converts mechanical movement into
a digital voltage pattern to the logics for variable Circuit
drive motor speed. A way for current to go from the positive (+) side of
an electrical power source to the negative (-) side
Activate of an electrical power source. This can be through
A word used with a component or circuit. To wires and electrical components.
change from the normal condition to the “activated”
condition because of an application of force or Coil
electricity. A component made from many circles or turns of
wire used to concentrate a magnetic field.
Ammeter
An electric meter used to measure current flow in Collector
amperes. A terminal of a transistor through which main
current flows (see Transistor).
Ampere (or Amp)
The unit of measurement of current flow. The Commutator
amount of current that one volt can push through a An armature component used to transfer current
resistance of one ohm. from the brushes to the armature windings.

Analog to Digital Converter Compound Motor

A device that converts an analog voltage into a A motor which has a field winding in series with the
pattern of digital HIGH and LOW voltage signals. armature and a shunt field winding in parallel with
the series winding and armature.
Anode
The positive (+) side of a diode. Compound/Series Motor
Similar to a compound motor, except the parallel
Armature shunt field windings are controlled on and off to
The rotating portion of an electric motor or vary speed and torque.
generator.
Conduct
Base To allow the flow of current.
The terminal of a transistor through which control
current flows (see Transistor). Conductor
A material that provides a path for current flow.
Battery
Two or more cells connected together for a supply Connector
of electric current. Part of a wire assembly or harness that connects
with another wire assembly or harness. Used for
BDI (Battery Discharge Indicator) ease of assembly and disassembly.
An electrically controlled display showing the
operator the state of battery charge. Contactor Assembly
An electrical component consisting of an electro-
Brush magnetic coil and a set of heavy contact tips.
A conductor, normally a block of carbon, that Control current passes through the coil, building a
makes sliding contact between the stationary and magnetic field which closes or opens the contact
moving part of the motor or generator. tips.
Bus Bar Contactor Coil
A heavy electrical conductor to which other smaller An electromagnet used to close or open contact
wires are connected. tips in a contactor assembly.

6
 SENB8604-02

Contact Tips or Contacts Drain

The portion of a switch, relay or contactor where Terminal of a MOSFET through which main current
the circuit can be opened or closed. flows (see MOSFET).
Continuity Electrical Braking
Having the ability to allow current flow. Electrically trying to rotate the drive motor opposite
to the direction of truck movement.
Control Circuits
The wires and components carrying low current Electromagnet
used to signal the logics unit, turn on main compo- A coil of wire, most often wound on an iron core,
nents, or support auxiliary circuits (indicated by which produces a strong magnetic field when
thin lines on a schematic). current is sent through the coil.
Counter Electromotive Electromotive Force (EMF)
An opposing voltage set up by a collapsing or The force that causes an electric current to flow in
increasing magnetic field within a Force (CEMF) a circuit. This force is measured in volts.
coil.
Emitter
Current A terminal of a transistor through which low control
The movement or flow of electricity through a current and main current flow (see Transistor).
conductor. A circuit must be complete for current
Ferrite Bead
to flow.
A small bead located on the base connection of
Current Limit the power transistors to reduce high frequency
The maximum allowable armature current of a oscillation at the power transistor.
stalled drive motor during pulsing.
Field Windings
Current Sensor The stationary coils that produce a magnetic field
A hall-effect sensor in the drive motor circuit that in motors and generators.
produces an increasing voltage output as the drive
Filter
motor current increases.
An electrical device or component for restriction or
Current Shunt suppression of undesired voltage spikes.
A precision low-value resistor connected in series
Fuse
with the armature of a motor. The logics uses the
A component in an electrical circuit that will open
measured voltage drop across the shunt to control
the circuit if too much current goes through it.
maximum current allowed in selected power
circuits. Gate
Terminal of a MOSFET where voltage is applied to
Deactivate
control the device (see MOSFET).
To change from the activated condition back to the
normal (deactivated) condition. It can be caused Grounded
by the application of force, the removal of force, or A wire or wires that are in contact with the metal
the removal of electricity. chassis of the vehicle (ground). Can be caused by
a loss of insulation from the wire, or by connecting
Digital Signal
the wire to the vehicle.
A signal in which the elements may be either of
two distinct values. For example high voltage, low Harness
volt age. An assembly made of two or more wires that are
held together.
Diode
A semiconductor device that allows current to flow Heat Sink
in one direction, from the anode to the cathode. A mounting frame used for semiconductor cooling.
Display Hour Meter
An electrical device that converts voltage inputs to An electrically activated device used to record the
a visual output. amount of usage a truck receives.

