Thanks for all of the information gentlemen.
It's always good to continue to look for ways to learn more about the systems that we work on. There is always something that is not known or the proper procedures on diagnostics and repairs.
Apparently, the issue with this unit came down to being a defective EV-100 card. It was replaced as previously mentioned and settings set as described. The customer has had no complaints after.
Thanks for all your help and hope that I can be of some help in other areas.

setting it to what it actually reads (if it has 36.5 vdc after 15 minuites operation, set it to 36) will help a lot with getting the right voltage readings even if you don't set the internal resistance compensation (function 14).
95% charged to 60% (after 3 hours operation) charged sounds "close enough" to me, especially if the battery is not new.
Remember those numbers you asked about near "the main plug side "what does the o2-1b-vg on the main plug side"?
those are numbering that is particular to the type and make of truck, so that is the one set of numbers that should be the same between the different EV100 cards that will work in the truck.

Edward,
Thanks for the information sent.
I have some questions on the settings of 14 and 15.
Let's say the customer charges the battery overnight and after a full charge the battery reads 37.10 volts before operating the machine. Then after 15 minutes of operating the machine it reads 36.10 or 35.4 volts. I'm just throwing some random numbers....How do I know what number #15 should be set to? I read somewhere in the past that #14 requires some math to determine the true state of the battery in order to be set. How is that determined? Can you lead me in the right direction?
The customer states that it shows around 95% after a full charge and after about three hours of use, it reads about 60%.
A little history:
I replaced the card with an used one before because it would not read voltage at times and when it it did it would read no more than 50%. The voltage on the Bdi was jumping all over the place. Somtimes it would go into lift lock-out and sometimes it would show all zeros and the unit would not move. At this time, it seems like changing the card solved that issue.
Thanks,
Eli

numbers 14 and 15 have to do with setting the battery meter and voltage the card expects, your were set to what is most likely the "default" settings, function 15 allowing either a 36 or 48 volt battery to be installed and operate and not setting function 14 "internal resistance compensation". These should not effect the operation with a good battery, but I suggest that you set function 15 to the exact voltage at rest your battery shows after a good (overnight) charge and 15 min of operation.

Function 1 is the last stored fault code. 49 is the #5 Rec fail to turn on properly. Check the #5 Rec,Gate led ,#25 Rec(Snubber),Open Capacitor ,or for loose connections.

Thanks Truck Tech.

I will input these settings tomorrow. The numbers you gave me are very close to the numbers I recorded from the card with the exception of #14 and #15. I have 40 at #14 and 224 at #15.
I did not note down 16, 17, and 18.
What is the number 1 for? I notice that you don't have it listed. I have a number 49 shown.
Let me show what I have.
1=49
2=025
3=005
4=255
5=150
6=255
7=001
8=000
9=000
10=000
11=053
12=000
13=000
14=040
15=224

Thanks for taking the time for the info.

F2=Creep Speed 018-022
F3=C/A & 1A Time 004-006
F4= Current Limit 250-255
F5=Plugging Dist. 148-152
F6=1A Drop out 250-255
F6=1A Drop out w/7.250" Drive motor 106-110
F7= Turn Switch Speed Limit 001-003
F8= NOT USED
F9= NOT USED
F10=NOT USED
F11=Speed Limit 1 052-055
F12=Speed Limit 2 000-001
F13=Speed Limit 3 000-001
F14=I R Comp. 014-019
F15=Battery Voltage 032-044
F16=Pedal Pos. Plug 038-042
F17= Card Type 000-004
F18=Steer Pump T/D 175-177