Cat Lift Trucks (& Caterpillar) 2EC25:
MOSTLY DEAD

We recently acquired a used forklift. When we received this unit, the battery's were dead, (this machine sat for several years). We started charging the battery, and when we plugged in the pack, we could hear the pump kick in when you moved the fork leavers, and the steering worked. When you steeped on the gas, You could hear the traction motor wanting to kick in, but the pumps spooled down, I was sure it was because the battery's were near enough charged. Now the battery is charged, when you turn on the key, the strobe comes on, back-up alarm comes on when you shift to reverse, but no pump when moving the fork levers, no steering, traction motor does not even click, and no display on dash. When you manually push in the Pump and steering contractor, the respective motor comes on.

Ser # A2EC220569

Any ideas appreciated, and any info about this unit appreciated (year, maintance issues etc)

Thanks:

Tim
  • Posted 6 May 2008 04:56
  • Discussion started by tpotter
  • Kansas, United States
Tim
Quality Service @ Competitive Prices
shawneegoodyear a t sbcglobal d o t net
Showing items 1 - 9 of 9 results.
looks like a bad dash, or the connections to it.
  • Posted 9 May 2008 08:30
  • Reply by edward_t
  • South Carolina, United States
Ok,

*No display at all, no lights come on on the icon strip.

*I replaced the Key switch and verified batt. volts when on

*I unplugged the 4 connectors to verify the pins didn't slip out, All plugs are plunged in.

* off seat/key off off seat/key on on seat/on key on seat/off key
TB1=29 1.01v 3.48v 3.48v.98v
TB4=10 4.12v 35.41v 35.4v 6.26v
TB2=15 189 mv 357mv 350mv 234mv
TB5=6 1.45v 1.29v 5.28v 1.34v
TB3=7/13 5.2v 5.4v 35.25v 6.2v
TB6=8.71v.48v 1.16v.392v

*As far as ohms:
between batt connector on forklift and frame
+ 7.35 mohms
- 6.94 mohms

between batt connector attached to battery and frame:
+ open
-1.35 mohms

*The controller has a "EV100" sticker on it.

Thank you for your input,

Tim
  • Posted 9 May 2008 00:53
  • Modified 9 May 2008 23:41 by poster
  • Reply by tpotter
  • Kansas, United States
Tim
Quality Service @ Competitive Prices
shawneegoodyear a t sbcglobal d o t net
Is this truck ev100 or microcomand? Big flat card 12x24 est microcomand ,smaller card ev100
  • Posted 8 May 2008 22:01
  • Reply by proshadetree
  • Tennessee, United States
when you say "no display on the dash" do you mean there is nothing on the dash at all? or just no display you recognize? including the icon strip? is the key switch still working?
On the "main logics board" (EV100 card), there is a terminal board consisting of 2 rows of 3 wire connections each row, held on with screws in between 2 small plugs and 2 larger plugs, are those plugs in all the way, and what voltages do you have on the 6 wires attached with the screws, first with the key switch off, then the key switch on, then someone on the seat with the key on, and off the seat with the key on. in particular, the one on your left in the row on the back, as far as voltage from the key on and off, and the top row all the way to your right (looking at the card from standing at the rear of the truck) as far as someone on the seat.
Also, on this truck what is the ohms (not volts) showing between frame and battery connectors, both sides, with battery disconnected, (must be less than 100K ohms, but that causes weird intermittent failures [A.K.A. "WIF"] not "no display", but a display failure can be one of the WIF caused by short to frame, and you should know that battery forklifts do not have "ground" like an auto, but do have 'negative return to battery' through wires and cables)
  • Posted 8 May 2008 11:30
  • Modified 8 May 2008 12:06 by poster
  • Reply by edward_t
  • South Carolina, United States
"it's not rocket surgery"
Thank you for the reply:
*Measured voltage between battery connectors and frame - less than 1 volt showing on DVOM
*Battery voltage on both sides of all 6 fuses
  • Posted 8 May 2008 08:02
  • Modified 8 May 2008 08:03 by poster
  • Reply by tpotter
  • Kansas, United States
Tim
Quality Service @ Competitive Prices
shawneegoodyear a t sbcglobal d o t net
Unplug battery chek between neg and frame then positive and frame.I noticed no display on dash sounds like a power dist. problem.Do you have voltage at fuses?
  • Posted 7 May 2008 09:37
  • Modified 7 May 2008 09:39 by poster
  • Reply by proshadetree
  • Tennessee, United States
*Checked fuses - 3 big fuses, and 3 small fuses is what I found, - all ok
*Batt. volts about 38v open circuit, drops to 34v when you manually engage the hyd pump
contactor.
*I am curious about the "Battery Bleed" concept - what is that and how do I check it?

Thank You for the responses so far...

Tim
  • Posted 6 May 2008 23:01
  • Reply by tpotter
  • Kansas, United States
Tim
Quality Service @ Competitive Prices
shawneegoodyear a t sbcglobal d o t net
Whats battery volts at ? do you have a bleed from battery to frame with battery unplugged? Might want to isolate battery to get bleed to 10v or less.
  • Posted 6 May 2008 20:22
  • Reply by proshadetree
  • Tennessee, United States
check and replace the fuses?
  • Posted 6 May 2008 08:12
  • Reply by edward_t
  • South Carolina, United States
"it's not rocket surgery"

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