DIAGNOSTIC

TROUBLESHOOTING
MANUAL
E2.2-3.5XN (E45-70XN) [A268];
E1.6-2.0XN (E30-40XN) [A269];
J2.2-3.5XN (J45-70XN) [A276];
J1.6-2.0XN (J30-40XN) [A935];
J4.0-5.0XN (J80-100XN) [A970];
A1.3XNT, A1.5XNT (A25XNT, A30XNT) [D203];
J1.5-2.0XNT (J30-40XNT) [K160];
E4.0-5.5XN, E5.0XNS (E80-120XV, E100XNS) [A099]

This manual contains information that is confidential and/or proprietary to Hyster

Company, its subsidiaries and/or vendors. Copying or distribution of any sections
of this manual marked "Confidential/Proprietary" is prohibited.

PART NO. 1688885 9000 SRM 1377

 SAFETY PRECAUTIONS
TROUBLESHOOTING PROCEDURES
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Diagnostic Troubleshooting Manual Table of Contents

TABLE OF CONTENTS

SECTION 9010 - OPERATIONAL DIAGNOSTIC PROCEDURES

Group 05 - Operational Checkout......................................................................................................9010-05-1
SECTION 9025 - TRACTION MOTOR
Group 10 - Principles of Operation.................................................................................................... 9025-10-1
Group 30 - Observed Symptoms....................................................................................................... 9025-30-1
SECTION 9030 - ELECTRICAL SYSTEM
Group 03 - General Maintenance and Diagnostic Data.....................................................................9030-03-1
Diagnostic Trouble Code (DTC) Chart........................................................................................... 9030-03-6
Group 10 - Principles of Operation.................................................................................................... 9030-10-1
Group 20 - Diagnostic Trouble Codes............................................................................................... 9030-20-1
Group 30 - Observed Symptoms....................................................................................................... 9030-30-1
Group 55 - Icons and Graphics..........................................................................................................9030-55-1
SECTION 9035 - DRIVE AXLE/UNIT
Group 10 - Principles of Operation.................................................................................................... 9035-10-1
Group 30 - Observed Symptoms....................................................................................................... 9035-30-1
SECTION 9050 - HYDRAULIC SYSTEMS
Group 10 - Principles of Operation.................................................................................................... 9050-10-1
Group 33 - Observed Symptoms-Gear Pump................................................................................... 9050-33-1
Group 43 - Tests and Adjustments-Gear Pump................................................................................ 9050-43-1
SECTION 9060 - OPERATORS STATION
Group 10 - Principles of Operation.................................................................................................... 9060-10-1
SECTION 9070 - FRONT END (MAST) AND CHASSIS
Group 10 - Principles of Operation.................................................................................................... 9070-10-1
Group 30 - Observed Symptoms....................................................................................................... 9070-30-1
SECTION 9080 - SUPPLEMENTARY DATA
Group 50 - Abbreviations and Acronyms...........................................................................................9080-50-1

This section is for the following models:

E2.2-3.5XN (E45-70XN) [A268];

E1.6-2.0XN (E30-40XN) [A269];
J2.2-3.5XN (J45-70XN) [A276];
J1.6-2.0XN (J30-40XN) [A935];
J4.0-5.0XN (J80-100XN) [A970];
A1.3XNT, A1.5XNT (A25XNT, A30XNT) [D203];
J1.5-2.0XNT (J30-40XNT) [K160];
E4.0-5.5XN, E5.0XNS (E80-120XV, E100XNS) [A099]

©2016 HYSTER COMPANY i

How To Use This Troubleshooting Manual Diagnostic Troubleshooting Manual

How To Use This Troubleshooting Manual

GENERAL INSTRUCTIONS AND SAFETY • 9060 – Operator's Station
INFORMATION • 9070 – Front End (Mast) and Chassis
• 9080 – Supplementary Data
WARNING
DO NOT add to or modify the lift truck. Any modi- Groups: The sections of the manual are further sub-
fication that affects the safe operation of the truck divided into groups, where applicable, that identify
cannot be undertaken without written authoriza- specific functions, operating criteria, or maintenance
tion of the Hyster company. tasks.
• 01 – Introduction to the Troubleshooting Man-
Any change to the lift truck, the tires, or its equip-
ual
ment can change the lifting capacity. The lift truck
must be rated as equipped and the nameplate • 03 – General Maintenance/Diagnostic Data
must show the new rating capacity. • 05 – Operational Checkout
• 10 – Principles of Operation
WARNING • 20 – Diagnostic Trouble Codes
The technician must be aware of, and follow, all • 30 – Observed Symptoms
general safety precautions that are published in
the Operating Manual and that are posted as • 33 – Observed Symptoms – Gear Pump
Safety Decals on and in the lift truck. • 43 – Test and Adjustments – Gear Pump
• 50 – Abbreviation and Acronyms
Before starting, the technician should be familiar with
certain policies, requirements, and instructions used • 55 – Icons and Graphics
in the troubleshooting procedures. Using the trouble- • 70 – Fault Mode Indicator Reference
shooting procedures correctly helps the technician to
perform the procedure safely and prevents damage to For Diagnostic Trouble Code listings, see Electrical
the machine and support equipment. System, General Maintenance and Diagnostic Data,
Diagnostic Trouble Codes, Page 9030-03-6.
HOW TO USE DIAGNOSTIC
TROUBLESHOOTING MANUAL NOTE: Not all groups will appear in all sections.

Manual Layout: Supplementary Data: The supplementary data sec-

tion of the manual includes information and data that
Sections: The manual is divided into eight sections, apply to many sections or groups and is stored here
each representing a major system, functional area, or for access by all users of the manual. This data in-
specific operation on the lift truck. cludes, but is not limited to:
• 9010 – Operational Diagnostic Procedures • Abbreviations and Acronyms
• 9025 – Traction Motor • Special Tools List
• 9030 – Electrical System • Fault Mode Indication Reference Table
• 9035 – Drive Axle/Unit • Supplier Specification Data
• 9050 – Hydraulic Systems

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ii Confidential/Proprietary - Do Not Copy or Duplicate
Diagnostic Troubleshooting Manual How To Use This Troubleshooting Manual

GENERAL INSTRUCTIONS As an example of this linking option:

Assume that during a procedure or test,
1. Become familiar with the content, layout, and it is necessary to refer to a different sec-
access provisions of data in this manual. This tion of manual, in this case, the Light
will improve your efficiency and decrease the Circuit Check in the Operational Check-
time required to resolve the problems. out part of this manual.
2. Use all sections of the manual for relevant in- The instruction would read, "refer to, or
formation on the subject system. see" followed by text identifying what the
3. Once you begin a troubleshooting procedure, reference is (for hard-copy, paper man-
do not skip steps. ual use). When the cursor is placed over
4. If you reach the end of a procedure without re- the text, it will then indicate that it is ac-
solving the problem and you are not directed to tive, and left-clicking will direct the sys-
another procedure contact Resident Service tem to take you directly to that refer-
Engineering through the Contact Management ence.
System. Try it using the process below:
5. Do not limit yourself, remember to apply your See Operational Diagnostic Procedures,
own experience and knowledge to assist in re- Operational Checkout, Page 9010-05-
solving the problems, but do not compromise 5.
safety in doing so. When you have reviewed the reference
6. Most of the cross-reference data in the manual document or manual, and need to return
will be electronically linked for rapid and easy to the troubleshooting procedure, the
access. Use the links wherever the cursor "BACK" button will permit you to do this.
highlights an item as a linkable option.

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Confidential/Proprietary - Do Not Copy or Duplicate iii
 Diagnostic Troubleshooting Manual

SERVICE MANUAL LOOKUP Capacities and Specifications 8000SRM1527

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)
The following service manuals are referenced
throughout this manual. Be sure to have the correct Capacities and Specifications 8000SRM1542
service manual for your lift truck model.
• J4.0-5.0XN (A970)
AC Motor Repair 0620SRM1385
Capacities and Specifications 8000SRM1578
• E2.2-3.5XN (E45-70XN) (A268)
• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
• E1.6-2.0XN (E30-40XN) (A269) (A099)
• J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN (A970) Cylinder Repair (Mast S/N A270-72, A551, A555,
A559, A626, A627, A751-52, B551, B555, B586-91,
• J1.5-2.0XNT (J30-40XNT) (K160) B749-54, C661-63, C665, D507-09, D515, D562-64,
• J1.6-2.0XN (J30-40XN) (A935) E509, E564) 2100SRM1382
• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS) • E2.2-3.5XN (E45-70XN) (A268)
(A099) • J2.2-3.5XN (J45-70XN) (A276)

AC Motor Repair 0620SRM1515 • J1.5-2.0XNT (J30-40XNT) (K160)

• A1.3-1.5XNT (A25XNT, A30XNT) (D203) • J1.6-2.0XN (J30-40XN) (A935)

• J4.0-5.0XN (A970)
Brake System 1800SRM1332 • E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
• J1.5-2.0XNT (J30-40XNT) (K160) (A099)
• J1.6-2.0XN (J30-40XN) (A935)
Cylinder Repair (Mast S/N B551, B555, B559)
Brake System 1800SRM1359 2100SRM1440

• E2.2-3.5XN (E45-70XN) (A268) • E1.6-2.0XN (E30-40XN) (A269)

Brake System 1800SRM1438 Cylinder Repair (Mast S/N A270, A271, A272,
C661, C662, C663) 2100SRM1521
• E1.6-2.0XN (E30-40XN) (A269)
• A1.3-1.5XNT (A25XNT, A30XNT) (D203)
Brake System 1800SRM1518
Diagrams 8000SRM1341
• A1.3-1.5XNT (A25XNT, A30XNT) (D203)
• J1.5-2.0XNT (J30-40XNT) (K160)
Capacities and Specifications 8000SRM1340 • J1.6-2.0XN (J30-40XN) (A935)
• J1.5-2.0XNT (J30-40XNT) (K160)
Diagrams 8000SRM1384
Capacities and Specifications 8000SRM1374 • E2.2-3.5XN (E45-70XN) (A268)
• E2.2-3.5XN (E45-70XN) (A268) • E1.6-2.0XN (E30-40XN) (A269)
• J2.2-3.5XN (J45-70XN) (A276)
Capacities And Specifications 8000SRM1375
• J4.0-5.0XN (A970)
• J2.2-3.5XN (J45-70XN) (A276)
• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
Capacities and Specifications 8000SRM1376 (A099)

• J1.6-2.0XN (J30-40XN) (A935) Diagrams 8000SRM1528

Capacities and Specifications 8000SRM1443 • A1.3-1.5XNT (A25XNT, A30XNT) (D203)

• E1.6-2.0XN (E30-40XN) (A269)

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Diagnostic Troubleshooting Manual

Drive Axle Repair 1300SRM1575 • J2.2-3.5XN (J45-70XN) (A276)

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS) • J4.0-5.0XN (A970)
(A099) • E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
(A099)
Drive Axle, Speed Reducer, and Differential
1300SRM1366 Hydraulic System 1900SRM1519
• E2.2-3.5XN (E45-70XN) (A268) • A1.3-1.5XNT (A25XNT, A30XNT) (D203)
• E1.6-2.0XN (E30-40XN) (A269)
ALL LIFT TRUCK MODELS
Electrical System 2200SRM1337
• J1.5-2.0XNT (J30-40XNT) (K160) Industrial Battery 2240SRM0001

• J1.6-2.0XN (J30-40XN) (A935) ALL LIFT TRUCK MODELS

Electrical System 2200SRM1369 Load Axle 1300SRM1516

• E2.2-3.5XN (E45-70XN) (A268) • A1.3-1.5XNT (A25XNT, A30XNT) (D203)

• E1.6-2.0XN (E30-40XN) (A269) Main Control Valves 2000SRM1334

• J2.2-3.5XN (J45-70XN) (A276) • E2.2-3.5XN (E45-70XN) (A268)
• J4.0-5.0XN (A970) • J2.2-3.5XN (J45-70XN) (A276)
• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS) • J4.0-5.0XN (A970)
(A099)
• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
Electrical System 2200SRM1524 (A099)

• A1.3-1.5XNT (A25XNT, A30XNT) (D203) • J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)
Frame 0100SRM1329
• J1.5-2.0XNT (J30-40XNT) (K160) Main Control Valves 2000SRM1439

• J1.6-2.0XN (J30-40XN) (A935) • E1.6-2.0XN (E30-40XN) (A269)

Frame 0100SRM1342 Main Control Valves 2000SRM1520

• E2.2-3.5XN (E45-70XN) (A268) • A1.3-1.5XNT (A25XNT, A30XNT) (D203)

• E1.6-2.0XN (E30-40XN) (A269) Mast Repair (S/N A551, A555, A559, B551, B555,
• J2.2-3.5XN (J45-70XN) (A276) D507, D562, D508, D563, D509, D564, D515, E509,
• J4.0-5.0XN (A970) E564) 4000SRM1338

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS) • E2.2-3.5XN (E45-70XN) (A268)

(A099) • J2.2-3.5XN (J45-70XN) (A276)

Frame 0100SRM1514 Mast Repair (S/N A270, A271, A272) 4000SRM1386

• A1.3-1.5XNT (A25XNT, A30XNT) (D203) • J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
Hydraulic System 1900SRM1333
• J1.5-2.0XNT (J30-40XNT) (K160) Mast Repair (S/N C661, C662, C663, C665)
• J1.6-2.0XN (J30-40XN) (A935) 4000SRM1405
• J1.5-2.0XNT (J30-40XNT) (K160)
Hydraulic System 1900SRM1367 • J1.6-2.0XN (J30-40XN) (A935)
• E2.2-3.5XN (E45-70XN) (A268)
• E1.6-2.0XN (E30-40XN) (A269)

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 Diagnostic Troubleshooting Manual

Mast Repair (S/N B551, B555, and B559) Periodic Maintenance 8000SRM1577
4000SRM1441 • E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
• E1.6-2.0XN (E30-40XN) (A269) (A099)

Mast Repair (S/N A270, A271, A272, C661, C662, Steering Axle 1600SRM1360
and C663) 4000SRM1525 • E2.2-3.5XN (E45-70XN) (A268)
• A1.3-1.5XNT (A25XNT, A30XNT) (D203) • E1.6-2.0XN (E30-40XN) (A269)

Mast Repair (S/N A626-27, A751-52, B590-91, and • J2.2-3.5XN (J45-70XN) (A276)
B749-54) 4000SRM1540 • J1.6-2.0XN (J30-40XN) (A935)
• J4.0-5.0XN (A970) • J4.0-5.0XN (A970)
• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
Mast Repairs (S/N A551, A555, A559, A751, A752, (A099)
B586, B587, B588, B590, B591, B749, B750, B751,
B752, and B754) 4000SRM1576 Steering System 1600SRM1331
• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS) • J1.5-2.0XNT (J30-40XNT) (K160)
(A099)
Steering System 1600SRM1363
Operator's Cab 0100SRM1446
• E2.2-3.5XN (E45-70XN) (A268)
• E2.2-3.5XN (E45-70XN) (A268)
• E1.6-2.0XN (E30-40XN) (A269)
• J2.2-3.5XN (J45-70XN) (A276)
• J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN (A970)
• J1.6-2.0XN (J30-40XN) (A935)
• J1.5-2.0XNT (J30-40XNT) (K160)
• J4.0-5.0XN (A970)
• J1.6-2.0XN (J30-40XN) (A935)
• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
• A1.3-1.5XNT (A25XNT, A30XNT) (D203) (A099)

Periodic Maintenance 8000SRM1339 Steering System 1600SRM1517

• J1.5-2.0XNT (J30-40XNT) (K160) • A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Periodic Maintenance 8000SRM1364 Transaxle 1300SRM1330

• E2.2-3.5XN (E45-70XN) (A268) • J1.5-2.0XNT (J30-40XNT) (K160)

Periodic Maintenance 8000SRM1372 • J1.6-2.0XN (J30-40XN) (A935)

• J2.2-3.5XN (J45-70XN) (A276) Transaxle 1300SRM1370

Periodic Maintenance 8000SRM1373 • J2.2-3.5XN (J45-70XN) (A276)

• J1.6-2.0XN (J30-40XN) (A935) Transaxle 1300SRM1539

Periodic Maintenance 8000SRM1442 • J4.0-5.0XN (A970)

• E1.6-2.0XN (E30-40XN) (A269) User Interface Service Technician 2200SRM1336

Periodic Maintenance 8000SRM1541 ALL LIFT TRUCK MODELS

• J4.0-5.0XN (A970) User Interface Supervisor 2200SRM1335

Periodic Maintenance 8000SRM1526 ALL LIFT TRUCK MODELS

• A1.3-1.5XNT (A25XNT, A30XNT) (D203) Wire Harness Repair 2200SRM1128

ALL LIFT TRUCK MODELS

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Diagnostic Troubleshooting Manual

CONVENTIONAL BATTERY BOX (CBB)

UNITS
The Operator's seat is higher due to the position of the battery box which sits above the axles for these units. See
Figure 9000-01-1.