7
SENB8604-02

Indicator Normal Condition

A lamp or LED that gives an indication of some Words used with a switch or relay. Their normal
vehicle condition when it turns on or flashes. condition is their condition when they are not
controlled by the application of force, temperature,
Input
pressure, or electricity.
A voltage change at the incoming connection of a
component. Normally Closed (N.C.)
A switch or relay whose contacts are closed in the
Insulator
normal condition.
A material that has a very large resistance so that
it will not let current flow through it. Normally Open (N.O.)
A switch or relay whose contacts are open in the
LED
normal condition.
Light Emitting Diode - a diode that emits light
(lights) when current flows in the forward direction. OFF-Time
The amount of time current does not flow through
Linear Output Hall Effect Transducer (LOHET)
a transistor.
A device that converts an increasing magnetic field
to an increasing linear output voltage Ohm
The unit of measurement of resistance. The
Logics or Logic Unit
amount of resistance that will let one volt push
The main printed circuit board containing a micro
only one ampere of current through it.
processor and circuits to condition the voltage
signals that go into or come out of the logics. It ON-Time
electronically monitors and controls the truck’s The amount of time current flows through a
functions. transistor.
Magnetic Field Open Circuit
The area around a magnet where magnetic forces Wiring or components of a circuit that have no
can be detected. continuity.
Microprocessor Optical Switch
A small computer chip preprogrammed to control An electronic device made up of an infrared light
the various electrical functions on a lift truck. signal generator and photosensitive signal receiver
that changes a digital voltage when the light
MOSFET
pattern is conducting or blocked.
A semiconductor component used in electrical lift
trucks as an electronic switch. A MOSFET most Output
often has three terminals: a Gate (G) a Source (S) The current flow from a component which is initiated
and a Drain (D). The main current flows between from a voltage change at the component’s input.
the drain and the source. The main current flow is
Source
controlled by a voltage applied between the gate
Terminal of a MOSFET through which the main
and the source.
current flows (See MOSFET).

8
 SENB8604-02

Terminal Volt
An electrical connection point on an electrical The unit of measurement of electromotive force.
component. One volt is the force needed to make one ampere
of current flow through one ohm of resistance in a
Thermal Switch
circuit.
A switch that activates at a set temperature.
Watt
Transistor
The unit of measurement of power. The amount of
A semiconductor component used in electric lift
power used when one volt pushes one ampere of
trucks as an electronic switch. A transistor most
current through a resistance of one ohm. The
often has three terminals, a base (B), a collector
result of amperes (current) multiplied by volts (volt
(C), and an emitter (E). The main current flow is
age) is watts (power).
between the collector and emitter. This main
current flow is controlled by a much smaller Wire
current flow between the base and emitter. A conductor used to provide a path for current to
flow to and from electrical components.
Turn ON
When an electrical component conducts current. Wiring Diagram
A drawing using visual representation of compo
Varistor
nents the way they actually look. It is used to show
A component terminated across the horn connec-
the locations of components and the connections
tions to eliminate voltage spikes when the horn is
between them.
activated.
Zener Diode
A special diode used to regulate voltage or as an
overvoltage (too high a voltage) protector.

