SENB8464-02

Service Manual

M70D, M80D, M100D, M120D Lift Trucks

MicroCommand Control System

36/48 VOLT 72/80 VOLT

M70D 7FG00600 3CJ00600
A1EC4-60001 A1EC4-80001
M80D 7FG00600 3CJ00600
A1EC4-60001 A1EC4-80001
M100D 8AG00600 4AJ00600
A1EC5-60001 A1EC5-80001
M120D 8AG00600 4AJ00600
A1EC5-60001 A1EC5-80001
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the nec-
essary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.

Do not operate or perform any lubrication, maintenance or repair of this product until you have read and
understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING”
as shown below.

WARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially pre-
sented.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publica-
tion.

Mitsubishi Caterpillar Forklift cannot anticipate every possible circumstance that might involve a potential haz-
ard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure,
work method or operating technique not specifically recommended by Mitsubishi Caterpillar Forklift is used,
you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. Caterpillar dealers have the most current infor-
mation available. For a list of the most current publication form numbers available, see the Service Manual
Contents Microfiche, REG1139F.

MicroCommand Control System Index

SPECIFICATIONS
Component Measurements
Meter Meter Pos. Meter Neg.
Component Scale ( + ) Lead ( - ) Lead Desired Indication
DIODES (voltage indication)
All Diode Anode Cathode .3 to .9 V
All Diode Cathode Anode OL
RESISTORS (resistance indication)
R312, R322 (36/48V) 200 Ω 39 ohms + 5%
R312, R322 (72/80V) 200 Ω 82 ohms + 5%
R313, R323 (36/48V, 72/80V 200 Ω 7.5 ohms + 5%
Charging 2KΩ 1425 to 1575 ohms
CAPACITOR (resistance indication)
20 K Ω Positive side of Negative side of 0 then changes to
Head Capacitor capacitor (+) capacitor (-) above 10 K ohms
CONTACTOR COILS (resistance indication)
Directional 200 Ω X Y 28.8 to 43.2 ohms1
Line, pump, bypass, regen 200 Ω X Y 36.0 to 54.0 ohms1
1 Measured resistance with one terminal disconnected.

Current Measurements Transistor Connections

Measurement 36/48 V 72/80 V 1 2
Current Limit 600 A + 5% 500 A + 5%
Regen Limit 300 A + 5% 200 A + 5%
Bypass Dropout 1100 A + 5% 800 A + 5%

Transistor Measurements
927566
Multimeter ( + ) Test ( -) Test Results E199 3
Setting Lead Lead
(1) Emitter Connection.
Resistance Emitter Base 45 to 135 Ω
(2) Base Connection.
Diode Base Collector .3 to .9 V (3) Collector Connection.
Diode Collector Base OL
Diode Emitter Collector .3 to .9 V Logic Board Layout
Diode Collector Emitter OL

MicroCommand Control System 5 Specifications

Display Layout Console

E338 E202

(1) Tighten bolts that fasten the cover to a torque

of ...............................1.5 to 2.5 N·m (13 to 22 lb in)
Instrument Panel

Direction Switch

E200

(1) Tighten screws that fasten the instrument panel

to a torque of ................ 0.5 to 0.7 N·m (4 to 6 lb in) E200

(1) Put a bead of 9S3263 Thread Lock on the inner

radius of clamp before installation.

(2) Tighten bolts that hold clamp to steering col-

umn to a torque of .....4.5 to 5.5 N·m (40 to 50 lb in)

(3) Tighten bolts that hold clamp to switch to a

torque of ....................4.5 to 5.5 N·m (40 to 50 lb in)

MicroCommand Control System 6 Specifications

Thermal Switch Head Capacitor
Contacts open at ........... 81 to 89°C (178 to 192°F)

Contacts close at ........... 69 to 77°C (156 to 170°F)

Contactor Tip Clearance

(Gap)
Line, lift, bypass, regen .................... no adjustment

Direction (forward and reverse) ........ 2.62+ .08 mm E337

(.103+ .003 in) NOTE: Proper torque and assembly of capacitor

hardware is critical. Avoid disassembly unless
Fuses capacitor has to be replaced.