Figure 9000-01-1. Conventional Battery Box

Hyster Unit Code European Model Designation America Model Designation

A269 E1.6-2.0XN E30-40XN
A268 E2.2-3.5XN E45-70XN
A099 E4.0-5.5XN, E4.5XNS E80-120XN, E100XNS

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 Diagnostic Troubleshooting Manual

DROP BATTERY BOX (DBB) UNITS

The battery is “dropped” between the front and rear axles (or wheels) for these units. See Figure 9000-01-2.

Figure 9000-01-2. Drop Battery Box

Hyster Unit Code European Model Designation America Model Designation

D203 A1.3XNT, A1.5XNT A25XNT, A30XNT
K160 J1.5-2.0XNT J30-40XNT
A935 J1.6-2.0XN J30-40XN
A276 J2.2-3.5XN J45-70XN
A970 J4.0-5.0XN J80-100XN

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 SECTION 9010

OPERATIONAL DIAGNOSTIC PROCEDURES

TABLE OF CONTENTS

Group 05 - Operational Checkout

Operational Checkout Procedures.......................................................................................................... 9010-05-1
Key Icon Illuminated........................................................................................................................... 9010-05-2
Wrench Icon Illuminated..................................................................................................................... 9010-05-2
Display Panel (DP) Check.................................................................................................................. 9010-05-2
Operator Presence System Check..................................................................................................... 9010-05-3
Display Backlight and Icon Power Check........................................................................................... 9010-05-4
Light Circuit Check..............................................................................................................................9010-05-5
Horn Circuit Check..............................................................................................................................9010-05-5
Backup Alarm Check (If equipped)..................................................................................................... 9010-05-5
Heater Check (If equipped).................................................................................................................9010-05-5
Brake Pedal Check............................................................................................................................. 9010-05-6
Park Brake Sensor Check.................................................................................................................. 9010-05-6
Park Brake Check...............................................................................................................................9010-05-7
Brake and Axle Drag Check............................................................................................................... 9010-05-8
Priority Flow Divider Valve Check.......................................................................................................9010-05-8
Mast Cushion Check - Free Lift Cylinder............................................................................................ 9010-05-9
Lift Drift Check.................................................................................................................................... 9010-05-9
Lift/Tilt Mast Adjustment Check........................................................................................................ 9010-05-10
Tilt Function Drift Check................................................................................................................... 9010-05-10
Tilt Racking Check............................................................................................................................9010-05-11
Tilt Function, Tilt Lock Piston............................................................................................................9010-05-11
Mast Cushion Check - Main Lift Cylinder..........................................................................................9010-05-11
Mast Channel Check........................................................................................................................ 9010-05-12
Mast Mounting Check....................................................................................................................... 9010-05-12
Chain and Header Hose Adjustment Check..................................................................................... 9010-05-12
Chain Sheave Check........................................................................................................................ 9010-05-13
Carriage Adjustment Check..............................................................................................................9010-05-13
Carriage Adjustment Check (Standard and Integral Side Shift)....................................................... 9010-05-13
Steering Relief Valve Low Pressure Check...................................................................................... 9010-05-13

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Confidential/Proprietary - Do Not Copy or Duplicate 9010-1
9010-2
Operational Diagnostic Procedures Operational Checkout

Group 05

Operational Checkout

Operational Checkout Procedures

These procedures are designed so technicians can • DO NOT use blocks to support the mast
make a quick check of the operation of the machine weldments nor to restrain their movement.
while sitting in operator’s seat. • Mast repairs require disassembly and re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
WARNING cedures in the correct Service Manual for
Be sure to read the warnings prior to performing the mast.
the checkout procedures.
Adequate space is required to do the driving checks.
WARNING Some checks require the lift truck and other major
components to be at operating temperature.
Before operating the lift truck, FASTEN YOUR
SEAT BELT.

There are a number of operations, if not per-

formed carefully, that can cause the lift truck to
tip. If you have not read the WARNING page in
front of the Operating Manual, do so NOW. As you
study the following information about how to
properly operate a lift truck, remember the Warn-
ings.

WARNING
Mast parts are heavy and can move. Distances be-
tween parts are small. Serious injury or death can
result if part of the body is hit by parts of the mast Before performing the operational checkout, complete
or the carriage. the INSPECTION BEFORE OPERATION in the Op-
• Never put any part of the body into or under erating Manual.
the mast or carriage unless all parts are
completely lowered or a safety chain is in-
stalled. Also make sure the power is OFF
and the key is removed. Fasten a DO NOT
OPERATE tag in the operator’s compart-
ment.
• Be careful of the forks. When the mast is
raised, the forks can be at a height that may
cause an injury.
• DO NOT climb on the mast or lift truck at
any time. Use a ladder or personnel lift to
work on the mast.

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Operational Checkout Operational Diagnostic Procedures

Before starting operational checkout, talk to the oper- • If the answer indicates that the check is not
ator and check Diagnostic Trouble Codes (DTC) us- OK, you will be given a required SRM repair or
ing the Display Panel (DP). See Troubleshooting be linked to the test to perform.
Guidelines and Procedures. All DTCs must be correc-
ted or cleared before starting this checkout. When a problem is found, stop operational checkout
and correct it before going to the next check. Repeat
No special tools or gauges are needed. Always start check after repair to confirm repair was successful be-
sequence from left to right. Before doing check, read fore proceeding with the remaining checks.
each check completely.

At the end of each check, a question is asked:

• If the answer indicates the check is OK, you
will be instructed to go to next check.

CHECK PROCEDURE ACTION

Key Icon Illumina- Turn Keyless Start Switch or Key Switch to ON posi- YES: Shut key OFF. Wait 30
ted tion with park brake applied. seconds for power cycling
then turn key ON. Key icon
Does the Key Icon appear on the Display and should not stay lit.
remain illuminated? NO: Display power is OK. Go
to next step.

Wrench Icon Illumi- Turn Keyless Start Switch or Key Switch to ON posi- YES: Reinstall newest ver-
nated tion with park brake applied. sion of software. See User
Interface Supervisor
Does the Wrench Icon appear on the Display 2200SRM1335 or User Inter-
and remain illuminated? face Service Technician
2200SRM1336.
NO: Display power is OK. Go
to next step.

Display Panel (DP) 1. Turn key or keyless switch to ON position. YES: Refer to Electrical Sys-
Check 2. Check display for any DTCs. See Electrical tem, General Maintenance
System, General Maintenance and Diagnostic and Diagnostic Data, Diag-
Data, Diagnostic Trouble Codes, Page nostic Trouble Codes, Page
9030-03-6. 9030-03-6.
NO: DTCs are OK. Go to
Are any DTCs displayed? next check.

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Operational Diagnostic Procedures Operational Checkout

Operator Presence NOTE: This procedure requires Service Password. YES: Continue with this pro-
System Check cedure.
Operator presence sensor requires a minimum of NO: Go to DTC 12816, Seat
45.4 kg (100 lb) to actuate. Sensor Out of Range Low
(OORL) or DTC 12819 and
1. While operator is in seat, power truck ON. troubleshoot per procedure.
2. See Display Panel Flowchart. At the Display
Panel, Enter Main Display, enter password,
scroll to Diagnostics, Enter.
3. Scroll to Seat Symbol Enter. Read display.

Does display show 1.4 volts or greater?

Continue: YES: Operator presence sen-

sor is OK. Go to next check.
While operator is out of seat, power truck ON. NO: Operator presence sen-
sor has failed. Replace seat
Does display show less than 0.8 volts? sensor. See Electrical Sys-
tem 2200SRM1337.
NOTE: BEFORE PROCEEDING TO NEXT CHECK,
RETURN TO SEAT AND FASTEN SEAT BELT.

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Operational Checkout Operational Diagnostic Procedures

Display Backlight YES: Display power is OK.

and Icon Power Go to next step.
Check NO: See No Display/No
Truck Operation.

1. INDICATOR LIGHT, PERFORMANCE MODE

2. WARNING LIGHT, LOW BRAKE FLUID
3. WARNING LIGHT, FASTEN SEAT BELT
4. INDICATOR LIGHT, BATTERY DISPLAY IN-
DICATOR (BDI)
5. INDICATOR LIGHT, DIRECTION INDICA-
TORS
6. INDICATOR LIGHT, LOAD WEIGHT
7. INDICATOR LIGHT, SYSTEM TIME
8. WARNING LIGHT, SERVICE DUE LIGHT
9. WARNING LIGHT, MOTOR TEMPERATURE
HIGH WARNING
10. INDICATOR LIGHT, HAZARD FLASHERS
11. INDICATOR LIGHT, STEER ANGLE
12. INDICATOR LIGHT, FRONT WORK LIGHTS
13. INDICATOR LIGHT, REAR WORK LIGHTS

Turn Keyless Start Switch or Key Switch to ON posi-

tion with park brake applied.

Do the Display Backlight and icons appear on

the LCD screen?
NOTE: Fasten seat belt, icon will turn off after 10
seconds.

Continue:

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Operational Diagnostic Procedures Operational Checkout

Light Circuit Check 1. Turn front and rear work light switches ON. YES: Go to next check.
NO: Refer to Observed
Do lights turn on? Symptom, Lights Inoperative.

Horn Circuit Check NOTE: There can be up to three horn buttons on the YES: Horn is OK. Go to next
lift truck: check.
1. Steering Wheel NO: Refer to Observed
Symptoms, Observed Symp-
2. Right Rear Grab Handle toms, Horn Failure, Page
3. MLM Armrest 9030-30-32.

Press horn button.

Does horn sound?

Backup Alarm 1. With lift truck running, apply service brake. YES: Back up alarm is OK.
Check (If equipped) 2. Release park brake. Go to next check.
NO: Check wiring connec-
3. Select reverse direction. tions.

Does backup alarm sound?

Heater Check (If 1. Turn key switch to ON position. YES: Correct error codes.
equipped) 2. Check display for any error codes. See Electrical System
2200SRM1337 or Electrical
Are any error codes displayed? System 2200SRM1369 .
NO: Heater is okay. Go to
next check.

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Operational Checkout Operational Diagnostic Procedures

Brake Pedal Check YES: Brake adjustment is

OK. Go to next check.
NO: Adjust brakes. see
Brake System
1800SRM1332.

A. TOP OF FLOOR MAT

1. With lift truck running, release park brake.

2. Depress and hold brake pedal with approxi-
mately 45.4 kg (100 lb) force.
3. Measure pedal distance from floor mat as
shown in the illustration.

Does brake pedal remain at least

15 mm (0.6 in.) off floor mat?

Park Brake Sensor 1. With lift truck running, release park brake. YES: Park brake sensor is
Check 2. Slowly apply park brake and note when park OK. Go to next check.
brake display comes ON. NO: Adjust park brake, see
Brake System
Does display come on before park brake rea- 1800SRM1332.
ches first click of engagement?

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Operational Diagnostic Procedures Operational Checkout

Park Brake Check YES: Park brake is OK. Go to

next check.
NO: Adjust park brake, see
Brake System
1800SRM1332.

WARNING
Ensure load is secured so it will not move when
mast is tilted fully forward.

1. Stop lift truck in an uphill direction with rated

load on 15% grade or less, and apply park
brake.
2. Shut lift truck OFF and note if machine remains
static.
3. Start lift truck and remove rated load.
4. Position lift truck with No Load in a downhill di-
rection, on 15% grade or less, and apply park
brake.
5. Shut lift truck OFF and note if machine remains
static.

Does machine remain static on grade in both

directions?

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Operational Checkout Operational Diagnostic Procedures

Brake and Axle NOTE: Move truck to level surface before performing YES: Repair brakes. See
Drag Check the following steps. Brake System
1800SRM1359.
1. Raise lift truck until drive tires are off ground. NO: Brakes are OK. Con-
Support lift truck using suitable shop standard. tinue with this procedure.
(See "How to Raise Drive Tire" procedure in
Operating Manual.)
2. Shut lift truck OFF and release park brake.
Handle provided under floor plate to manually
release the park brake.
3. Check brakes for dragging.

Are the brakes dragging?

Continue: YES: Axle is OK. Adjust park

brake back to correct setting.
Manually turn one tire by hand. Go to next check.
NO: If opposite wheel does
Does the tire turn with moderate force and not turn, differential is dam-
does the other tire turn in the opposite direc- aged. If equipped, remove
tion? differential cover and inspect.
See Transaxle
1300SRM1330.

Priority Flow Di- 1. Turn steering wheel to right axle stop and then YES: Continue with this pro-
vider Valve Check back to left axle stop in one continuous cycle cedure.
while raising lift carriage. NO: If no steering, flow di-
vider spool is stuck. Remove,
Does carriage lift speed decrease while steer- clean, and inspect spool. De-
ing? pending on your lift truck see,
Main Control Valves
2000SRM1334 or Main Con-
trol Valves 2000SRM1439.

Continued: YES: Flow divider is OK. Go

to next check.
2. Release steering wheel. NO: Inspect and clean relief
valves. Depending on your lift
Does carriage lift speed increase when not truck see, Main Control
steering? Valves 2000SRM1334 or
Main Control Valves
2000SRM1439.

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Operational Diagnostic Procedures Operational Checkout

Mast Cushion NOTE: This check applies to free lift cylinders. YES: Free lift is OK. Go to
Check - Free Lift next check.
Cylinder 1. Raise forks at maximum lift speed with no load. NO: Remove oil fill port
2. When free cylinder reaches top of stroke, ob- screw at top of free lift cylin-
serve transition to main lift cylinder phase and der; add 100 cc (3.40 oz) of
speed of free lift rod during transition. hydraulic oil. Depending on
your lift truck see, Cylinder
Repair (Mast S/N A270-72,
Does free lift rod speed slow and does hissing A551, A555, A559, A626,
sound come from top of cylinder, with no au- A627, A751-52, B551, B555,
dible impact at top of stroke? B586-91, B749-54, C661-63,
C665, D507-09, D515,
D562-64, E509, E564)
2100SRM1382 or Cylinder
Repair (Mast S/N B551,
B555, B559) 2100SRM1440.