9
SENB8604-02

Location of Control Panel

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

CP Components

10
 SENB8604-02

Symbol Library

1 2 3 4 5 6 7 8
9

10

11

12

13

14

15

16

24 17
23 22 21 20 19 18

24 25
28

26 27

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

11
SENB8604-02

Components Behind Logic Unit (1)

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

Control Panel and Driver Board with Regen / 10300V2

Control Panel and Driver Boards Plug Only / 10200V2

12
 SENB8604-02

MicroCommand II Control Panel

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

Control Panel Cover off with Regen / 10300V3

Control Panel Cover off Plug Only / 10200V3

13
SENB8604-02

General Information The MicroCommand II control system operates the

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

14
 SENB8604-02

Programmable Setup Options

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

15
SENB8604-02

PROGRAMMABLE SETUP OPTIONS

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

Functional Descriptions of Option 4 - Tilt Speed

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

17
SENB8604-02

Second Group Option 16 - BDI Reset Value

• Settings: 0/10/5 0-10 RESET VALUE
Option 10 - Auxiliary Input For Lift And Drive Speed This option sets the value above which we
• Settings: 0/4/0 consider a battery to be recharged. If the truck
0 Disabled enters a dead battery condition, it will remain in
1 Disable Lift On Low this state even if the key switch is cycled until a
2 Speed Limit On Low battery that equals or exceeds the BDI reset value
3 Disable Lift On High is connected to the truck.
4 Speed Limit On High
• This option is used in conjunction with the lift limit Option 17 - Dead Battery Lift Lockout
input P1-14. This input is internally pulled up on • Settings: 0/1/1 OFF/ON
the logic to +15V. This option determines the action of the lift during
a dead battery condition.
Option 11 - Auxiliary Travel Speed Limit
• Settings: 1/20/10 Option 18 - Dead Battery Travel Speed With Disable
This option is used in conjunction with option 10 • Settings: 0/20/10 1 - 20 KPH WITH 0 = DISABLE
when the speed limit portion of option 10 is used. This option determines the maximum truck speed
during a dead battery condition.
Option 12 - Pulsing Stall Timer
• Settings: 3/30/5 Option 19 - Variable Regen On Accelerator
This option allows some adjustment (3 to 30 • Settings: 0/1/0 OFF/ON
seconds) to the time it takes the truck to shut When enabled, this option allows the accelerator to
down when the drive motor current is too high for control the level of braking in regen. The option
too long in transistor mode. This condition, called a works only on trucks equipped with regen. It is
drive stall timer failure, produces an error code 20 influenced by the setting of option 20. (It will not
on the display. Option 12 helps prevent drive motor work with settings EAB1 or EAB3 because they
abuse. require the accelerator to be off.)
Option 13 - Park Brake Duty Cycle Limit
Option 20 - Regen Function On Accelerator Or Brake
• Settings: 0/15/3 • Settings: 0/3/3
This option controls the maximum drive duty cycle 0 DISABLED/EAB1/EAB2/EAB3
when the park brake is applied. It allows the drive 1 EAB1 - Service Brake is on; Accel must be off
system to operate much like a car when the park 2 EAB2 - Service Brake is on; Accel does not matter
brake is applied. The truck will try to move, but be 3 EAB3 - Whenever accel is off
unable. This should help remind the operator that
the park brake is applied. This option allows the use of the Electrical
Assisted Braking (EAB). The three modes are
Option 14 - BWI Operation defined above. Only one mode can be enabled at a
• Settings: 0/1/1 time. This option works only on trucks equipped
NO EFFECT/BWI AFFECTS TRUCK OPERATION with regen because the added braking load would
This option determines what will happen if either overheat a truck equipped only with plugging.
the drive or pump motor brush wear indicator
(BWI) is activated: Option 21 - Regen Enable For 2EC15/18 36/48V Truck
• Pump BWI active - Lift Lockout • Settings: 0/1/0 DISABLED/YES
• Drive BWI active - Truck is slowed to 1/2 of This option allows a person to enable regen on a
current maximum speed or 6 KPH, whichever truck that did not previously have regen. After the
is slower. necessary components have been added, this
option is enabled.
Option 15 - 80% Bypass Option
• Settings: 0/1/1 OFF/ON Option 22 - Service Brake Duty Cycle Limit
If enabled, this option will not allow the truck to • Settings: 0/15/3 ACCEL POS LIMIT
enter bypass when the truck is in current limit. This This option controls the maximum drive duty cycle
option in conjunction with the drive pulsing stall when the service brake is applied. This allows
timer (option 12) will help to reduce drive motor some drive while the service brake is on so that the
abuse in hard applications. truck can be two-footed. If the truck is being
abused because of two-footing, option 22 can be

