®

Lift
Trucks

Service Manual

MicroCommand II Control
2EC15 A2EC1-60001-79999
2EC18 A2EC1-60001-79999
2EC20 A2EC2-60001-79999
2EC25 A2EC2-60001-79999
2EC25E A2EC3-60001-79999
2EC30 A2EC3-60001-79999

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Table of Contents

Cat Lift Truck Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Component Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Current Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Transistor Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Transistor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Head Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Control Panel Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Contactors Tip Clearance (Gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive and Pump Motor Shunt Field Resistances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Systems Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Location of Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Symbol Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Programmable Setup Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Accessing Programmable Setup Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Operational Circuit Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Run-Time Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Chat Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Accelerator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Power Transistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

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Testing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Accessing Stored Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Troubleshooting Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Control And Power System Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Systems Operation and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Conductor And Switch Continuity Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Driver Board Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Traction Motor Current Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Actuation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Capacitor Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Hydraulic Pump Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

Testing Transistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Electrical System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163

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A Power Transistors . . . . . . . . . . . . . . . . . . 34
Regenerative Braking . . . . . . . . . . . . . . . 37
Accelerator
Thermal Protection Circuits . . . . . . . . . . 44
Adjustment . . . . . . . . . . . . . . . . . . . . . . 163
Contactors
Continuity Test . . . . . . . . . . . . . . . . . . . . 128
Continuity Test . . . . . . . . . . . . . . . . . . . . 131
Control Diagnostic . . . . . . . . . . . . . . . . . . 30
General Information . . . . . . . . . . . . . . . . . 30
B Pump Contactor Operation Circuit . . . . 155
Continuity Tests
Battery
Accelerator Control . . . . . . . . . . . . . . . .130
BDI Adjustment Charts . . . . . . . . . . . . . 169
Contactors . . . . . . . . . . . . . . . . . . . . . . . 131
Cell Voltage Test . . . . . . . . . . . . . . . . . . . 49
DC/DC Converter . . . . . . . . . . . . . . . . .133
Hydrometer Test . . . . . . . . . . . . . . . . . . . 49
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . 49
Head Capacitor . . . . . . . . . . . . . . . . . . . 130
Maintenance . . . . . . . . . . . . . . . . . . . . . . 49
Vehicle Monitoring System . . . . . . . . . . 133
Brakes
Control Panel
Parking Brake Switch Adjustment . . . . 164
Component Location . . . . . . . . . . . . . . . 10
Plugging Circuit . . . . . . . . . . . . . . . . . . . . 39
Electrical Testing . . . . . . . . . . . . . . . . . . 162
Regen Circuit . . . . . . . . . . . . . . . . . . . . . . 37
Specifications . . . . . . . . . . . . . . . . . . . . . . 5
Test and Adjust Electric Brakes . . . . . . 167
Thermal Protection Circuit . . . . . . . . . . . 44
Bypass Circuit
Control System Checks . . . . . . . . . . . . . . . . 51
Circuit with Shunt Field Activated . . . . . 45
Circuit Without Shunt Field Activated . . 46
D
C DC/DC Converter
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chat Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Continuity Test . . . . . . . . . . . . . . . . . . . . 133
Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . 54
Diagnostics
Circuits
Built-In Diagnostic Operation . . . . . . . . . 52
Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Chat Mode . . . . . . . . . . . . . . . . . . . . . . . . 30
DC/DC Converter . . . . . . . . . . . . . . . . . . 31
Run-Time Diagnostic Functions . . . . . . . 52
Drive Control . . . . . . . . . . . . . . . . . . . . . . 32
Run-Time Diagnostics . . . . . . . . . . . . . . . 26
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . 41
Self-Diagnostics . . . . . . . . . . . . . . . . . . . 53
Drive Power . . . . . . . . . . . . . . . . . . . . . . . 33
Stored Fault Codes . . . . . . . . . . . . . . . . . 47
Failure Protection Circuit . . . . . . . . . . . . . 44
Drive Motor
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hydraulic Circuits . . . . . . . . . . . . . . . . .138
Current Limit . . . . . . . . . . . . . . . . . . . . . .43
Plugging Circuit . . . . . . . . . . . . . . . . . . . . 39
Drive Control Circuit . . . . . . . . . . . . . . . . 32

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Drive Power Circuit . . . . . . . . . . . . . . . . . 33 Lift Power . . . . . . . . . . . . . . . . . . . . . . .149