Lift Drift Check Ensure the following before starting procedure: YES: Go to Lift Cylinder
• Truck operating on flat surface. Leakage Test to isolate if
problem is in cylinder or con-
• Hydraulic oil at operating temperature. trol valve.
NO: Main cylinder drift is OK.
WARNING Continue with this procedure.
Ensure load is secured so it will not
move when mast is tilted fully for-
ward.
• Secured capacity load on forks.
1. Install angle meter on mast and position mast
at approximately 90° angle to ground.
2. Raise mast until approximately 75 mm (3 in.) of
main lift cylinder rods are exposed on mast.
Record this measurement.
3. Shut lift truck OFF.
4. After 5 minutes, measure mast main lift cylin-
der drop.

Does main lift cylinder rod retract more than

50 mm (2 in.)?

Continue: YES: Go to Lift Cylinder

Leakage Test to isolate if
5. Raise free lift cylinder approximately problem is in cylinder or con-
75 mm (3 in.) and mark cylinder rod to record trol valve.
movement. NO: Free lift drift is OK. Go to
6. After 5 minutes, measure free lift cylinder drop. next check.

Does free lift drop more than 50 mm (2 in.)?

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Operational Checkout Operational Diagnostic Procedures

Lift/Tilt Mast Adjust- Ensure the following before starting procedure: YES: Shim lift cylinders. See
ment Check • Truck operating on flat surface. Mast Repair (S/N A270,
A271, A272) 4000SRM1386.
• Adequate overhead clearance to raise forks to NO: Mast cylinder is adjusted
maximum height. OK. Continue with this proce-
• No load on forks. dure.

1. Raise forks to maximum height.

Does the top sections of mast kick to one side

at maximum height?

Continue: YES: Shim and adjust mast.

See Mast Repair (S/N A270,
2. Slowly tilt the mast full forward and then full A271, A272) 4000SRM1386.
backward at maximum height and observe NO: Mast shimming is OK.
movement of mast. Go to next check.

Does the top sections of mast make noise

during tilting and show excessive movement
of mast sections?

Tilt Function Drift Ensure the following before starting procedure: YES: Go to Tilt Cylinder
Check • Truck operating on flat surface. Leakage Test to confirm if
cylinder or control valve is
• Hydraulic oil at operating temperature. leaking.
NO: Tilt drift is OK. Go to
WARNING next check.
Ensure load is secured so it will not
move when mast is tilted fully for-
ward.
• Secured capacity load on forks.
1. Raise mast approximately 300 mm (12 in.) off
floor.
2. Install angle meter on mast and position mast
at approximately 90° angle to ground.
3. Ensure lift truck is OFF.
4. After 5 minutes, measure mast angle and com-
pare to original reading.

Does mast tilt drift more than 2 degrees in 5

minutes?

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Operational Diagnostic Procedures Operational Checkout

Tilt Racking Check Actuate mast back tilt function until hydraulic valve YES: Tilt stops are adjusted
goes over relief. OK. Go to next check.
NO: Adjust tilt stops. See
Do both sides of mast stop evenly? Mast Repair (S/N A270,
A271, A272) 4000SRM1386.

Tilt Function, Tilt YES: Tilt lock is OK. Go to

Lock Piston WARNING next check.
Ensure load is secured so it will not move when NO: Repair tilt lock piston
mast is tilted fully forward. valve in tilt spool. Depending
on your lift truck see, Main
1. Put secured capacity load on forks and raise Control Valves
forks approximately 1 m (3 ft). 2000SRM1334 or Main Con-
2. Tilt load back to tilt stop. trol Valves 2000SRM1439.

3. Move tilt lever to tilt forks forward full stroke

and observe speed.

Can tilt speed be controlled?

Mast Cushion Ensure the following before starting procedure: YES: Piston ring is OK. Go to
Check - Main Lift • Truck operating on flat surface. next check.
Cylinder NO: Inspect and clean piston
• Adequate overhead clearance to raise forks to ring. Depending on your lift
maximum height. truck see, Cylinder Repair
(Mast S/N A270-72, A551,
WARNING A555, A559, A626, A627,
A751-52, B551, B555,
Ensure load is secured so it will not
B586-91, B749-54, C661-63,
move when mast is tilted fully for-
C665, D507-09, D515,
ward.
D562-64, E509, E564)
• Secured capacity load on forks. 2100SRM1382 or Cylinder
1. Raise forks to maximum height of main lift cyl- Repair (Mast S/N B551,
inders. B555, B559) 2100SRM1440.
2. Lower forks as fast as possible and observe
cylinder rod as main lift cylinders reach bottom
of stroke.

Does fork speed slow and does a hissing

sound come from cylinder at bottom of
stroke?

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Operational Checkout Operational Diagnostic Procedures

Mast Channel NOTE: This is a visual check of the mast to deter- YES: Repair mast channels.
Check mine if parts are worn or out of adjustment. See Mast Repair (S/N A270,
A271, A272) 4000SRM1386.
1. Raise mast to full height without load and shut NO: Mast wear is OK. Con-
lift truck OFF. tinue with this procedure.
2. Inspect outer and inner channels for wear pat-
tern and gouging.
3. Move forks to lowered position.
4. Inspect the inner channel wear pattern for wear
or gouging.

Do channels show signs of excess wear?

Continue: YES: Channel spacing is OK.

Go to next check.
5. Inspect spacing between channels. NO: Adjust or repair mast.
See Mast Repair (S/N A270,
Is the channel spacing even on each side? A271, A272) 4000SRM1386.

Mast Mounting 1. Move mast to lowered position and shut lift YES: Inspect and repair mast
Check ruck OFF. mounting. See Mast Repair
2. Inspect the mounting hardware at axle. (S/N A270, A271, A272)
4000SRM1386.
3. Push the top of mast by hand while off the lift NO: Mast mounting is OK.
truck and note any movement of lift truck. Go to next check.
NOTE: If the mast mounting is loose, mast will move
without moving truck frame.

Is the mast mounting loose?

Chain and Header Ensure the following before starting procedure: YES: Adjust lift chains. See
Hose Adjustment • Truck operating on flat surface. Mast Repair (S/N A270,
Check A271, A272) 4000SRM1386.
• Hydraulic oil at operating temperature. NO: Chains are adjusted OK.
• No load on forks. Continue with this procedure.
1. Install angle meter on mast and position mast
at approximately 90° angle to ground.
2. Raise and lower forks through two complete lift
cycles.
3. Lower forks to lowest position.

NOTE: The carriage safety stop does not make con-

tact at full extension, but that a minimum gap of
6 mm (0.25 in.) remains.

NOTE: The correct fork height adjustment is approxi-

mately 6 mm (0.25 in.) off floor.

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Operational Diagnostic Procedures Operational Checkout

Does the heel of forks touch the floor?

Continue: YES: Adjust header hoses.

See Mast Repair (S/N A270,
4. Look at condition of hoses as they go over A271, A272) 4000SRM1386.
sheaves. NO: Hose tension is OK.
Continue with this procedure.
Are the hoses compressed?

Continue: YES: Adjust header hoses.

NO: Hose adjustment is OK.
5. Inspect contact of hoses with any crossmem- Go to next check.
ber or load backrest near sheave area.

Are the hoses contacting any crossmember or

the load backrest?

Chain Sheave 1. Lower forks. Shut lift truck OFF. YES: Chain sheaves are OK.
Check 2. Inspect wear pattern on chain sheaves. Go to next check.
NO: Replace chain sheaves.
Does sheave show a wear pattern without side See Mast Repair (S/N A270,
wear? A271, A272) 4000SRM1386.

Carriage Adjust- 1. Lower forks to approximately 50 mm (2 in.) off YES: Adjust or repair car-
ment Check ground. Shut lift truck OFF. riage bearings. See Mast
2. Rock the carriage frame side to side. Repair (S/N A270, A271,
A272) 4000SRM1386.
Does carriage move more than NO: Carriage adjustment is
0.5 mm (0.020 in.) at tightest point? OK. Go to next check.

Carriage Adjust- 1. Lower forks. Shut lift truck OFF. YES: Chains are out of ad-
ment Check (Stand- 2. Inspect wear on carriage stop. justment. See Mast Repair
ard and Integral (S/N A270, A271, A272)
Side Shift) Does carriage stop show a wear pattern on it? 4000SRM1386.
NO: Checks complete.

Steering Relief 1. Turn key switch to ON position. YES: Relief pressure is OK.
Valve Low Pressure 2. Position steer axle wheels straight to start Go to next check.
Check check. NO: If steer axle wheels do
not turn stop-to-stop, pres-
3. Turn steering wheel stop-to-stop in both direc- sure is too low. Adjust steer-
tions. ing relief pressure. Go to
Steering Relief Pressure Test
Does steer axle wheels turn stop-to-stop with- and Adjustment.
out stopping?

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 NOTES

9010-05-14
 SECTION 9025

TRACTION MOTOR

TABLE OF CONTENTS

Group 10 - Principles of Operation

Traction Motor......................................................................................................................................... 9025-10-1
Principles of Operation ...................................................................................................................... 9025-10-1
MASTER DRIVE UNIT....................................................................................................................... 9025-10-6
Group 30 - Observed Symptoms
Poor Tractive Performance..................................................................................................................... 9025-30-1

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9025-2
Traction Motor Principles of Operation

Group 10

Principles of Operation

Traction Motor
PRINCIPLES OF OPERATION These AC motors have a temperature sensor built
into the stator to monitor motor temperature and pro-
All electric forklift trucks covered by this manual use vide continual temperature feedback to the thermal
three-phase alternating current (AC) induction traction management system. That system is designed to pro-
motors. AC motors are all very similar motors used tect components from failure due to overheating. If the
across the product line, but do vary in some ways. motor winding temperature reaches its specified limit,
This Principles of Operation will identify the significant the VSM signals the traction controller to reduce the
differences. motor performance or may even disable traction to
protect the motor. When the traction system compo-
The AC induction motor is an electrical device which nents are in thermal management, there is no affect
uses an AC current provided to a wire wound stator on the hydraulic system performance. The connector
supplied by a DC to AC inverter to induce north and for this temperature sensor is serviceable, but the
south magnetic poles to an internal rotating device in sensor itself is not.
a controlled environment. The reaction between the
internal rotor and stator creates a push-pull effect on The rotor shaft extends out each side of the traction
the rotor causing the rotor to turn, creating a force to motor. The drive end head interfaces to the drive unit
do mechanical work. or drive axle, depending upon configuration. For lift
trucks A935, A268, A269, and A099 a short, round
In lift trucks the DC current is provided by the lead section of the shaft protrudes from the non-drive end
acid battery. The DC (direct current) voltage is head of the motor. This end supports the parking
changed to AC (alternating current) by the traction brake hub using a woodruff key and a snap ring.
motor controller. By changing the frequency of the AC There is a bearing between the motor and the parking
power to the motor, the motor speed can be control- brake. The parking brake is replaceable.
led. This job is done by the traction motor controller.
The controller also manages the direction of the motor UL safety rated EE traction motors are available as an
and thus the lift truck. It works in conjunction with the option on these forklifts. These motors have covered
VSM. vent holes and are only a part of the necessary equip-
ment required for the EE safety rating.
A speed sensor is used to detect and communicate
the speed and direction of the rotor to the controller. Traction motors are long life components and very
This is done by sending electric pulses on two sepa- low maintenance. They have no motor brushes. The
rate channels to the controller. The controller knows motor bearings, rotor, stator and speed sensor are
the direction of the motor by which channel’s signal it serviceable.
receives first. It knows the speed by the frequency of
the pulses. The controller’s software continually moni-
tors this information. Using this feedback, the AC mo-
tor control system can provide regenerative braking,
controlled acceleration and deceleration. By changing
the frequency of the AC power to the motor, which is
also managed by the motor controller, the motor
speed can be controlled.

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Principles of Operation Traction Motor

The traction motors vary depending upon the configu- A935, A276 and A970 use two traction motors and
ration of your forklift. Lift truck model D203 uses a two motor controllers. A motor is mounted to a drive
traction motor vertically mounted to the drive unit. The unit on each side of the vehicle and powers the drive
drive unit is refered to as the Master Drive Unit tires. The speed sensor for these motors is physically
(MDU). For further information on the MDU see MAS- located on the drive unit housing, not on the motor.
TER DRIVE UNIT. The model designation K160, See Figure 9025-10-1.

1. TRANSMISSION 7. TRACTION MOTOR

2. PARKING BRAKE WIRE HARNESS 8. SPLINED HUB
3. SOCKET HEAD CAPSCREW 9. SNAP RING
4. LOCKWASHER 10. WOODRUFF KEY
5. WASHER 11. TRACTION MOTOR MOUNTING CAPSCREW
6. PARKING BRAKE

Figure 9025-10-1. Transaxle Assembly J1.5-2.0XNT (J30-J40XNT) (K160) J1.6-2.0XN (A935)

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Traction Motor Principles of Operation

1. RIGHT SIDE TRANSMISSION OUTPUT

2. RIGHT SIDE GEARBOX
3. RIGHT COVER HOUSING
4. TRACTION MOTORS
5. LEFT COVER HOUSING
6. LEFT SIDE GEARBOX
7. LEFT SIDE TRANSMISSION OUTPUT

Figure 9025-10-2. Transaxle Assembly J4.0-5.0XN (A970)

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Principles of Operation Traction Motor

The model designation A268, A269 and A099 uses

only one traction motor and one traction controller. It
is mounted perpendicular to the drive axle. The speed
sensor for this motor is located on the motor itself.
See Figure 9025-10-3.

1. TRANSMISSION 2. TRACTION MOTOR

Figure 9025-10-3. Transmission Mounting for Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)

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Traction Motor Principles of Operation

1. DRIVE AXLE 2. TRACTION MOTOR

Figure 9025-10-4. Transmission Mounting for Lift Truck Models E4.0-5.5XN (E80-120XN) (A099)

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Principles of Operation Traction Motor

MASTER DRIVE UNIT

The heart of the traction system is the master drive
unit (MDU). A stationary traction motor eliminates the
power cables from the traction motor to the traction
controller from rotating or flexing. The MDU features
an integrated pinion with a splined motor to MDU cou-
pling. The support bearings and pinion are integral to
the MDU eliminating the potential of damaging the
gears when assembling the motor to the MDU. By in-
tegrating the pinion, the gear mesh can be better con-
trolled resulting in a quieter MDU. The splined cou-
pling allows for quick removal and installation of the
traction motor.

1. CAPSCREW
2. TRACTION MOTOR
3. COUNTERWEIGHT
4. STEER MOTOR
5. PLATE
6. MASTER DRIVE UNIT

Figure 9025-10-5. Master Drive Unit

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Traction Motor Observed Symptoms

Group 30

Observed Symptoms

Poor Tractive Performance

POSSIBLE CAUSE
A. INCORRECT SPEED LIMIT SET.
B. SPEED LIMITING ENABLED.
C. FAILED CHECKLIST ITEM.
D. INCORRECT STEER POSITION SENSOR CALIBRATION.
E. INCORRECT MOTOR CONTROLLER SETTINGS IN CONFIGURATION DATA FILE (CDF).
F. E-BOOST ACTIVE.
G. MOTOR PHASE SHORTED TO FRAME.
H. INCORRECT MOTOR INSTALLED.