18
 SENB8604-02

used to prevent the situation. Third Group

Option 23 - Chat Timer Option 28 - EE Option
• Settings: 0/20/5 • Settings: 0/2/0
1-20 SECOND TIMER WITH 0=DISABLE OFF/EE DRIVE ONLY/EE DRIVE&PUMP
This option controls the amount time required to The EE option is used to slow down the pump and
enter chat mode. drive system, which results in cooler running motors.
The EE option accomplishes this by always keeping
Option 24 - French BDI Option (nonactive) the shunt field on when the motor is operating.
• Settings: 0/1/0 OFF/ON
This option allows the use of a different BDI Option 29 - Tire Wear Adjustment
discharge curve for use with tubular plate batteries. • Settings: 0/40/20 =
These batteries have a flatter discharge curve than NO ADJUSTMENT SMALLEST/LARGEST
normal so the voltage at which they are considered This option allows the speedometer to be adjusted
dead is higher than the normal battery. See the based on the amount of tire wear. The speedometer
topic, “Battery Discharge Indicator (BDI) calculations are based on a certain tire size. If we
Adjustment,” in the Testing and Adjusting section deviate from this tire size, the speedometer will not
of this manual. work.

Option 25 - Pump And Drive Pulsing Frequency Option 30 - Truck Size and Type
• Settings: 0/1/0 NORMAL/DOUBLE FREQUENCY • Settings: SIZES SHOWN:
This option allows the 187.5 Hz transistor pulsing O 0 0.0 C 1.6 C 1.8 C 2.0 C 2.5 C 3.0
frequency used for drive and lift related pump This option is used to tell the logics the size and
operation to be changed to 375 Hz. For some type of the truck. Special care should be applied
people the 375 Hz pulsing may be more accept- here. The value of this option is used to configure
able than 187.5 Hz pulsing. The 15 kHz used for the drive and pump operation for the truck and if
pump steering functions is unaffected by this set incorrectly could result in erratic truck operation.
option and remains at 15 kHz. When the logics are received out of the parts system
or initially put on a truck on the production line,
Option 26 - Regen Adjustment For Brake Regen option 30 is set to 0 0.0. If the truck is powered up
• Settings: 3/10/5 in RUN mode without first setting this option to
50% TO 100% OF P3 POT IN 10% INCREMENTS some value other than 0 0.0, the truck will shut
This option allows the EAB regen to be adjusted down and an error code 65 will be displayed.
independent of the level of regen set by pot P3. It
is independent as long as the desired EAB regen Option 31 - 34 - Blank
level is lower than that set by P3. This allows the • Settings: 0
user to set the EAB regen softer than normal regen. These options are intentionally left blank.

Option 27 - Pump Transistor Upgrade Option 35 - Bypass Stall Timer

• Settings: 0/2/0 DISABLED/2 200A/2 300A • Settings: 1.5/20/1.5
In an 2EC16 OR 2EC18, option 27 allows the user to
upgrade the pump transistor to a higher capacity
configuration. In a heavy application where the user
is suffering too many pump transistor failures, this
option along with the addition of bigger pump
transistors improves reliability.