Electrical Testing . . . . . . . . . . . . . . . . . .162 Power Steering Idle . . . . . . . . . . . . . . . . 141
Thermal Protection Circuit . . . . . . . . . . . 44 Power Steering In Use . . . . . . . . . . . . . 146
Driver Board Tests Pump Contactor . . . . . . . . . . . . . . . . . . 155
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Pump Motor . . . . . . . . . . . . . . . . . . . . . 140
Drive Driver Board . . . . . . . . . . . . . . . . . 134 Pump Power Transistor Turn-Off . . . . . 158
Pump Driver Board . . . . . . . . . . . . . . . . 134 Pump Shunt Field . . . . . . . . . . . . . . . . . 145
Pump Shunt Field Circuit . . . . . . . . . . . 145
E Tilt and Auxiliary Control . . . . . . . . . . . . 156
Electrical System Adjustments . . . . . . . . . . 163
Method A (Mechanical) . . . . . . . . . . . . . 163 L
Method B (Electrical) . . . . . . . . . . . . . . . 163 Lift Control
Electrical Tests and Adjustments Additional Information . . . . . . . . . . . . . . 157
Accelerator Group . . . . . . . . . . . . . . . . . 163 Lift Control Circuit . . . . . . . . . . . . . . . . . 148
Current Limit Test and Adjust . . . . . . . . 166 Lift Power Circuit . . . . . . . . . . . . . . . . . .149
Electric Braking . . . . . . . . . . . . . . . . . . .167 Logics
Harness Wiring Circuit Guide . . . . . . . . 171 Circuit Elements . . . . . . . . . . . . . . . . . . . 23
Logic Board Layout . . . . . . . . . . . . . . . . 168 Component Tests . . . . . . . . . . . . . . . . . 126
Park Brake Switch . . . . . . . . . . . . . . . . . 164 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 126
Resistor R312 . . . . . . . . . . . . . . . . . . . . 162 Test Board Layout . . . . . . . . . . . . . . . . .168
Transistor Replacement . . . . . . . . . . . . 161 Voltage Check . . . . . . . . . . . . . . . . . . . . 127
Transistors . . . . . . . . . . . . . . . . . . . . . . . 160 Voltage Test Chart . . . . . . . . . . . . . . . . . 128

G O
General Information . . . . . . . . . . . . . . . . . . . 14 Operational Circuit Elements . . . . . . . . . . . . 23
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
P
H Power Steering
Harness Wiring Circuit Guide . . . . . . . . . . .171 Power Steering Idle . . . . . . . . . . . . . . . . 141
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Power Steering In Use . . . . . . . . . . . . .146
Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . 138 Power System Checks . . . . . . . . . . . . . . . . . 51
Actuation Circuit . . . . . . . . . . . . . . . . . . 138 Programmable Setup Options
Capacitor Charging Circuit . . . . . . . . . . 139 General Information . . . . . . . . . . . . . . . . . 15
Flyback Circuit . . . . . . . . . . . . . . . . . . . . 147 Setup Option 1 . . . . . . . . . . . . . . . . . . . . 21
Lift Control . . . . . . . . . . . . . . . . . . . . . . . 148 Setup Options Other Than Option 1 . . . .22

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R
Rapid Tune-Up . . . . . . . . . . . . . . . . . . . . . . 165

S
Safety Information . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stored Fault Codes . . . . . . . . . . . . . . . . . . . . 47
Symbol Library . . . . . . . . . . . . . . . . . . . . . . . 11
Systems Operation and Test Equipment
Continuity Tests
Head Capacitor . . . . . . . . . . . . . . . . 130

T
Test Equipment . . . . . . . . . . . . . . . . . . . . . . 125
Testing and Adjusting . . . . . . . . . . . . . . . . . . 47
Thermal Protection Circuits . . . . . . . . . . . . . 44
Tilt/Auxiliary Control
Tilt/Auxiliary Circuit . . . . . . . . . . . . . . . . 156
MicroCommand II Control Panel . . . . . . . . .13
Transistors
Electrical Tests . . . . . . . . . . . . . . . . . . . . 160
Power Transistor Circuit . . . . . . . . . . . . . 34
Replacement . . . . . . . . . . . . . . . . . . . . . 161
Troubleshooting
Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 48
Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . 54
Preparation Tests . . . . . . . . . . . . . . . . . . . . . 49

V
Vehicle Monitoring System Display Unit
Circuit Test . . . . . . . . . . . . . . . . . . . . . . . 133
General Information . . . . . . . . . . . . . . . . . 24

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Cat Lift Truck Important Mitsubishi Caterpillar Forklift America Inc. (MCFA) can-
not anticipate every possible circumstance that might
Safety Information involve a potential hazard. The warnings in this publi-
cation and on the product are therefore not all-inclu-
Most accidents involving product operation, mainte- sive. If a tool, procedure, work method or operating
nance and repair are caused by failure to observe basic technique not specifically recommended by Mitsubishi
safety rules or precautions. An accident can often be Caterpillar Forklift America Inc. (MCFA) is used, you
avoided by recognizing potentially hazardous situations must satisfy yourself that it is safe for you and others.
before an accident occurs. A person must be alert to You should also ensure that the product will not be
potential hazards. This person should also have the damaged or made unsafe by the operation, lubrication,
necessary training, skills and tools to perform these maintenance or repair procedures you choose.
functions properly.
The information, specifications, and illustrations in this
Improper operation, lubrication, maintenance or repair publication are on the basis of information available at
of this product can be dangerous and could result in the time it was written. The specifications, torques,
injury or death. pressures, measurements, adjustments, illustrations,
Do not operate or perform any lubrication, mainte- and other items can change at any time. These
nance or repair on this product, until you have read changes can affect the service given to the product.
and understood the operation, lubrication, maintenance Obtain the complete and most current information
and repair information. before starting any job.
Safety precautions and warnings are provided in this Cat lift truck dealers have the most current information
manual and on the product. If these hazard warnings available.
are not heeded, bodily injury or death could occur to
you or other persons.
The hazards are identified by the “Safety Alert Symbol”
and followed by a “Signal Word” such as “WARNING”
as shown below.

! WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning, explain-
ing the hazard, can be either written or pictorially pre-
sented.
Operations that may cause product damage are identi-
fied by NOTICE labels on the product and in this publi-
cation.