CAUSE A - INCORRECT SPEED LIMIT SET.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of the lift truck can cause injury or death. Do not operate the lift truck until prob-
lem has been repaired.

1. Adjust speed limit setting on Display Panel. If problem still present go to Cause B.

CAUSE B - SPEED LIMITING ENABLED.

PROCEDURE OR ACTION:
1. Verify optional speed limiting is correctly set on Display Panel. See the appropriate User Interface, Service
Technician SRM . If problem is still present, go to Cause C.

CAUSE C - FAILED CHECKLIST ITEM.

PROCEDURE OR ACTION:
1. Review checklist history and run check as required. Lift truck will not operate correctly until all checklist item
requirements have been satisfied.
Have all checklist requirements been satisfied?
YES: Go to Cause D.
NO: Perform necessary actions to fulfill checklist requirements. If checklist requirements have been satisfied
and the problem is still present, go to Cause D.

CAUSE D - INCORRECT STEER POSITION SENSOR CALIBRATION.

PROCEDURE OR ACTION:
1. Rerun calibration procedure on the steering position sensor. Refer to the appropriate Calibration SRM .
Did re-calibrating steering position sensor resolve issue?
YES: Problem resolved. Resume operation.
NO: Go to Cause E.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9025-30-1
Observed Symptoms Traction Motor

CAUSE E - INCORRECT MOTOR CONTROLLER SETTINGS IN CONFIGURATION DATA FILE (CDF).

PROCEDURE OR ACTION:
1. Go to Hypass Online and download a new CDF from the software options.
2. Install new CDF into lift truck's controller and test drive lift truck.
Is problem still present?
YES: Go to Cause F.
NO: Issue resolved. Resume operation.

CAUSE F - E-BOOST ACTIVE.

PROCEDURE OR ACTION:
1. Make sure the service brakes are not locked up or dragging. See the appropriate Brake System SRM . Use
the Display Panel to verify e-Boost is not interfering with the traction motor. If e-Boost is active, deactivate it.
Is the problem still present?
YES: Go to Cause G.
NO: Issue resolved. Resume operation.

CAUSE G - MOTOR PHASE SHORTED TO FRAME.

PROCEDURE OR ACTION:
1. Turn lift truck power OFF.
2. Disconnect battery.
3. Disconnect power cables to tractions motor.
4. Change DMM to ohms scale. Verify zero reading.
5. Measure continuity between each power terminal of the traction motor and ground.
Is resistance low or close to zero ohms?
YES: Replace traction motor with new traction motor.
NO: Go to Cause H.

CAUSE H - INCORRECT MOTOR INSTALLED.

PROCEDURE OR ACTION:
1. Check that the part number of traction motor is the correct part number for the lift truck. If the part number is
not correct, use the correct traction motor.

END SYMPTOM

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9025-30-2 Confidential/Proprietary - Do Not Copy or Duplicate
 SECTION 9030

ELECTRICAL SYSTEM

TABLE OF CONTENTS

Group 03 - General Maintenance and Diagnostic Data

Troubleshooting Guidelines and Procedures.......................................................................................... 9030-03-1
Troubleshooting Guidelines................................................................................................................ 9030-03-1
Troubleshooting Procedures...............................................................................................................9030-03-4
Troubleshooting Procedures, Identification.................................................................................... 9030-03-4
Troubleshooting Procedures, Location...........................................................................................9030-03-4
Troubleshooting Procedures, Structure..........................................................................................9030-03-4
Troubleshooting Procedures, Performance....................................................................................9030-03-5
Troubleshooting Procedures, Final.................................................................................................9030-03-5
Diagnostic Trouble Codes.................................................................................................................. 9030-03-6
Wiring Reference Data..........................................................................................................................9030-03-12
Harness Assembly Data........................................................................................................................9030-03-16
Group 10 - Principles of Operation
Electrical System.....................................................................................................................................9030-10-1
General Description............................................................................................................................ 9030-10-1
PRINCIPLES OF OPERATION, COMPONENTS............................................................................ 9030-10-13
PRINCIPLES OF OPERATION, SYSTEM....................................................................................... 9030-10-22
Battery............................................................................................................................................ 9030-10-7
DC/DC Converter........................................................................................................................... 9030-10-8
Operator Interface.......................................................................................................................... 9030-10-8
Controllers...................................................................................................................................... 9030-10-8
System Controlled Outputs...........................................................................................................9030-10-11
Power Distribution........................................................................................................................ 9030-10-13
Operator Interface........................................................................................................................ 9030-10-15
E-Steer......................................................................................................................................... 9030-10-16
Controllers.................................................................................................................................... 9030-10-17
Battery (Plug-In)........................................................................................................................... 9030-10-22
Key ON and Operation................................................................................................................. 9030-10-22
Sensors........................................................................................................................................ 9030-10-22
Switches....................................................................................................................................... 9030-10-23
Outputs.........................................................................................................................................9030-10-23
Group 20 - Diagnostic Trouble Codes
Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL):
12844 - Load Weigh Pressure
12836 - Service Brake Pressure.........................................................................................................9030-20-1
Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH):
12845 - Load Weigh Pressure
12837 - Service Brake Pressure.........................................................................................................9030-20-6
Accelerator Pedal Position A/B Out of Range Low (OORL):
12808 - Accelerator Pedal Position A
12810 - Accelerator Pedal Position B............................................................................................... 9030-20-11
Accelerator Pedal Position A/B Out of Range High (OORH):
12809 - Accelerator Pedal Position A
12811 - Accelerator Pedal Position B............................................................................................... 9030-20-15
Accelerator Pedal Position A/B Data Incorrect:

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-1
 12812 - Accelerator Pedal Position A to B........................................................................................9030-20-20
Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL):
12820 - Steering Wheel Position
12824 - Steering Axle Position......................................................................................................... 9030-20-25
Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH):
12821 - Steering Wheel Position
12825 - Steering Axle Position......................................................................................................... 9030-20-30
Steer Axle Calibration Required:
4098 - Steer Axle Calibration............................................................................................................9030-20-35
Hydraulic Temperature Sensor Out of Range High (OORL) :
12852 - Hydraulic Temperature........................................................................................................ 9030-20-39
Hydraulic Temperature Sensor Out of Range High (OORH) :
12853 - Hydraulic Temperature........................................................................................................ 9030-20-43
Hydraulic Fluid Level Sensor Out Of Range Low (OORL):
12872 - Hydraulic Fluid Level........................................................................................................... 9030-20-48
Hydraulic Fluid Level Sensor Out Of Range High (OORH):
12873 - Hydraulic Fluid Level........................................................................................................... 9030-20-53
Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL):
12832 - Park Brake Position
12840 - Mast Tilt Position................................................................................................................. 9030-20-57
Park Brake/Mast Tilt Position Sensor Out of Range High (OORH):
12831 - Park Brake Position
12841 - Mast Tilt Position................................................................................................................. 9030-20-62
Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL):
12800 - Directional Select A
12804 - Directional Select B............................................................................................................. 9030-20-67
Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH):
12801 - Directional Select A
12805 - Directional Select B............................................................................................................. 9030-20-71
Seat Sensor Out of Range Low (OORL):
12816 - Seat Sensor.........................................................................................................................9030-20-76
Seat Sensor Out of Range High (OORH):
12819 - Seat Sensor.........................................................................................................................9030-20-80
Battery OORH/OORL:
12545 - Battery OORH
12546 - Battery OORL...................................................................................................................... 9030-20-85
VSM 5 Volt Supply (OORL) (OORH):
13056 - 5V OORL
13057 - 5V OORH............................................................................................................................ 9030-20-92
Manual Hydraulic Position Sensors Out Of Range Low (OORL):
12856 - Manual Hyd 1
12860 - Manual Hyd 2
12864 - Manual Hyd 3
12868 - Manual Hyd 4...................................................................................................................... 9030-20-99
Manual Hydraulic Position Sensor Out Of Range High (OORH):
12857 - Manual Hyd 1
12861 - Manual Hyd 2
12865 - Manual Hyd 3
12869 - Manual Hyd 4.................................................................................................................... 9030-20-103
E-Hydraulic Enable System Data Incorrect:
12332 - Data Incorrect.................................................................................................................... 9030-20-108
E-Hydraulic Coils Short To Battery Positive (STBP):
8960 - Lift
8964 - Lower

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-2 Confidential/Proprietary - Do Not Copy or Duplicate
 8968 - Tilt Forward
8972 - Tilt Back
8978 - Aux 1A
8980 - Aux 1B
8984 - Aux 2A
8988 - Aux 2B................................................................................................................................. 9030-20-113
E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC):
13312 - Lift
13316 - Lower
13320 - Tilt Forward
13324 - Tilt Back
13328 - Aux 1A
13332 - Aux 1B
13336 - Aux 2A
13340 - Aux 2B............................................................................................................................... 9030-20-118
A935 – K160 CAN Communication Failure:
33025 - VSM to Display
33026 - VSM to Traction 1 (Right)
33027 - VSM to Traction 2 (Left)
33029 - VSM to Pump
33034 - VSM to MLM (DCS)
33035 - VSM to Impact
33036 - VSM to CAN Reserved 1
33037 - VSM to CAN Reserved 2
33038 - VSM to CAN Reserved 3
33057 - Display to VSM.................................................................................................................. 9030-20-123
CBB 4 Wheel CAN Communication:
33025 - VSM to Display
33026 - VSM to Traction 1 (Right)
33027 - VSM to Traction 2 (Left)
33029 - VSM to Pump
33034 - VSM to MLM (DCS)
33035 - VSM to Impact
33036 - VSM to CAN Reserved 1
33037 - VSM to CAN Reserved 2
33038 - VSM to CAN Reserved 3
33057 - Display to VSM.................................................................................................................. 9030-20-137
DBB 4 Wheel CAN Communication:
33025 - VSM to Display
33026 - VSM to Traction 1 (Right)
33027 - VSM to Traction 2 (Left)
33029 - VSM to Pump
33034 - VSM to MLM (DCS)
33035 - VSM to Impact
33036 - VSM to CAN Reserved 1
33037 - VSM to CAN Reserved 2
33038 - VSM to CAN Reserved 3
33057 - Display to VSM.................................................................................................................. 9030-20-155
MLM Failure:
21830 - MLM EEPROM Write Error
21834 - MLM Sensor 1 Out of Range
21835 - MLM Sensor 2 Out of Range
21836 - MLM Sensor 3 Out of Range
21837 - MLM Sensor 4 Out of Range

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-3
 25344 - MLM Checksum Error........................................................................................................9030-20-170
MLM Incorrect Lever Installed:
4112 - Incorrect Lever 1 Installed
4113 - Incorrect Lever 2 Installed
4114 - Incorrect Lever 3 Installed
4115 - Incorrect Lever 4 Installed
4116 - Incorrect Lever 5 Installed................................................................................................... 9030-20-176
VSM 12 Volts Supply OORL/OORH:
13060 - VSM 12V OORL
13061 - VSM 12V OORH................................................................................................................9030-20-179
Display Internal Failure:
22032 - Display EEPROM Checksum Error
22033 - Display Cell Write Error
33056 - Display Internal CAN Failure
33057 - Display Communications Error with VSM
8704 - Display Internal LCD Backlight
12934 - Display Internal LCD Backlight
12935 - Display Internal LCD Backlight
8705 - Display Internal LCD Heater
12936 - Display Internal LCD Heater
12937 - Display Internal LCD Heater
22528 - Display Button *
22529 - Display Button #
22530 - Display \ Arrow
22531 - Display ] Arrow
22532 - Display Button 1
22533 - Display Button 2
22534 - Display Button 3
22535 - Display Button 4
22536 - Display Button 5
22537 - Display Button 6
22538 - Display Button 7
22539 - Display Button 8
22540 - Display Button 9
22541 - Display Button 0................................................................................................................ 9030-20-188
Display Failure – Keyswitch Relay Output:
9041 - Display Keyswitch Output
12940 - Display Keyswitch Output
12941 - Display Keyswitch Output
13070 - Keyswitch Data Incorrect...................................................................................................9030-20-195
VSM Controller Check:
21760 - VSM BOOT_BLOCK Checksum failure
21761 - CDF_Checksum_failure
21762 - VSM APPLICATION_SOFTWARE Checksum failure/Error
21764 - VSM EEPROM Checksum failure/Error
21766 - VSM EEPROM Cell failure Write Error
21792 - VSM Serial Number Error..................................................................................................9030-20-207
Controller Logic Failure:
65299 - Controller Logic Failure..................................................................................................... 9030-20-213
Display Failure – Temperature/Buzzer:
12928 - Display Temperature Sensor (Freezer Option Only)
12929 - Display Temperature Sensor (Freezer Option Only)
9040 - Display Buzzer Output
12938 - Display Buzzer Output

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-4 Confidential/Proprietary - Do Not Copy or Duplicate
 12939 - Display Buzzer Output.......................................................................................................9030-20-221
Contactor/Relay/Valve Coil Short to Battery Positive (STBP):
9000 - Diverter Valve
9004 - E Hyd Enable
9008 - Clamp Solenoid (Optional)
9012 - Acc 2 Relay
9016 - Forward Relay
9020 - Reverse Relay
9026 - Spare 1 Relay
9028 - Spare 2 Relay
9032 - Main Contactor
9036 - 2nd Contactor...................................................................................................................... 9030-20-227
Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC):
13352 - Diverter Valve
13356 - Hyd Enable
13360 - Acc 1 Relay
13364 - Acc 2 Relay
13368 - Motion Relay
13372 - Reverse Relay
13376 - Spare 1 Relay
13380 - Brake Light Relay Short to B(-) or Open
13384 - Main Contactor
13388 - 2nd Contactor.................................................................................................................... 9030-20-232
Motor Controller Contactor Failure:
21569 - Contactor Open
21570 - Contactor Closed
65318 - Contactor Open
65317 - Contactor Closed
65354 - Driver Shorted High
65355 - Driver Shorted Low............................................................................................................9030-20-238
A935 – K160 D203 Motor Controller Capacitor Failure:
12592 - Capacitor Charge.............................................................................................................. 9030-20-249
A935 – K160 D203 Motor Speed Sensor Failure:
29456 - Sensor Fault...................................................................................................................... 9030-20-256
CBB/DBB Motor Speed Sensor Failure:
25104 - Sensor Fault
29456 - Sensor Fault...................................................................................................................... 9030-20-267
A935 – K160 Motor Auto Brake Failure:
8786 - Brake Coil Shorted
12834 - Aux Driver Short to Bat (-) Brake Coil Open Circuit
12835 - Aux Driver Open Circuit Excess Current........................................................................... 9030-20-279
A935 – K160 D203Motor Controller Power Mosfet Failure :
65513 - Power MOS Shorted..........................................................................................................9030-20-288
A935 – K160 D203Motor/Motor Controller Failure:
12576 - Motor Voltage Not OK....................................................................................................... 9030-20-296
A935 – K160 D203 Motor Controller Failure:
65280 - Controller Failure............................................................................................................... 9030-20-306
CBB/DBB Motor/Motor Controller Failure:
8976 - AC Current – Over Current
9024 - AC Current – Short Circuit...................................................................................................9030-20-313
A935 – K160 D203 Motor Controller CAN Communication Failure:
65527 - No CAN Communication................................................................................................... 9030-20-324
CBB/DBB Motor Controller CAN Communication Failure:
33024 - CAN Communication Failure............................................................................................. 9030-20-332