19
SENB8604-02

Accessing Programmable Setup

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

20
 SENB8604-02

Programming Setup Option 1 Application A - Factory

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

OPTION 1 MODES / VALUES

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

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

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

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

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

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

Option 1 Applications

21
SENB8604-02

Programming Setup Options Activating Default Settings

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

22
 SENB8604-02

Operational Circuit Elements

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

Logic Board

A jumper should be installed on one of the jumper

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

23
SENB8604-02

Vehicle Monitoring System Battery Discharge Indicator

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

Speed / Fault Code Indicator

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

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

24
 SENB8604-02

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

3 4
2 5 6 7
1

Action Lights

1. Service Reminder - The wrench symbol lights

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

25
SENB8604-02

Run-Time Diagnostics DISPLAY = 11 - Drive armature transistor’s emitter low

when not expected
The MicroCommand II Control System controls and Components Involved: T1D and/or T2D
monitors all the electrical and hydraulic operations of Location: Panel
the lift truck. An important part of its job is to detect Cause: A code 11 results when the processor
problems and signal the operator or maintenance per- senses the drive armature transistor emitter
son to take corrective action. Run-time diagnostics being low when it should be high. This error is
function during truck operation. detected during the Close Line Contactor
During truck start-up or operation, if the logics detects Routine (CLOSLC).
a problem, a diagnostic code will appear in the Response: Truck shuts down and the error code
Speed/Fault Code Indicator instead of vehicle speed. is displayed.
The “!” symbol flashes in the action light strip at the
same time the code is displayed. The codes indicate
an improper operating sequence or a defect in the DISPLAY = 15 - D6D anode low when not expected
truck electrical system. • REGEN-EQUIPPED PANELS
Components Involved: D6D, Regen Contactor,
Run-time diagnostics cover the following areas of truck Sense Wire
operation and protection: Location: Panel
• Truck, drive motor, and pump motor hours Cause: A code 15 results when the processor
senses the D6D anode low when it should be
• Service reminder hours high. This error is detected during the first
• Motor brush wear 50mS of regen. This check prevents a regen
contactor that is welded shut from causing the
• Stall protection truck to act unpredictably. It is also possible
• Overtemperature protection of the drive motor, that this error is caused by a broken wire.
pump motor, and the control panel. Response: Truck shuts down and the error code
is displayed.
• Brake fluid level
• PLUG-ONLY PANELS
Listed below are all the possible Run-time error codes, Components Involved: Sense Wire
the components involved and their location (if applica- Location: Panel
ble), the cause of the error code, and the truck Cause: A code 15 results when the processor
response to the problem. Also see the “Troubleshooting senses the D6D sense wire is low. Since this
Problem List” and the troubleshooting flow charts in truck lacks regen, this sense wire is perma-
the Testing and Adjusting section of this manual. nently connected +BAT. If this wire is sensed
low it means that the wire is broken or the
truck size and type have been set to indicate
DISPLAY = 10 - Drive armature transistor emitter high
that the truck is equipped with regen when it
when not expected
really isn’t. This error is sense during the Close
Components Involved: T1D and/or T2D Line Contactor Routine (CLOSLC) and anytime
Location: Panel the regen contactor is closed.
Cause: A code 10 results when the processor Response: Truck shuts down and the error code
senses the drive armature transistor emitter is displayed.
being high when it should be low. This error is
detected during the Close Line Contactor
Routine (CLOSLC) and anytime the line
contactor is in.
Response: Truck shuts down and the error code
is displayed.