Key .................................................................... 10A (1) Tighten capacitor terminal bolt to a torque

Line of .............................. 4.5 to 5.5 N·m (40 to 50 lb in)

(72/80 V) ................................................. 675V (2) Spring washer 8T2229.

(36/48) .................................................... 750A (3) Ring terminal of wire assembly.

Horn (if equipped) ............................................... 3A (4) Lockwasher 8C3398.

Drive shunt field ................................................ 10A (5) Head capacitor terminal.

Pump shunt field ............................................... 10A

MicroCommand Control System 7 Specifications

Control Panel

E339

NOTE: Apply a small amount of 5P8937 or 5P9210 (4) Tighten diode 6 drive (D6D) to a torque
Thermal Joint Compound on the surface of the of ................................ 34 to 46 N·m (26 to 34 lb in)
transistor, diode, or thermal switch that contacts
the heatsink. (5) Tighten bolts that fasten power transistors to
the positive heatsink to a torque of...4 to 6 N·m
(1) Tighten screw and nut that hold bumper to a (35 to 55 lb in)
torque of .................. 4 to 6 N·m (35 to 55 lb in)
(6) Tighten head capacitor terminal bolts to a
(2) Tighten screws at power transistor base con- torque of ............ 4.5 to 5.5 N·m (40 to 50 lb in)
nections to a torque of .............. 1.3 to 1.7 N·m
(7) Tighten bolts that hold diode bracket to the
(11.5 to 15 lb in)
heatsink to a torque of .................... 4 to 6 N·m
(3) Two holes adjacent to each other used for ther- (35 to 55 lb in)
mal switch depending on threads.

MicroCommand Control System 8 Specifications

(8) Tighten bolt that holds bus bar to the heatsink
to a torque of ......... 4 to 6 N·m (35 to 55 lb in)

(9) Use four springs concave side down for each

bolt that holds the positive heatsink to the
control panel. Tighten the bolts to a torque
of ................................................. 11 to 15 N·m
(99 to 135 lb in)

(10) Use four springs concave side down for each

bolt that holds the negative heatsink to the
control panel. Tighten the bolts to a torque
of .......................5.5 to 9.5 N·m (49 to 84 lb in)

(11) Use a backup wrench when tightening cables

to contactors and nuts on contactor bus bars.

Tighten 1/4 inch fasteners to a torque

of ............................ 7 to 9 N·m (62 to 80 lb in)

Tighten 5/16 inch fasteners to a torque

of .................... 12 to 18 N·m (107 to 160 lb in)

(12) Tighten the bolts that fasten the wiring harness

negative wires to the negative heatsink to a
torque of ................. 4 to 6 N·m (35 to 55 lb in)

(13) Tighten the bolts that fasten the bus bars

to the power transistors to a torque
of ..................................................... 4 to 6 N·m
(35 to 55 lb in)

(14) Tighten diode 4 pump (D4P) to a torque

of ........................ 34 to 46 N·m (26 to 34 lb in)

(15) Tighten diode 4 drive (D4D) to a torque

of ........................ 34 to 46 N·m (26 to 34 lb in)

(16) Tighten the bolt that fastens the current sensor

ground to the negative heatsink to a torque
of ............................ 4 to 6 N·m (35 to 55 lb in)

(17) Tighten the bolt that fastens the bus bar to the
negative heat sink to a torque of ... 4 to 6 N·m
(35 to 55 lb in)

(18) Tighten diode 5 drive (D5D) to a torque

of ...................... 11 to 15 N·m (99 to 135 lb in)

(19) Control panel plate. Apply a small amount of

5P8937 or 5P9210 Thermal Joint Compound
on the control panel plate and mating surface
before assembling.

NOTE: The control panel is equipped with three

head capacitors. The text and schematic reference
these three as head capacitor.

MicroCommand Control System 9 Specifications