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-5
 Travel Direction Select Incorrect:
12802 - Direction Select Data Incorrect – Direction Signals Incorrect............................................9030-20-341
Travel Direction Select Data Incorrect – 2 Sources:
12806 - Direction Select – Data Incorrect 2 + Direction Devices Installed..................................... 9030-20-349
Direction Select Data Incorrect - No DCS Source:
12807 - Direction Select Data Incorrect - No DCS Source............................................................. 9030-20-353
CBB/DBB Motor/Motor Controller Temperature Sensor Failure:
16912 - Motor Temperature High
17168 - Controller/Heatsink Temperature High
25105 - Temperature Sensor Failure..............................................................................................9030-20-361
CBB/DBB Motor Controller Current Sensor Failure :
21008 - Current Sensor Offset Calibration Error............................................................................ 9030-20-373
Hydraulic Calibration Required:
4096 - Hydraulic Calibration Required............................................................................................9030-20-379
CBB/DBB Motor Controller 15 – 5 Volt Internal Failure:
20753 - 15 Volt Supply Low Voltage
20755 - 5 Volt Supply Low/High Voltage........................................................................................ 9030-20-383
CBB/DBB Motor Controller DC Bus Low/High:
12576 - DC Bus Charging Timeout
12817 - DC Bus Hi – Software Detected
12818 - DC Bus Hi – Hardware Detected
12833 - DC Bus Low – Hardware/Software....................................................................................9030-20-388
CBB/DBB Traction Controller Driver Current High:
21520 - Aux Driver Current High
25106 - Park Brake Solenoid and Fan Driver Current High............................................................9030-20-405
Synchronous Steering Coil Current:
DTC 8992 - Synchronous Steering Coil Current.............................................................................9030-20-417
DTC 13344 - Synch Steering Coil Open Circuit.................................................................................. 9030-20-418
DTC 9012 - ACC 2 Current OORH..................................................................................................... 9030-20-420
DTC 65526 - Aux Driver Open............................................................................................................ 9030-20-420
DTC 65534 - Aux Driver Short............................................................................................................ 9030-20-420
DTC 65288 - Loss of Communication Between the Primary and Secondary Controller.....................9030-20-422
DTC 65293 - EEPROM Checksum Failure......................................................................................... 9030-20-423
DTC 95520 - Key Switch Voltage OORL............................................................................................ 9030-20-424
DTC 65296 - Motor U-W Phase Voltage Measurement Fault.............................................................9030-20-427
DTC 65297 - Motor U-V Phase Voltage Measurement Fault..............................................................9030-20-429
DTC 65352 - Motor W-V Phase Voltage Measurement Fault............................................................. 9030-20-431
DTC 65312 - Motor Phase Voltage Out of Range...............................................................................9030-20-433
DTC 65333 - Standby Current Too High.............................................................................................9030-20-435
DTC 65340 - DC Bus Capacitor Charge Timeout............................................................................... 9030-20-436
DTC 65341 - Controller Temperature Above Limit..............................................................................9030-20-439
DTC 65345 - Motor Temperature Above Limit.................................................................................... 9030-20-440
DTC 65350 - Controller Internal Error................................................................................................. 9030-20-443
DTC 65487 - Controller Internal Error................................................................................................. 9030-20-444
DTC 65488 - Controller Internal Error................................................................................................. 9030-20-445
DTC 65490 - Primary and Secondary Controller Version Mismatch...................................................9030-20-446
DTC 65492 - Controller Internal Error................................................................................................. 9030-20-447
DTC 65493 - Default Parameter Restore............................................................................................9030-20-448
DTC 65495 - Controller Internal Error................................................................................................. 9030-20-449
DTC 65496 - Controller Internal Error................................................................................................. 9030-20-450
DTC 65501 - Controller Internal Error................................................................................................. 9030-20-451
DTC 65505 - Controller Internal Error................................................................................................. 9030-20-452
DTC 65517 - Controller Internal Error................................................................................................. 9030-20-453
DTC 65525 - Controller Internal Error................................................................................................. 9030-20-454

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-6 Confidential/Proprietary - Do Not Copy or Duplicate
 DTC 65530 - Controller Internal Error................................................................................................. 9030-20-455
DTC 65533 - Controller Internal Error................................................................................................. 9030-20-456
DTC 65498 - Controller Software Mismatch....................................................................................... 9030-20-457
DTC 65489 - Controller Internal Error................................................................................................. 9030-20-458
DTC 65350 - Motor Phase W Current OORL......................................................................................9030-20-459
DTC 65351 - Motor Phase V Current OORL.......................................................................................9030-20-461
DTC 65353 - Motor Phase U Current OORL...................................................................................... 9030-20-463
DTC 65531 - Controller Initialization Test Failed................................................................................ 9030-20-465
DTC 65494 - Rapid Change in Steering Wheel Position.................................................................... 9030-20-468
DTC 65528 - Steer Wheel Sensor Output Mismatch.......................................................................... 9030-20-470
DTC 65378 - Steering Wheel Position Error....................................................................................... 9030-20-472
DTC 65491 - TFD Current within Range but Lower than Expected.................................................... 9030-20-474
DTC 65496 - TFD Resistance Out of Range...................................................................................... 9030-20-476
DTC 65515 - TFD Short to battery Negative.......................................................................................9030-20-478
DTC 65516 - TFD Stand-by Current OORH....................................................................................... 9030-20-480
DTC 65500 - Steering Motor Locked.................................................................................................. 9030-20-482
DTC 65521 - Steer Axle Slow Response............................................................................................ 9030-20-484
DTC 65508 - Steer Axle Position Mismatch........................................................................................9030-20-486
DTC 65532 - Steer Axle Sensor Output Mismatch............................................................................. 9030-20-490
DTC 65503 - Rapid Change in Steer Axle Position............................................................................ 9030-20-494
DTC 65524 - Primary and Secondary Parameter Mismatch...............................................................9030-20-498
DTC 65527 - Loss of CAN Communication........................................................................................ 9030-20-499
DTC 33050 - E-Steer CAN Communications Failure Right.................................................................9030-20-499
DTC 33051 - E-Steer CAN Communications Failure Left................................................................... 9030-20-499
DTC 9045 - Internal Error - Software.................................................................................................. 9030-20-503
DTC 13058 - 5V Internal Supply Out of Range...................................................................................9030-20-504
DTC 13104 - Sensor Ground Current OORH..................................................................................... 9030-20-505
DTC 16913 - Motor Temperature Sensor Open Circuit...................................................................... 9030-20-509
DTC 16914 - Motor Temperature Sensor Short Circuit.......................................................................9030-20-513
DTC 16912 - Motor Temperature OORH............................................................................................ 9030-20-517
DTC 65341 - Controller Internal Temperature OORH.........................................................................9030-20-521
DTC 65342 - Thermal Protection / Motor Temperature High.............................................................. 9030-20-521
DTC 65341 - Controller Internal Temperature OORL......................................................................... 9030-20-522
DTC 21521 - Fan Driver Current OORH............................................................................................. 9030-20-523
DTC 21776 - Internal Error - Hardware...............................................................................................9030-20-526
DTC 29232 - Sensor Supply Reference voltage Out of Range...........................................................9030-20-527
DTC 21522 - Automatic Park Brake Driver Current OORH................................................................ 9030-20-528
DTC 29216 - Speed Sensor High Current.......................................................................................... 9030-20-530
DTC 29217 - Speed Sensor Not Connected.......................................................................................9030-20-532
DTC 29233 - Sensor Supply Circuit Out of Range..............................................................................9030-20-534
DTC 29536 - Loss of Speed Sensor Channel A................................................................................. 9030-20-536
DTC 65362 - Encoder Error................................................................................................................ 9030-20-536
DTC 65512 - Wrong Encoder Set....................................................................................................... 9030-20-536
DTC 29552 - Loss of Speed Sensor Channel B................................................................................. 9030-20-538
DTC 65362 - Encoder Error................................................................................................................ 9030-20-538
DTC 65512 - Wrong Encoder Set....................................................................................................... 9030-20-538
DTC 65346 - Battery Low....................................................................................................................9030-20-540
DTC 65529 - Check Up Needed......................................................................................................... 9030-20-542
DTC 95360 - Forw + Back.................................................................................................................. 9030-20-543
DTC 65481 - Wrong Slave Version.....................................................................................................9030-20-547
DTC 65519 - Controller Mismatch.......................................................................................................9030-20-547
DTC 65522 - Parameter Transfer....................................................................................................... 9030-20-547
DTC 65511 - No Slave Enabled..........................................................................................................9030-20-547
DTC 65486 - Initial VMN High.............................................................................................................9030-20-548

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-7
 DTC 65333 - Standby Current High.................................................................................................... 9030-20-548
DTC 65310 - VMN Low....................................................................................................................... 9030-20-548
DTC 65311 - VMN High...................................................................................................................... 9030-20-548
DTC 65504 - Waiting for Node............................................................................................................9030-20-550
DTC 12836 - Brake Pedal Sensor A OORL........................................................................................ 9030-20-552
DTC 12837 - Brake Pedal Sensor A OORH....................................................................................... 9030-20-552
DTC 12876 - Brake Pedal Sensor B OORL........................................................................................ 9030-20-552
DTC 12877 - Brake Pedal Sensor B OORH....................................................................................... 9030-20-552
DTC 12813 - Foot Brake Position Rationality..................................................................................... 9030-20-552
DTC 4117 - FOC Configuration Mismatch.......................................................................................... 9030-20-554
DTC 33040 - Various CAN Errors....................................................................................................... 9030-20-556
Group 30 - Observed Symptoms
No Display/No Truck Operation:
None - No Display/No Truck Operation.............................................................................................. 9030-30-1
A935 – K160 D203 Motor Controller Fan Failure:
None - Motor Controller Fan Failure................................................................................................... 9030-30-8
A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure:
None - Motor/Motor Controller Temperature Sensor Failure............................................................ 9030-30-21
Horn Failure.......................................................................................................................................... 9030-30-32
Lights Inoperative..................................................................................................................................9030-30-35
Group 55 - Icons and Graphics
Icon Glossary.......................................................................................................................................... 9030-55-1
Introduction to Icons........................................................................................................................... 9030-55-1

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-8 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System General Maintenance and Diagnostic Data

Group 03

General Maintenance and Diagnostic Data

Troubleshooting Guidelines and Procedures

TROUBLESHOOTING GUIDELINES • DISPLAY Fault Log
These fault history logs are accessible to service
The troubleshooting procedures that will be encoun- level technicians. See Troubleshooting Proce-
tered in this manual require that the individual be fa- dures for directions on how to access fault history
miliar with certain policies, requirements, and instruc- logs.
tions before starting any of the procedures. These are
included to assure the safety of the technician per- 3. Abbreviations and Acronyms will be defined when
forming the tasks, simplify the procedures, and pre- first used in a procedure. They are also listed and
vent damage to the machine and supporting equip- defined in Abbreviations and Acronyms that ac-
ment. companies this document.

4. Most procedures will require the use of a Digital

WARNING MultiMeter (DMM) and associated probes. The
All safety precautions for working on and around service technician should be familiar with the op-
powered vehicles must be observed and main- eration, range scales, polarity selection, and
tained. (Refer to Operating or Repair Manual.) measurement techniques.

1. Initial conditions will be with the vehicle power a. Unless otherwise directed, the RED probe of
OFF and park brake set, unless directed other- the DMM will always be connected to the point
wise. indicated as (+) and the BLACK probe will al-
ways be connected to the point indicated as (-).
2. The Diagnostic Trouble Code (DTC) Chart in-
cludes: b. When performing a continuity check, all signal
circuits should be equal or less than 0.5 ohms.
• Diagnostic Trouble Code
At the start of troubleshooting procedures, ver-
• A brief description of the fault/symptom ify that the DMM will display 0 ohms when the
• Page number of applicable Troubleshoot- resistance scale is selected and the probes are
ing Procedures shorted together. If the DMM display indicates
a value less than 1 ohm and that value is con-
This number is the number displayed in the Liquid
sistently repeated, it may be considered as the
Crystal Display (LCD) section of the Display
zero value. Resistance readings during testing
Panel (DP). In addition to active faults that will be
will require correction by this small value. If the
displayed on the LCD, the system is capable of
DMM display is not correct or is greater than 1
displaying fault history data that is stored in the
ohm, have the meter calibrated/serviced.
VSM and other controller units, if equipped.
• VSM Fault Log c. In some improved DMMs, when the test probes
are shorted together, a momentary push-button
• Traction Controller 1 and 2 Fault Log
switch will re-zero the meter scale and main-
• HYDR PUMP Controller Fault Log tain that zero position as a reference until the
• LIGHT Controller Fault Log meter is turned off. If this feature is available,
be sure to re-zero each time meter power is cy-
• MLM Fault Log
cled.
• IMPACT Fault Log

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General Maintenance and Diagnostic Data Electrical System

d. Probing the back of connectors for obtaining in- NOTE: The Electrical System Schematic referenced
line voltage measurements requires a special in this manual will be supplied in Diagrams. Verify that
probe extension for the meter probes. Failure this data is current and the revisions are up to date
to use this tool can result in damage to the in- before making any changes or alterations to the truck
tegrity of the connector seal and may cause a wiring.
failure in the harness/connector assembly. See
Wire Harness Repair 2200SRM1128. Prior to making any corrections or changes to
the wiring, verify that the wire number and color
5. Most electrical problems will be harness related: coincide with the information on the referenced
• Connectors not fully engaged and locked schematics, wiring diagrams, or special instruc-
tions, if any.
• Connector pins not fully inserted
• Circuit repairs incorrectly wired at connec- NOTE: There may be customer options and equip-
tors ment installed on the lift trucks by third-party services
that do not comply with the standard wiring specifica-
• Damaged connector pins tions and standards. Suppliers are encouraged to fol-
6. Major component service tips: low these standards for circuits when possible.

a. Vehicle System Manager (VSM): 8. The chassis wiring used in these vehicles con-
forms to the electrical circuit identification stand-
• Connectors are keyed and color coded ard ES-1359 and in addition to surface marked ID
• Non-serviceable part circuit numbers, generally utilizes the colors that
• Last replaceable item in troubleshooting are indicated below.
procedures a. Red = Battery level power circuits
• Do not transfer VSMs or Display Panel
from other trucks b. Black = Heavy current grounds
• Always confirm VSM/Display Panel and c. Green = Signal Grounds
lift truck serial numbers match before
doing any servicing d. White = Other circuits

7. When troubleshooting electrical/electronic faults e. Twisted Pair (preferred CAN option)

and symptoms: • Yellow = CANbus Hi
a. Verify that the connector is properly engaged • Green = CANbus Lo
and that connector security clips, tabs, and
other locking devices are properly attached. f. Twisted Pair (non-preferred CAN option)
• White = CAN-Hi
b. Visually examine the connectors and harness
• White = CAN-Lo
termination points for “pushed” or “recessed”
pins or sockets. g. Orange = 5 volt
c. The Electric Truck Battery Negative and Posi- h. Pink = 12 volt
tive are isolated from the Vehicle Frame. Un-
less directed in a Procedure, no measurements 9. Connectors used on schematics and reference
will be made using the vehicle frame as an drawings are identified as follows: See Fig-
electrical path. ure 9030-03-1 in this section.

d. Before opening any connector or removing any a. CPSXXX -- Connector Plug Socket (CPS),
wires from their termination point, disconnect with XXX being the identity number.
the circuits from the battery as directed in the
procedure. Trucks are equipped with a Emer- b. CRPXXX -- Connector Receptacle Pin
gency Disconnect Switch. Pushing the emer- (CRP), with XXX being the identity number.
gency disconnect switch in until it clicks, dis-
10. At the completion of a Troubleshooting Proce-
connects the power supply to the lift truck.
dure, verify the following:

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Electrical System General Maintenance and Diagnostic Data

a. All components removed for replacement, test f. If operation is complete and the lift truck is to
or access purposes have been correctly rein- be stored or shut down, verify:
stalled.
(1) Mast/Carriage/Forks are properly posi-
b. All electrical connections are restored. tioned.

c. If operational test or checkout is to be per- (2) By pushing the emergency disconnect

formed, make sure operating area is free of switch down until it clicks, disconnects the
personnel, obstructions, and ground hazards. power supply to the lift truck.

d. Vehicle is in proper location and configuration (3) Cab (if equipped) is closed and secured.
for safe operation.

e. Support equipment and tools are removed and

properly stored.