26
 SENB8604-02

DISPLAY = 16 - D6D anode high when not expected DISPLAY = 20 - Drive stall timer failure
REGEN-EQUIPPED PANELS Components Involved:
Components Involved: D6D, Regen Contactor, Location: Logics Panel
Sense Wire Cause: A code 20 occurs when the processor
Location: Panel senses that the drive motor has been drawing
Cause: A code 16 results when the processor too much current for too long. The time before
senses the D6D anode high when it should be the failure occurs will be dependent on the
low. It can be caused when the truck type and level of current being drawn. The more the
size are set to indicate that it is a plug-only overload, the shorter the time before a failure.
truck when it isn’t. It can also be caused by a This error is detected anytime the drive motor
bad regen contactor or logic. is being driven. The stall timer failure timer can
Response: Truck shuts down and the error code be set in setup mode. See the topic,
is displayed. “Programmable Setup Option,” option 12, in
this section of the manual.
PLUG-ONLY PANELS
Response: Truck shuts down and the error code
Components Involved: Sense Wire
is displayed.
Location: Panel
Cause: This error is not used on plug-only panels DISPLAY = 21 - Drive current sensor not operating
because the sense wire is permanently tied to Components Involved: E361 (Current Sensor)
+BAT and therefore should always be high. Location: Panel
Cause: A code 21 occurs when the processor
DISPLAY = 18 - Drive shunt field transistor’s drain is
senses a zero reading that is outside of the
high when not expected
allowed bounds. This is an indication that the
Components Involved: T371
sensor is not working correctly or has failed.
Location: Drive Driver Board
This error is detected anytime the directional
Cause: A code 18 occurs when the processor
contactors are open and the truck is in neutral.
senses the drive SF collector being high when
Response: Truck shuts down and the error code
it should be low. This error is detected during
is displayed.
the Close Line Contactor Routine (CLOSLC).
Response: Truck shuts down and the error code DISPLAY = 24 - Drive output overcurrent fault
is displayed. Cause: A code 24 occurs when the processor
senses that the output driver(Q109) is going
DISPLAY = 19 - Drive shunt field transistor’s drain is
into a current limit situation.
low when not expected
Response: Truck shuts down and the error code
Components Involved: T371
is displayed.
Location: Drive Driver Board
Cause: A code 19 occurs when the processor DISPLAY = 25 - Accelerator fault low
senses the drive SF collector being low when Cause: A code 25 occurs when the processor
it should be high. This error is detected during senses that the pulse width modulation (PWM)
the Close Line Contactor Routine (CLOSLC). voltage from the accelerator is too low. This
Response: Truck shuts down and the error code error is detected at all times.
is displayed. Response: Truck shuts down and the error code
is displayed.

27
SENB8604-02

DISPLAY = 26 - Accelerator fault high DISPLAY = 33 - Combination of 31 and 32

Cause: A code 26 occurs when the processor Cause: A code 33 occurs when the processor
senses that the pulse width modulation (PWM) senses that the pump armature transistor
voltage from the accelerator is too high. This emitter is low when it should be high while
error is detected at all times. testing the B and B0 terminals. This error is
Response: Truck shuts down and the error code detected during the Close Line Contactor
is displayed. Routine (CLOSLC).
Response: Truck shuts down and the error code
DISPLAY = 29 - Speed sensor failure
is displayed.
Cause: A code 29 occurs when the processor
senses that the speed sensor is not working DISPLAY = 38 - Pump shunt field transistor’s drain is
correctly. high when not expected
Response: Truck shuts down and the error code Components Involved: T351
is displayed. Location: Drive Driver Board
Cause: A code 38 occurs when the processor
DISPLAY = 30 - Pump armature transistor’s emitter is
detects the pump SF transistor collector high
high when not expected
when it should be low. This error is detected
Components Involved: T1P and/or T2P
during the Close Line Contactor Routine
Location: Panel
(CLOSLC).
Cause: A code 30 occurs when the processor
Response: Truck shuts down and the error code
senses that the pump armature transistor emit-
is displayed.
ter is high when it should be low. This error is
detected during the Close Line Contactor DISPLAY = 39 - Pump shunt field transistor’s drain is
Routine (CLOSLC) and any time the line con- low when not expected
tactor is in. Components Involved: T351
Response: Truck shuts down and the error code Location: Drive Driver Board
is displayed. Cause: A code 39 occurs when the processor
detects the pump SF transistor collector low
DISPLAY = 31 - Pump armature transistor’s emitter is
when it should be high. This error is detected
low when not expected while driving B terminal
during the Close Line Contactor Routine
Components Involved: T1P and/or T2P
(CLOSLC).
Location: Panel
Response: Truck shuts down and the error code
Cause: A code 31 occurs when the processor
is displayed.
senses that the pump armature transistor
emitter is low when it should be high while DISPLAY = 40 - Pump stall timer failure
driving the B terminal of the transistor(s). This Cause: A code 40 occurs when the processor
error is detected during the Close Line senses that the pump motor has been
Contactor Routine (CLOSLC). drawing too much current for too long. This
Response: Truck shuts down and the error code error is detected any time the pump motor is
is displayed. being driven.
Response: Truck shuts down and the error code
DISPLAY = 32 - Pump armature transistor’s emitter is
is displayed.
low when not expected while driving b0 terminal
Components Involved: T1P and/or T2P DISPLAY = 41 - Pump current shunt not operating
Location: Panel Components Involved: Pump Shunt, Wires #29
Cause: A code 32 occurs when the processor and 119
senses that the pump armature transistor Location: Panel
emitter is low when it should be high while Cause: A code 41 occurs when the processor
driving the B0 terminal of the transistor(s). This senses that the pump shunt is not registering
error is detected during the Close Line current when it should be.
Contactor Routine (CLOSLC). Response: Truck shuts down and the error code
Response: Truck shuts down and the error code is displayed.
is displayed.

