I installed a used (and guaranteed) control unit I purchased on eBay. The handset connected right away. Had to reprogram the card to my units specs. Everything works now. Thanks for your help. The card was the problem.

I've had good luck with cards and panels from FS. I can't remember the accelerator setup on that model but usually you can repair them yourself with the proper speed pot and switches.

That's good to know. I checked with Flight Systems for an accelerator circuit. They said they don't have any exchange units in stock. They never did tell me how long it would take to rebuild mine. Any experience with them on rebuilds?

There is a z-plug kit for replacing wallowed out plugs. (The connection at the z-plug has been a problem since the first EV-100s) They sell for about $50 each but I just had one on back order for two months before giving up on it. Flight Systems sells them. But I don't think anyone has them in stock right now.
Part # YT582072108

Scott, Your first post was correct about the card. I purchased a used card (actually the complete control unit) and that fixed the issue with the handset. The handset comes on now with the replaced unit. Now I need to program the card. It is the same model number but I am certain the settings will not be correct for my forklift. I am having trouble finding the programming settings for my forklift erc040acn36. Does anyone know where I can access the settings for a specific model? Thanks, Brad

FYI: Found one on Amazon Hyster P/N 1308651 if anyone in the future needs one. Does anyone know where I can purchase a couple of the 14-pin connectors (Z and Y) so I can make a bench setup to do testing on?

Ok, well one other thing could be the cable. I've had those go bad. Maybe you could try it on another EV100. Then you'd know if it was your tool or the truck that's broken.

I don't think so. It just have "ON" and "OFF" with the key switch.

Does the forklift have a line contactor that you close by turning the ignition switch to the "start" position? Some Hysters have this system and they're pretty much the same truck these days.
If you do have a line contactor you can use the handset by hot-wiring the line contactor closed then plugging in the handset as normal. (starting with the key switch off)

The PY plug on my card just has a cover. Not sure where the gauge is wired in on my unit. It looks like a non-smart gauge. Only shows battery charge level and hour meter. Don't think it has any other functions.

Brad l looked at what you said the gauge should not work when the handset is plugged into the py port that is usually where the power comes out of the ev100.to the gauges.

I will check to see if the gauge works when the handset is plugged in. I know it works without the handset, just haven't looked with the handset plugged in. The gauge only has battery charge level and hours.

I'll ohm the wires from the connector to the dash to check for any breaks.

I will check the wires on the handset and see if I can power it up with 24v.

Brad does the bdi gauge work when the handset is not plugged in if so I would think the handset is bad but there is a way to test the handset and card on a bench you need a 24volt battery 2 car batterys in series will work you need to hook a wire to Pz plug number2 and to the battery negative terminal than you need to hook 1 wire to number 7 on Pz plug than to battery positive than hook handset to py plug hand set should power on.
I believe the py plug goes to the instrument panel l believe they only use 5wires you could ohm the wires from the connector to the dash see if there is any breaks if not it is possible that you have a bad card. l believe py1 is white to panel py2 isblack to panel py3 is green to panel py 4 bare to panel py5 red to panel l don't think that py6 and 7 are used some of the wirs are for pump to traction card. To check you have to take card out of truck. It would be better if you had a cheater pz plug to do it with. Hope l was of help

I removed the seat switch jumper. Battery has 39.8v and TB4 has 39.5v. Handset still will not power up.

Is there a way to check the pins on the PY test connection to see if it is providing power to the handset?

The seat switch is jumped. I know this because we jumped it for troubleshooting before I got the handset. I will go to the shop tomorrow and pull the seat jumper. Also will check the TB4 and get back with you. Only has the battery/hour meter. Thank you.