1. PLUG TYPE CONNECTOR BODY 4. PIN-TYPE TERMINAL

2. RECEPTACLE TYPE CONNECTOR BODY 5. SECONDARY LOCK
3. CAVITY PLUG 6. SOCKET TYPE TERMINAL

Figure 9030-03-1. Typical DT Series Connector

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General Maintenance and Diagnostic Data Electrical System

TROUBLESHOOTING PROCEDURES tion below the relevant graphic. In the text explanation
symbols are used wherever possible. See Icon Glos-
This section describes the general process of identifi- sary for definitions.
cation, location, structure, and performance of the
troubleshooting procedures that are included in this Minor differences in the beginning of a procedure are
manual. determined by whether the procedure has:
• A single fault code with a single schematic dia-
Troubleshooting Procedures, Identification gram

The various procedures are identified by the fault • A single fault code with multiple schematic dia-
characteristic. grams
In this instance, the technician will have to se-
Troubleshooting Procedures, Location lect the appropriate schematic based on the
DTC and the lift truck type/configuration.
Once a DTC number has been displayed, indicating a • Multiple fault codes with a single or multiple
fault has been detected, the operator/service techni- schematic diagram(s)
cian can review the DTC chart in this section to deter- • A single fault code with no schematic dia-
mine where the appropriate troubleshooting proce- grams, used when only the operational check
dure is located. and replacement procedures are employed in
the procedure.
The reported DTCs are listed in numerical order,
along with the DTC title description of the detected Troubleshooting procedures include several ele-
fault. DTCs are also stored in the Fault Logs, where a ments.
history of repeat failures is maintained, until cleared
by an authorized service technician. • DTC number(s) which this procedure applies
to.
When working from an Integrated Electronic Techni- • DTC Identification e.g. Seat Sensor.
cal Manual (IETM) format, clicking on the DTC index • CHECK List - Determines if the Fault is still ac-
number, or the page in the Table of Contents, will link tive and helps identify the Possible Cause.
you to the applicable procedure in section 9030-20. If
working from a hardcopy (paper) manual, this capabil- • POSSIBLE CAUSES
ity is not available. • MAIN SCHEMATIC
• OPERATIONAL CHECKS
NOTE: Access to the following Fault Log menus re-
quires Service password. NOTE: If key icon remains illuminated after software
is installed, shut key OFF. Wait 30 seconds for power
NOTE: The only Fault Logs available for display are
cycling then turn key ON. Key icon should not stay lit.
those for the controllers installed in your lift truck, as
defined in the VSM's Configuration Data File (CDF)
• Verify the DTC is still a valid fault. If the DTC is
cleared during the power cycling, it may not
Access to Fault History Codes — Fault Logs store a
have been a hard failure and if it does not reoc-
history of DTCs within a specific controller file. These
cur on the display, there is no method of identi-
fault logs are accessible through the Display Panel
fying or troubleshooting the problem.
main menu. At the Display Panel menu enter the su-
If this situation occurs randomly or reoccurs
pervisor password, scroll to Diagnostics, ENTER, and
frequently with the same DTC, access and re-
scroll to appropriate fault log. See Display Menu Flow-
view the fault history log for that group to deter-
chart.
mine the frequency of failure and the last re-
ported time it occurred. This information can be
Troubleshooting Procedures, Structure
helpful in isolating intermittent problems when
known conditions under which it occurred can
The structure or makeup of the troubleshooting proce-
be repeated.
dures is generally the same for all entries. The proce-
dures are graphical in nature with some text explana-

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Electrical System General Maintenance and Diagnostic Data

• The operational check will also direct the tech- These may help to isolate the problem, eliminate
nician to the proper cause in the procedure, some steps or enforce the procedure that has been
based on truck/system configuration, other identified. These items are:
symptoms, and advise the user if any special • LOOK — Are there any observable symptoms,
conditions are required (i.e. Operate the truck visual evidence or obvious conditions that
until it has reached normal temperature, re- could result in, or contribute to, the reported
charge the battery before proceeding etc.). fault.
• The operational check is also performed to ver- Are the displayed Icons due to Interlocks? See
ify that the problem has been corrected and User Interface Supervisor 2200SRM1335 or
that the components and devices have been User Interface Service Technician
restored to an operating condition. 2200SRM1336 .
• LISTEN — If the lift truck can be operated with
The next item that appears in the procedure is the the reported problem, are there any unusual
CAUSE A. This introduces the troubleshooter to the noises or vibrations that could result in, or con-
first sequence of tests or measurements to follow. tribute to, the reported fault.
Continuing through the procedure in the step-by-step
directions will lead the user to: • TOUCH OR SMELL — High operating temper-
atures and excessive wear can sometimes pro-
• Additional possible causes duce an odor or visual evidence that can be
• Replacement/repair instructions linked to other faults or conditions.
• Correction of the fault • In general, let your senses and your experi-
• Operational check of the repaired/replaced de- ence assist you in resolving the problem in the
vice most efficient manner. Ask yourself:
• What is required for this device or oper-
It must be noted that Service Manual factory direc- ation to function correctly?
tions discourage probing of the connectors using any • Where are the devices/parts located?
type of wire or pin and that resistance or continuity
measurements of these connections should only be • Has this problem been reported before?
done with the appropriate service tool and breakout If so, how frequently? Use the fault his-
connectors. tory logs to help identify repeated prob-
lems. This can be very helpful in analyz-
Following through the procedure, the next items are ing faults of an intermittent nature which
the DIAGRAMS that support the troubleshooting and may be difficult to duplicate.
provide relevant data for wiring, connectors, power, • Has repair work, disassembly or other
signal and other reference data. These will enable the maintenance work been performed on
troubleshooter to measure, verify, and make critical suspect device or system recently?
decisions leading to the root cause. The diagrams • Once these questions have been considered,
may include: proceed with the DTC resolution as per the
• A mini-schematic of the suspect circuit procedure, using any additional information to
• Wire identification and circuit function assist in resolving the discrepancy.

• Connector pin-out locators Troubleshooting Procedures, Final

• Special reference data for device or compo-
nent DTCs are stored in the FAULT CODE LOGS, where a
history of repeat failures is maintained, until cleared
Troubleshooting Procedures, Performance by an authorized service technician. All DTCs are to
be cleared prior to operating the lift truck. Fault code
It is important to remember the basics of troubleshoot- logs should only be cleared once the data is recorded
ing when checking the electronically reported faults. by a authorized service technician. See Display Menu
Prior to starting any of the listed procedures, it is rec- Flowchart.
ommended that the items listed below be reviewed.

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General Maintenance and Diagnostic Data Electrical System

NOTE: Motor/Motor Controller Fault Logs cannot be play Panel or other Controllers. They will be displayed
cleared. Once the Motor Controller Log is full, DTCs via the Display Panel upon detection and will remain
are removed on a First In, First Out (FIFO) basis. in the applicable fault history logs until service inter-
vention clears the logs.
DIAGNOSTIC TROUBLE CODES The DTC list is comprised of the DTC number and a
brief description of the fault item.
The Diagnostic Trouble Codes that appear in the ta-
ble that follows are those codes that have been stored
in the memory of the VSM or in certain cases the Dis-

Diagnostic Trouble Code (DTC) Chart

DTC DESCRIPTION PAGE NO.

12332 Data Incorrect..................................................................................................................... 9030-20-108
12545 Battery OORH...................................................................................................................... 9030-20-85
12546 Battery OORL....................................................................................................................... 9030-20-85
12576 Motor Voltage Not OK........................................................................................................ 9030-20-296
12576 DC Bus Charging Timeout................................................................................................. 9030-20-388
12592 Capacitor Charge............................................................................................................... 9030-20-249
12800 Directional Select A.............................................................................................................. 9030-20-67
12801 Directional Select A.............................................................................................................. 9030-20-71
12802 Direction Select Data Incorrect – Direction Signals Incorrect............................................ 9030-20-341
12804 Directional Select B.............................................................................................................. 9030-20-67
12805 Directional Select B.............................................................................................................. 9030-20-71
12806 Direction Select – Data Incorrect 2 + Direction Devices Installed...................................... 9030-20-349
12807 Direction Select Data Incorrect - No DCS Source............................................................. 9030-20-353
12808 Accelerator Pedal Position A............................................................................................... 9030-20-11
12809 Accelerator Pedal Position A............................................................................................... 9030-20-15
12810 Accelerator Pedal Position B............................................................................................... 9030-20-11
12811 Accelerator Pedal Position B............................................................................................... 9030-20-15
12812 Accelerator Pedal Position A to B........................................................................................ 9030-20-20
12813 Foot Brake Position Rationality.......................................................................................... 9030-20-552
12816 Seat Sensor......................................................................................................................... 9030-20-76
12817 DC Bus Hi – Software Detected......................................................................................... 9030-20-388
12818 DC Bus Hi – Hardware Detected....................................................................................... 9030-20-388
12819 Seat Sensor......................................................................................................................... 9030-20-80
12820 Steering Wheel Position....................................................................................................... 9030-20-25
12821 Steering Wheel Position....................................................................................................... 9030-20-30
12824 Steering Axle Position.......................................................................................................... 9030-20-25
12825 Steering Axle Position.......................................................................................................... 9030-20-30
12831 Park Brake Position.............................................................................................................. 9030-20-62
12832 Park Brake Position.............................................................................................................. 9030-20-57
12833 DC Bus Low – Hardware/Software.................................................................................... 9030-20-388
12834 Aux Driver Short to Bat (-) Brake Coil Open Circuit........................................................... 9030-20-279
12835 Aux Driver Open Circuit Excess Current............................................................................ 9030-20-279
12836 Service Brake Pressure......................................................................................................... 9030-20-1
12836 Brake Pedal Sensor A OORL............................................................................................ 9030-20-552
12837 Service Brake Pressure......................................................................................................... 9030-20-6
12837 Brake Pedal Sensor A OORH............................................................................................ 9030-20-552
12840 Mast Tilt Position.................................................................................................................. 9030-20-57
12841 Mast Tilt Position.................................................................................................................. 9030-20-62
12844 Load Weigh Pressure............................................................................................................. 9030-20-1
12845 Load Weigh Pressure............................................................................................................. 9030-20-6

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Electrical System General Maintenance and Diagnostic Data

Diagnostic Trouble Code (DTC) Chart (Cont)

DTC DESCRIPTION PAGE NO.

12852 Hydraulic Temperature......................................................................................................... 9030-20-39
12853 Hydraulic Temperature......................................................................................................... 9030-20-43
12856 Manual Hyd 1....................................................................................................................... 9030-20-99
12857 Manual Hyd 1..................................................................................................................... 9030-20-103
12860 Manual Hyd 2....................................................................................................................... 9030-20-99
12861 Manual Hyd 2..................................................................................................................... 9030-20-103
12864 Manual Hyd 3....................................................................................................................... 9030-20-99
12865 Manual Hyd 3..................................................................................................................... 9030-20-103
12868 Manual Hyd 4....................................................................................................................... 9030-20-99
12869 Manual Hyd 4..................................................................................................................... 9030-20-103
12872 Hydraulic Fluid Level............................................................................................................ 9030-20-48
12873 Hydraulic Fluid Level............................................................................................................ 9030-20-53
12876 Brake Pedal Sensor B OORL............................................................................................ 9030-20-552
12877 Brake Pedal Sensor B OORH............................................................................................ 9030-20-552
12928 Display Temperature Sensor (Freezer Option Only)......................................................... 9030-20-221
12929 Display Temperature Sensor (Freezer Option Only)......................................................... 9030-20-221
12934 Display Internal LCD Backlight........................................................................................... 9030-20-188
12935 Display Internal LCD Backlight........................................................................................... 9030-20-188
12936 Display Internal LCD Heater.............................................................................................. 9030-20-188
12937 Display Internal LCD Heater.............................................................................................. 9030-20-188
12938 Display Buzzer Output....................................................................................................... 9030-20-221
12939 Display Buzzer Output....................................................................................................... 9030-20-221
12940 Display Keyswitch Output.................................................................................................. 9030-20-195
12941 Display Keyswitch Output.................................................................................................. 9030-20-195
13056 5V OORL.............................................................................................................................. 9030-20-92
13057 5V OORH............................................................................................................................. 9030-20-92
13058 5V Internal Supply Out of Range....................................................................................... 9030-20-504
13060 VSM 12V OORL................................................................................................................. 9030-20-179
13061 VSM 12V OORH................................................................................................................ 9030-20-179
13070 Keyswitch Data Incorrect................................................................................................... 9030-20-195
13104 Sensor Ground Current OORH.......................................................................................... 9030-20-505
13312 Lift...................................................................................................................................... 9030-20-118
13316 Lower................................................................................................................................. 9030-20-118
13320 Tilt Forward........................................................................................................................ 9030-20-118
13324 Tilt Back............................................................................................................................. 9030-20-118
13328 Aux 1A................................................................................................................................ 9030-20-118
13332 Aux 1B................................................................................................................................ 9030-20-118
13336 Aux 2A................................................................................................................................ 9030-20-118
13340 Aux 2B................................................................................................................................ 9030-20-118
13344 Synch Steering Coil Open Circuit...................................................................................... 9030-20-418
13352 Diverter Valve..................................................................................................................... 9030-20-232
13356 Hyd Enable......................................................................................................................... 9030-20-232
13360 Acc 1 Relay........................................................................................................................ 9030-20-232
13364 Acc 2 Relay........................................................................................................................ 9030-20-232
13368 Motion Relay...................................................................................................................... 9030-20-232
13372 Reverse Relay.................................................................................................................... 9030-20-232
13376 Spare 1 Relay.................................................................................................................... 9030-20-232
13380 Brake Light Relay Short to B(-) or Open............................................................................ 9030-20-232
13384 Main Contactor................................................................................................................... 9030-20-232
13388 2nd Contactor..................................................................................................................... 9030-20-232

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General Maintenance and Diagnostic Data Electrical System

Diagnostic Trouble Code (DTC) Chart (Cont)

DTC DESCRIPTION PAGE NO.