28
 SENB8604-02

DISPLAY = 44 - Pump output overcurrent fault DISPLAY = 63 - Frame Fault Negative voltage (nonactive)
Cause: A code 44 occurs when the processor Cause: Connection between the lift truck
senses that one or more of the output drivers frame and a negative voltage source.
(Q106 - Q108) are going into a current limit Response: Truck shuts down and error code
situation. is displayed.
Response: Truck shuts down and the error code
DISPLAY = 65 - Truck size not initialized
is displayed.
Cause: A code 65 occurs when the truck is
DISPLAY = 50 - Combination of 10 and 30 powered up in RUN mode with option 30
Cause: Combination of 10 and 30. (Truck size and type) equal to 0 0.0.
Response: Truck shuts down and the error code Response: Truck shuts down and the error code
is displayed. is displayed.
DISPLAY = 51 - Combination of 11, 31, and 32 DISPLAY = 66 - Watchdog timer failure
Cause: Combination of 11 and 31. Components Involved: Logic Card
Response: Truck shuts down and the error code Location: Panel
is displayed. Cause: A code 66 occurs when the logic senses
that its watchdog timer is not functioning.
DISPLAY = 60 - Serial communication fault
Because this circuit monitors the processor
Cause: A code 60 occurs when the serial
proper operation it must always be functional.
communication system fails to communicate a
Response: Truck shuts down and the error code
message in a given amount of time between
is displayed.
the logics and display.
Response: Truck shuts down and the error code DISPLAY = 67 - Battery volts too low
is displayed. Cause: A code 68 occurs when the processor
senses that the battery volts are too low for
DISPLAY = 61 - EEPROM error
the battery voltage chosen by the jumper.
Cause: A code 61 occurs when the processor
24 > 36/48V BATTERY
cannot program a location correctly, or when
60 > 72/80V BATTERY
reading an EEPROM value and its comple-
Response: Truck shuts down and the error code
ment, they don’t agree.
is displayed.
Response: Truck shuts down and the error code
is displayed. DISPLAY = 69 - Battery volts too high
Cause: A code 69 occurs when the processor
DISPLAY = 62 - Frame Fault positive voltage (nonactive)
senses that the battery volts are too high for
Cause: Connection between the lift truck
the battery voltage chosen by the jumper.
frame and a positive voltage source.
36/48V BATTERY > 60
Response: Truck shuts down and the error code
Response: Truck shuts down and the error code
is displayed.
is displayed.