16912 Motor Temperature High.................................................................................................... 9030-20-361
16912 Motor Temperature OORH................................................................................................. 9030-20-517
16913 Motor Temperature Sensor Open Circuit........................................................................... 9030-20-509
16914 Motor Temperature Sensor Short Circuit........................................................................... 9030-20-513
17168 Controller/Heatsink Temperature High.............................................................................. 9030-20-361
20753 15 Volt Supply Low Voltage............................................................................................... 9030-20-383
20755 5 Volt Supply Low/High Voltage......................................................................................... 9030-20-383
21008 Current Sensor Offset Calibration Error............................................................................. 9030-20-373
21520 Aux Driver Current High..................................................................................................... 9030-20-405
21521 Fan Driver Current OORH.................................................................................................. 9030-20-523
21522 Automatic Park Brake Driver Current OORH..................................................................... 9030-20-528
21569 Contactor Open.................................................................................................................. 9030-20-238
21570 Contactor Closed............................................................................................................... 9030-20-238
21760 VSM BOOT_BLOCK Checksum failure............................................................................. 9030-20-207
21761 CDF_Checksum_failure..................................................................................................... 9030-20-207
21762 VSM APPLICATION_SOFTWARE Checksum failure/Error.............................................. 9030-20-207
21764 VSM EEPROM Checksum failure/Error............................................................................. 9030-20-207
21766 VSM EEPROM Cell failure Write Error.............................................................................. 9030-20-207
21776 Internal Error - Hardware................................................................................................... 9030-20-526
21792 VSM Serial Number Error.................................................................................................. 9030-20-207
21830 MLM EEPROM Write Error................................................................................................ 9030-20-170
21834 MLM Sensor 1 Out of Range............................................................................................. 9030-20-170
21835 MLM Sensor 2 Out of Range............................................................................................. 9030-20-170
21836 MLM Sensor 3 Out of Range............................................................................................. 9030-20-170
21837 MLM Sensor 4 Out of Range............................................................................................. 9030-20-170
22032 Display EEPROM Checksum Error.................................................................................... 9030-20-188
22033 Display Cell Write Error...................................................................................................... 9030-20-188
22528 Display Button *.................................................................................................................. 9030-20-188
22529 Display Button #................................................................................................................. 9030-20-188
22530 Display \ Arrow................................................................................................................... 9030-20-188
22531 Display ] Arrow................................................................................................................... 9030-20-188
22532 Display Button 1................................................................................................................. 9030-20-188
22533 Display Button 2................................................................................................................. 9030-20-188
22534 Display Button 3................................................................................................................. 9030-20-188
22535 Display Button 4................................................................................................................. 9030-20-188
22536 Display Button 5................................................................................................................. 9030-20-188
22537 Display Button 6................................................................................................................. 9030-20-188
22538 Display Button 7................................................................................................................. 9030-20-188
22539 Display Button 8................................................................................................................. 9030-20-188
22540 Display Button 9................................................................................................................. 9030-20-188
22541 Display Button 0................................................................................................................. 9030-20-188
25104 Sensor Fault....................................................................................................................... 9030-20-267
25105 Temperature Sensor Failure.............................................................................................. 9030-20-361
25106 Park Brake Solenoid and Fan Driver Current High............................................................ 9030-20-405
25344 MLM Checksum Error........................................................................................................ 9030-20-170
29216 Speed Sensor High Current............................................................................................... 9030-20-530
29217 Speed Sensor Not Connected........................................................................................... 9030-20-532
29232 Sensor Supply Reference voltage Out of Range............................................................... 9030-20-527
29233 Sensor Supply Circuit Out of Range.................................................................................. 9030-20-534
29456 Sensor Fault....................................................................................................................... 9030-20-256

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Electrical System General Maintenance and Diagnostic Data

Diagnostic Trouble Code (DTC) Chart (Cont)

DTC DESCRIPTION PAGE NO.

29456 Sensor Fault....................................................................................................................... 9030-20-267
29536 Loss of Speed Sensor Channel A...................................................................................... 9030-20-536
29552 Loss of Speed Sensor Channel B...................................................................................... 9030-20-538
33024 CAN Communication Failure.............................................................................................. 9030-20-332
33025 VSM to Display................................................................................................................... 9030-20-123
33025 VSM to Display................................................................................................................... 9030-20-137
33025 VSM to Display................................................................................................................... 9030-20-155
33026 VSM to Traction 1 (Right)................................................................................................... 9030-20-123
33026 VSM to Traction 1 (Right)................................................................................................... 9030-20-137
33026 VSM to Traction 1 (Right)................................................................................................... 9030-20-155
33027 VSM to Traction 2 (Left)..................................................................................................... 9030-20-123
33027 VSM to Traction 2 (Left)..................................................................................................... 9030-20-137
33027 VSM to Traction 2 (Left)..................................................................................................... 9030-20-155
33029 VSM to Pump..................................................................................................................... 9030-20-123
33029 VSM to Pump..................................................................................................................... 9030-20-137
33029 VSM to Pump..................................................................................................................... 9030-20-155
33034 VSM to MLM (DCS)........................................................................................................... 9030-20-123
33034 VSM to MLM (DCS)........................................................................................................... 9030-20-137
33034 VSM to MLM (DCS)........................................................................................................... 9030-20-155
33035 VSM to Impact.................................................................................................................... 9030-20-123
33035 VSM to Impact.................................................................................................................... 9030-20-137
33035 VSM to Impact.................................................................................................................... 9030-20-155
33036 VSM to CAN Reserved 1................................................................................................... 9030-20-123
33036 VSM to CAN Reserved 1................................................................................................... 9030-20-137
33036 VSM to CAN Reserved 1................................................................................................... 9030-20-155
33037 VSM to CAN Reserved 2................................................................................................... 9030-20-123
33037 VSM to CAN Reserved 2................................................................................................... 9030-20-137
33037 VSM to CAN Reserved 2................................................................................................... 9030-20-155
33038 VSM to CAN Reserved 3................................................................................................... 9030-20-123
33038 VSM to CAN Reserved 3................................................................................................... 9030-20-137
33038 VSM to CAN Reserved 3................................................................................................... 9030-20-155
33040 Various CAN Errors............................................................................................................ 9030-20-556
33050 E-Steer CAN Communications Failure Right..................................................................... 9030-20-499
33051 E-Steer CAN Communications Failure Left........................................................................ 9030-20-499
33056 Display Internal CAN Failure.............................................................................................. 9030-20-188
33057 Display to VSM................................................................................................................... 9030-20-123
33057 Display to VSM................................................................................................................... 9030-20-137
33057 Display to VSM................................................................................................................... 9030-20-155
33057 Display Communications Error with VSM.......................................................................... 9030-20-188
4096 Hydraulic Calibration Required.......................................................................................... 9030-20-379
4098 Steer Axle Calibration.......................................................................................................... 9030-20-35
4112 Incorrect Lever 1 Installed.................................................................................................. 9030-20-176
4113 Incorrect Lever 2 Installed.................................................................................................. 9030-20-176
4114 Incorrect Lever 3 Installed.................................................................................................. 9030-20-176
4115 Incorrect Lever 4 Installed.................................................................................................. 9030-20-176
4116 Incorrect Lever 5 Installed.................................................................................................. 9030-20-176
4117 FOC Configuration Mismatch............................................................................................. 9030-20-554
65280 Controller Failure................................................................................................................ 9030-20-306
65288 Loss of Communication Between the Primary and Secondary Controller......................... 9030-20-422
65293 EEPROM Checksum Failure.............................................................................................. 9030-20-423

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General Maintenance and Diagnostic Data Electrical System

Diagnostic Trouble Code (DTC) Chart (Cont)

DTC DESCRIPTION PAGE NO.

65296 Motor U-W Phase Voltage Measurement Fault................................................................. 9030-20-427
65297 Motor U-V Phase Voltage Measurement Fault.................................................................. 9030-20-429
65299 Controller Logic Failure...................................................................................................... 9030-20-213
65310 VMN Low............................................................................................................................ 9030-20-548
65311 VMN High........................................................................................................................... 9030-20-548
65312 Motor Phase Voltage Out of Range................................................................................... 9030-20-433
65317 Contactor Closed............................................................................................................... 9030-20-238
65318 Contactor Open.................................................................................................................. 9030-20-238
65333 Standby Current Too High................................................................................................. 9030-20-435
65333 Standby Current High......................................................................................................... 9030-20-548
65340 DC Bus Capacitor Charge Timeout.................................................................................... 9030-20-436
65341 Controller Temperature Above Limit.................................................................................. 9030-20-439
65341 Controller Internal Temperature OORH............................................................................. 9030-20-521
65341 Controller Internal Temperature OORL.............................................................................. 9030-20-522
65342 Thermal Protection / Motor Temperature High.................................................................. 9030-20-521
65345 Motor Temperature Above Limit......................................................................................... 9030-20-440
65346 Battery Low........................................................................................................................ 9030-20-540
65350 Controller Internal Error...................................................................................................... 9030-20-443
65350 Motor Phase W Current OORL.......................................................................................... 9030-20-459
65351 Motor Phase V Current OORL........................................................................................... 9030-20-461
65352 Motor W-V Phase Voltage Measurement Fault................................................................. 9030-20-431
65353 Motor Phase U Current OORL........................................................................................... 9030-20-463
65354 Driver Shorted High............................................................................................................ 9030-20-238
65355 Driver Shorted Low............................................................................................................ 9030-20-238
65362 Encoder Error..................................................................................................................... 9030-20-536
65362 Encoder Error..................................................................................................................... 9030-20-538
65378 Steering Wheel Position Error............................................................................................ 9030-20-472
65481 Wrong Slave Version......................................................................................................... 9030-20-547
65486 Initial VMN High................................................................................................................. 9030-20-548
65487 Controller Internal Error...................................................................................................... 9030-20-444
65488 Controller Internal Error...................................................................................................... 9030-20-445
65489 Controller Internal Error...................................................................................................... 9030-20-458
65490 Primary and Secondary Controller Version Mismatch....................................................... 9030-20-446
65491 TFD Current within Range but Lower than Expected........................................................ 9030-20-474
65492 Controller Internal Error...................................................................................................... 9030-20-447
65493 Default Parameter Restore................................................................................................ 9030-20-448
65494 Rapid Change in Steering Wheel Position......................................................................... 9030-20-468
65495 Controller Internal Error...................................................................................................... 9030-20-449
65496 Controller Internal Error...................................................................................................... 9030-20-450
65496 TFD Resistance Out of Range........................................................................................... 9030-20-476
65498 Controller Software Mismatch............................................................................................ 9030-20-457
65500 Steering Motor Locked....................................................................................................... 9030-20-482
65501 Controller Internal Error...................................................................................................... 9030-20-451
65503 Rapid Change in Steer Axle Position................................................................................. 9030-20-494
65504 Waiting for Node................................................................................................................ 9030-20-550
65505 Controller Internal Error...................................................................................................... 9030-20-452
65508 Steer Axle Position Mismatch............................................................................................ 9030-20-486
65511 No Slave Enabled.............................................................................................................. 9030-20-547
65512 Wrong Encoder Set............................................................................................................ 9030-20-536
65512 Wrong Encoder Set............................................................................................................ 9030-20-538

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Electrical System General Maintenance and Diagnostic Data

Diagnostic Trouble Code (DTC) Chart (Cont)

DTC DESCRIPTION PAGE NO.

65513 Power MOS Shorted.......................................................................................................... 9030-20-288
65515 TFD Short to battery Negative........................................................................................... 9030-20-478
65516 TFD Stand-by Current OORH............................................................................................ 9030-20-480
65517 Controller Internal Error...................................................................................................... 9030-20-453
65519 Controller Mismatch........................................................................................................... 9030-20-547
65521 Steer Axle Slow Response................................................................................................ 9030-20-484
65522 Parameter Transfer............................................................................................................ 9030-20-547
65524 Primary and Secondary Parameter Mismatch................................................................... 9030-20-498
65525 Controller Internal Error...................................................................................................... 9030-20-454
65526 Aux Driver Open................................................................................................................. 9030-20-420
65527 No CAN Communication.................................................................................................... 9030-20-324
65527 Loss of CAN Communication............................................................................................. 9030-20-499
65528 Steer Wheel Sensor Output Mismatch............................................................................... 9030-20-470
65529 Check Up Needed.............................................................................................................. 9030-20-542
65530 Controller Internal Error...................................................................................................... 9030-20-455
65531 Controller Initialization Test Failed..................................................................................... 9030-20-465
65532 Steer Axle Sensor Output Mismatch.................................................................................. 9030-20-490
65533 Controller Internal Error...................................................................................................... 9030-20-456
65534 Aux Driver Short................................................................................................................. 9030-20-420
8704 Display Internal LCD Backlight........................................................................................... 9030-20-188
8705 Display Internal LCD Heater.............................................................................................. 9030-20-188
8786 Brake Coil Shorted............................................................................................................. 9030-20-279
8960 Lift...................................................................................................................................... 9030-20-113
8964 Lower................................................................................................................................. 9030-20-113
8968 Tilt Forward........................................................................................................................ 9030-20-113
8972 Tilt Back............................................................................................................................. 9030-20-113
8976 AC Current – Over Current................................................................................................ 9030-20-313
8978 Aux 1A................................................................................................................................ 9030-20-113
8980 Aux 1B................................................................................................................................ 9030-20-113
8984 Aux 2A................................................................................................................................ 9030-20-113
8988 Aux 2B................................................................................................................................ 9030-20-113
8992 Synchronous Steering Coil Current................................................................................... 9030-20-417
9000 Diverter Valve..................................................................................................................... 9030-20-227
9004 E Hyd Enable..................................................................................................................... 9030-20-227
9008 Clamp Solenoid (Optional)................................................................................................. 9030-20-227
9012 Acc 2 Relay........................................................................................................................ 9030-20-227
9012 ACC 2 Current OORH........................................................................................................ 9030-20-420
9016 Forward Relay.................................................................................................................... 9030-20-227
9020 Reverse Relay.................................................................................................................... 9030-20-227
9024 AC Current – Short Circuit................................................................................................. 9030-20-313
9026 Spare 1 Relay.................................................................................................................... 9030-20-227
9028 Spare 2 Relay.................................................................................................................... 9030-20-227
9032 Main Contactor................................................................................................................... 9030-20-227
9036 2nd Contactor..................................................................................................................... 9030-20-227
9040 Display Buzzer Output....................................................................................................... 9030-20-221
9041 Display Keyswitch Output.................................................................................................. 9030-20-195
9045 Internal Error - Software..................................................................................................... 9030-20-503
95360 Forw + Back....................................................................................................................... 9030-20-543
95520 Key Switch Voltage OORL................................................................................................. 9030-20-424
None No Display/No Truck Operation............................................................................................. 9030-30-1

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General Maintenance and Diagnostic Data Electrical System

Diagnostic Trouble Code (DTC) Chart (Cont)

DTC DESCRIPTION PAGE NO.

None Motor Controller Fan Failure.................................................................................................. 9030-30-8
None Motor/Motor Controller Temperature Sensor Failure........................................................... 9030-30-21

Wiring Reference Data

NOTE: When troubleshooting the electrical wir- • Wires which are connected only through an in-
ing harness for your lift truck, the wire connectors ternal connection in a controller shall have sep-
may be different but the pin numbers for the con- arate Function ID numbers.
nectors are the same between the different con- • Wire Function ID numbers will be stamped at
nectors. 50mm intervals along the wire length.

Function/Circuit Identification — A standard num- • The Function IDs are assigned into groups as
bering and color-coding system is used in the lift truck shown in the table. Unless noted otherwise,
wiring. This system will simplify repairs. The Electrical specific functions are to be preassigned to
Circuit Identification Specification is ES-1359. The ID unique Function IDs.
data is described in Table 9030-03-1. If a circuit function does not meet one of the preas-
signed numbers, and its function is unique within the
Each circuit Function ID has a number from 1 through truck series and option, then a number from the “Non-
999, as indicated in the Table 9030-03-1. Standard Functions” range may be used.
• A circuit labeled with a single numerical Func-
tion ID shall be electrically equivalent through-
out the harness (physically connected through
splices or connectors).