29
SENB8604-02

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

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

B75533P1

30
 SENB8604-02

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

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

97812-15600

NOTICE: Do not connect the 12 volt negative output

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

31
SENB8604-02

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

3
3
LIGHTS FUSE 15A
34
P12-13
KEY FUSE 10A 3 HORN BUTTON
P12-11 P12-12 3 P5-3 P46-2 4 P46-1
R319 R320 KEY SWITCH
P3-18 P5-4 4

P3-4 P5-12 12 P6-4 P6-2 4

DISPLAY
46

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

P2-12 LIFT LIMIT SW
P3-3 SEAT OPERATED BRAKE SW
P1-14 127 P5-21 P60-C P60-A
100 1 +
P2-13
SEAT SWITCH 1
P1-13 P5-7 7 1 HORN
2
PUMP MOTOR THERMOSTAT -
P3-2 77 P5-25 1

P3-1 76 P5-24 1
DRIVE MOTOR THERMOSTAT SERVICE BRAKE SWITCH 3
P1-12 P5-23 113 P40-C P40-B 1

P1-11 P5-19 91 1
PARK BRAKE SW BRAKE FLUID SWITCH
P2-20 P5-22 106 P33-2 P33-1

FWD
P1-10 P5-14 14 P7-B 4
DIR SW P7-A 1
34 REV
P1-9 P5-15 15 P7-C
39 P3-17
LINE COIL
XY 26 P3-9 FWD
P61-2
LIFT COIL P61-1 1
X Y 30 P3-10 FOOT DIR SW
REV
BYPASS COIL P38-8 P61-3
LOGICS

XY 35 P3-11
FWD COIL
P1-1 P5-13 13 P13-5 1
XY 20 P3-12
REV COIL LIFT 1 SW
XY 19 P3-13 P1-2 P5-27 81 P13-6 1 4
REGEN COIL LIFT 2 SW
XY 75 P3-14
3 P1-3 P5-34 89 P13-2 1 P32-3 1

38 P3-16 TILT SW
P32-4 3
LINE FUSE P1-4 P5-33 88 P13-3 1
2 TO 3 TON AUX 1 SW 4
36/48 VOLT
675 AMP P1-5 P5-32 87 P13-4 1 P13-1
600 AMP
1TON AUX 2 SW
P1-6 P5-26 78 P24-2 P24-1 1 1
LINE TWISTED PAIR TWISTED PAIR
CTR PRESSURE SWITCH
P1-19 116 P5-31 P52-2
SPEED
SENSOR
P1-18 115 P5-30 P52-1 SWITCH 1 1 4 1
BATTERY
36/48 VOLT P1-15 8 P5-8 P9-C P9-A
OR P9-B
72/80 VOLT ACCEL
CONTROL
P3-21

P1-21
P3-20
P2-21

P5-36

P5-37
P5-2

P5-1

2EC1513

32
 SENB8604-02

Drive Circuit controlled separately from the pump motor circuit by

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR

92
96

2EC1503

33
SENB8604-02

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

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR
P12-10

92
96

2EC1504

34
 SENB8604-02

When the drive power transistors (T1D and T2D) are

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR
P12-10

92
96

2EC1505

35
SENB8604-02

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

36
 SENB8604-02

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR
P12-10

92
96

2EC1506

37
SENB8604-02

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR
P12-10

92
96

2EC1507

38
 SENB8604-02

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR
P12-10

92
96

2EC1508

39
SENB8604-02

Plugging Circuit Plugging electrical braking (the standard configuration

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

92
96

2EC1509

40
 SENB8604-02

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR
P12-10

92
96

2EC1510

41
SENB8604-02

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR
P12-10

92
96

2EC1511

42
 SENB8604-02

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

43
SENB8604-02

Thermal Protection Circuits Hydraulic Pump Motor

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

44
 SENB8604-02

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR
P12-10

92
96

2EC1512

45
SENB8604-02

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

P12-16

R311

THERMOSTAT
Z313

P8-2
T315
T314

CONTROL
46

P12-15
34

R313
P2-12

D311
B B
T1D T2D 32 P3-3

P8-1
B0 B0 100 P2-13
T

R312
P12-14

R316
R315

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

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

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

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

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

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

OR CAP CTR CTR 38 P3-16

72/80 VOLT
D371
D4D

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

P16-3 85 P3-6
P2-11
E361

P2-2
R361

P2-1
T371

97
92
Z371

C371

CURRENT 96
96 SENSOR
R371

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

REGEN
P12-9

CTR

92
96

2EC1501

46