Table 9030-03-1. Circuit Group Identification

Function/Group Number Range

Grounds (IDs not preassigned within this range) 101-149
Current sense ground 150-199
Switched B+ (IDs not preassigned within this range) 200-239
Fused B+ (IDs not preassigned within this range) 240-249
Regulated Power 5V (IDs not preassigned within this range) 250-279
Regulated Power 12V 280-299
Analog Inputs – hydraulics / mast 300-319
Analog Inputs – chassis 320-339
Analog Inputs – powertrain 340-399
Analog Inputs – CAB / OHG 400-419
Reserved for additional analog inputs 420-499
Digital inputs – hydraulics / mast 500-509

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Electrical System General Maintenance and Diagnostic Data

Table 9030-03-1. Circuit Group Identification (Continued)

Function/Group Number Range

Digital inputs – chassis 510-539
Digital inputs – powertrain 540-559
Digital inputs – CAB / OHG 560-569
Encoder inputs 570-599
Reserved for additional digital inputs 600-699
Digital outputs – hydraulics / mast 700-719
Digital outputs – chassis 720-749
Digital outputs – powertrain 750-779
Digital outputs – CAB /OHG 780-799
PWM outputs – hydraulics / mast 800-829
PWM outputs – chassis 830-839
PWM outputs – powertrain 840-889
PWM outputs – CAB / OHG 890-899
Communications (eg., CANbus) 900-909
Non-Standard functions 910-999

Wiring Color Codes — The colors used to identify Table 9030-03-2. Hyster Wiring Color Codes
the lift truck wiring, in addition to the surface marked
circuit ID data, are identified in Table 9030-03-2. Color Use/Function
Many Diagrams and Schematics in this book can be Red Battery-level power
viewed and printed in color. If not printed or viewed in circuits
color refer to the electrical circuit identification located
Black Heavy current grounds
on schematic circuits. When viewing a color version of
the diagrams and schematics, the white chassis wires Green Signal grounds
are seen as yellow. Other wires are shown in colors White Other circuits
similar to actual colors, i.e., tan shows as yellow. Use
Twisted Pair (Yellow/Green) Preferred CAN Option
circuit identification for true wire color. MONOTROL® ,
Yellow CAN-Hi
wiring to sensors and other applications vary with re-
Green CAN-Lo
spect to wire colors.
Twisted Pair (Yellow/Green) Non-Preferred CAN
White Option
White CAN-Hi
CAN-Lo

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General Maintenance and Diagnostic Data Electrical System

Symbol Definitions each circuit ID has a suffix. The circuit connects to all
Type "S", Identifies information for UL Safety other wires in the vehicle with the same circuit ID
rated trucks. number. For example, 42-A will be connected to 42-B,
42-J, etc. Function ID numbers appear with suffix let-
Arrow Symbols, Go to specified page of sche- ters, the base number is not used by itself. For exam-
matic. Page number is located in the “hexagon ple, when labeling a circuit #42, start with “42-A”
symbol” on schematic. rather than “42”. Suffix letters should be assigned
---x, Go to specified sheet of diagram. Sheet from “A” to “Z” (but “Q” and “V” are not used). Addi-
number is located in lower right corner of fig- tional branches beyond “Z” to be assigned as “AA”,
ure. AB”, etc. If a Suffix is used, the parts of the circuit
identification number will be separated by dashes. For
Circuit Segment Suffix Letter — A circuit ID has a example:
segment suffix letter as required (splices or passing
through a connector). Each circuit ID is unique and

WIRE # 751 (RED), SEGMENTED, SUFFIX LET- WIRE #S 383, 384 (WHITE), NON-SEGMENTED,
TERS A, O, P TWISTED PAIR, SUFFIX LETTER A (SHOWN
WIRE # 870 (WHITE), NON-SEGMENTED, SUF- WITH SHIELD THAT TERMINATES AT PIN B2)
FIX LETTER A

Figure 9030-03-2. Single Wiring Sample Circuit

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Electrical System General Maintenance and Diagnostic Data

WIRE # 751 (RED), SEGMENTED, SUFFIX LET- WIRE #S 383, 384, 387, AND 388 (WHITE),
TERS A, O, P NON-SEGMENTED, TWISTED PAIR, SUFFIX
WIRE # 870, 871 (WHITE), NON-SEGMENTED, LETTER A (SHOWN WITH SHIELD THAT TER-
SUFFIX LETTER A MINATES AT PIN B2)

Figure 9030-03-3. Dual Wiring Sample Circuit

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General Maintenance and Diagnostic Data Electrical System

Harness Assembly Data

This section depicts the lift truck harness assemblies • Wire Harness Turn Signal Figure 9030-03-15
with their respective connector identifications. The • Wire Harness Synchro Steer Fig-
harnesses are arranged as follows: ure 9030-03-16
• Wire Harness – Auxiliary Key Switch Fig- • Wire Harness Park Brake Figure 9030-03-17
ure 9030-03-4
• Wire Harness LH OHG w/Turn Signals Fig-
• Wire Harness Steering Figure 9030-03-5 ure 9030-03-18
• Display Wire Harness Standard Fig- • Wire Harness Steering Column Fig-
ure 9030-03-6 ure 9030-03-19
• Display Wire Harness Freezer Fig- • Wire Harness Lights w/OHG - RH Fig-
ure 9030-03-7 ure 9030-03-20
• Wire Harness Main Electro – Hydraulic Fig- • Wire Harness Lights Chassis Main Fig-
ure 9030-03-8 ure 9030-03-21
• Wire Harness Main Manual – Hydraulic Fig- • Wire Harness Seat E-Hydraulic Fig-
ure 9030-03-9 ure 9030-03-22
• Wire Harness Front Switch Figure 9030-03-10 • Wire Harness Seat Manual-Hydraulic Fig-
• Wire Harness Back Up Alarm Strobe w/o ure 9030-03-23
[Link] 9030-03-11 • Wire Harness Main w/Manual – Hydraulic Fig-
• Wire Harness Lights LH - OHG Fig- ure 9030-03-24
ure 9030-03-12 • Wire Harness Main w/E – Hydraulic Fig-
• Wire Harness Manual Hydraulics Fig- ure 9030-03-25
ure 9030-03-13
• Wire Harness Display Freezer Fig-
ure 9030-03-14

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Electrical System General Maintenance and Diagnostic Data

1. T115 FUSE BLOCK 3. T114 KEY SWITCH

2. T116 FUSE BLOCK 4. T113 KEY SWITCH

Figure 9030-03-4. J1.5-2.0XNT (J30-40XNT) (K160) ; Wire Harness – Auxiliary Key Switch

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General Maintenance and Diagnostic Data Electrical System

1. TF15 HORN SWITCH NO 5. CPS128 STEER MAKE-UP VALVE

2. TF14 HORN SWITCH C 6. CRP132 MAIN HARNESS
3. CPS78 STEERING WHEEL POSITION SENSOR 7. CRP133 MAIN HARNESS
4. CPS28 DIAGNOSTIC CONNECTION

Figure 9030-03-5. J1.5-2.0XNT (J30-40XNT) (K160) ; Wire Harness Steering

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Electrical System General Maintenance and Diagnostic Data

1. CRP135 MAIN HARNESS 4. CPS103 RIGHT FRONT WORK LIGHT

2. CRP180 MAIN HARNESS 5. CPS166 RIGHT FRONT MARKER LIGHT
3. CPS20 DISPLAY 6. BUZZER
Figure 9030-03-6. J1.5-2.0XNT (J30-40XNT) (K160) ; Display Wire Harness Standard

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General Maintenance and Diagnostic Data Electrical System

1. CRP135 MAIN HARNESS 5. CPS166 RIGHT FRONT MARKER LIGHT

2. CRP180 MAIN HARNESS 6. CPS165 TEMPERATURE SENSOR
3. CPS20 DISPLAY 7. BUZZER
4. CPS103 RIGHT FRONT WORK LIGHT
Figure 9030-03-7. J1.5-2.0XNT (J30-40XNT) (K160) ; Display Wire Harness Freezer

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Electrical System General Maintenance and Diagnostic Data

Figure 9030-03-8. J1.5-2.0XNT (J30-40XNT) (K160) ; Wire Harness Main Electro – Hydraulic

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General Maintenance and Diagnostic Data Electrical System

Legend for Figure 9030-03-8

1. CPS31A STEER AXLE HARNESS 28. CPS156 RIGHT CONTROL COOLING FAN
2. CPS5 PUMP CONTROLLER 29. TR65 B-CONT.
3. CPS95B HYDRAULIC COOLING FAN 30. CPS3 RIGHT TRACTION MOTOR CONTROL-
4. CPS95A HYDRAULIC CONTROLLER COOLING LER
FAN 31. CPS74 E HYDRAULIC VALVE UPPER COILS
5. CPS146 MOTOR SPEED SENSOR 32. CPS75 E HYDRAULIC VALVE LOWER COILS
6. CPS61 MOTOR TEMPERATURE SENSOR 33. CPS10 LIFT PRESSURE SENSOR
7. CRP52-55 MLM SEAT HARNESS 34. CPS102 BATTERY GATE MAGNETIC SWITCH
8. TF67 ESD HYDRAULIC TANK 35. CPS153 RIGHT TRACTION MOTOR SPEED
9. CPS114 OHG HORN SWITCH SENSOR
10. CPS135 DISPLAY HARNESS 36. CRP8 TILT POSITION SENSOR
11. CPS180 DISPLAY LIGHT HARNESS 37. CPS24 RIGHT ELECTRIC BRAKE
12. TF72 FLASHER − 38. CPS155 RIGHT TRACTION MOTOR TEMPERA-
13. TF71 FLASHER + TURE SENSOR
14. TF70 FLASHER L 39. CPS1 VSM
15. CRP206 RR WORK LIGHT SWITCH 40. CPS2 VSM
16. CRP205 NO MARK LIGHT SWITCH 41. CPS272 ACCELERATOR JUMPER
17. CPS133 STEER MAKE UP VALVE 42. TR3 MN CONTACT BATTERY +
18. CPS132 STEER HARNESS 43. CPS152 LEFT TRACTION SPEED SENSOR
19. CPS134 TURN SIGNAL SWITCH 44. TF11 MN CONTROLLER COIL
20. CPS138 LIGHT OPTION HARNESS 45. TF10 MN CONTROLLER COIL
21. CPS90 DC-DC CONVERTER 46. CPS26 LEFT ELECTRIC BRAKE
22. CPS157 LEFT CONTROL COOLING FAN 47. CPS154 LEFT TRACTION MOTOR SENSOR
23. CPS4 LEFT TRACTION MOTOR CONTROLLER 48. CRS110 BRAKE LIGHT RELAY
24. CPS11 SERV. BRAKE SENSOR 49. CRS209 E HYDRAULIC EN-RELAY
25. TBF3 BRAKE FLUID LEVEL SENSOR 50. CRS210 BACK UP LIGHT RELAY
26. TBF4 BRAKE FLUID LEVEL SENSOR 51. CRS208 KEY SWITCH RELAY
27. CPS151 HORN ASM 52. FUSES

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Electrical System General Maintenance and Diagnostic Data

Figure 9030-03-9. J1.5-2.0XNT (J30-40XNT) (K160) ; Wire Harness Main Manual – Hydraulic

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General Maintenance and Diagnostic Data Electrical System

Legend for Figure 9030-03-9

1. CPS31A STEER AXLE HARNESS 29. TR65 B-CONT.

2. CPS5 PUMP CONTROLLER 30. CPS3 RIGHT TRACTION MOTOR CONTROL-
3. CPS95B HYDRAULIC COOLING FAN LER
4. CPS95A HYDRAULIC CONTROLLER COOLING 31. CPS162 MANUAL HYDRAULIC SPOOL POSI-
FAN TION SENSOR
5. CPS146 MOTOR SPEED SENSOR 32. CPS10 LIFT PRESSURE SENSOR
6. CPS61 MOTOR TEMPERATURE SENSOR 33. CPS192 TO MAN. HYDRAULIC
7. CRP52-55 MLM SEAT HARNESS 34. CPS190B CLAMP INTERLOCK COIL
8. TF67 ESD HYDRAULIC TANK 35. CPS102 BATTERY GATE MAGNETIC SWITCH
9. CPS114 OHG HORN SWITCH 36. CPS160B SPOOL INTERLOCK SOLENOID 2
10. CPS135 DISPLAY HARNESS 37. CPS160A SPOOL INTERLOCK SOLENOID 1
11. CPS180 DISPLAY LIGHT HARNESS 38. CPS153 RIGHT TRACTION MOTOR SPEED
12. TF72 FLASHER (-) SENSOR
13. TF71 FLASHER (+) 39. CPS155 RIGHT TRACTION MOTOR TEMPERA-
14. TF70 FLASHER (L) TURE SENSOR
15. CRP206 RR WORK LIGHT SWITCH 40. CPS24 RIGHT ELECTRIC BRAKE
16. CRP205 NO MARK LIGHT SWITCH 41. CPS1 VSM
17. CPS133 STEER MAKE UP VALVE 42. CPS2 VSM
18. CPS132 STEER HARNESS 43. CPS272 ACCELERATOR JUMPER
19. CPS134 TURN SIGNAL SWITCH 44. TR3 MN CONTACT BATTERY +
20. CPS138 LIGHT OPTION HARNESS 45. CPS154 LEFT TRACTION MOTOR SENSOR
21. CPS90 DC-DC CONVERTER 46. CPS26 LEFT ELECTRIC BRAKE
22. CPS157 LEFT CONTROL COOLING FAN 47. TF11 MN CONTROLLER COIL
23. CPS4 LEFT TRACTION MOTOR CONTROLLER 48. TF10 MN CONTROLLER COIL
24. CPS11 SERV. BRAKE SENSOR 49. CPS152 LEFT TRACTION SPEED SENSOR
25. TBF3 BRAKE FLUID LEVEL SENSOR 50. CRS110 BRAKE LIGHT RELAY
26. TBF4 BRAKE FLUID LEVEL SENSOR 51. CRS210 BACK UP LIGHT RELAY
27. CPS151 HORN ASM 52. CRS208 KEY SWITCH RELAY
28. CPS156 RIGHT CONTROL COOLING FAN 53. FUSES

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Electrical System General Maintenance and Diagnostic Data

1. CRP206 REAR WORK LIGHT 3. CRP211 HARNESS-LIGHT CHASSIS MAIN

2. CRP205 FRONT WORK LIGHT/TAIL LIGHT

Figure 9030-03-10. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness – Front
Switch

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General Maintenance and Diagnostic Data Electrical System

1. CRP112 BACK UP ALARM 3. CRP210 REVERSE RELAY

2. CRP137 MAIN HARNESS 4. CRP138 LIGHT OPTION HARNESS

Figure 9030-03-11. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness – Back Up
Alarm Strobe w/o Conv.

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Electrical System General Maintenance and Diagnostic Data

1. CPS106 TAIL LIGHT RH 5. CPS107 DOME LIGHT W/SWITCH

2. CPS87 STROBE LIGHT 6. CPS104 WORK LIGHT FRONT LH
3. CPS116 REAR WORK LIGHT 7. CRP138 MAIN LIGHT HARNESS
4. CPS105 TAIL LIGHT LH
Figure 9030-03-12. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Lights LH -
OHG

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General Maintenance and Diagnostic Data Electrical System

1. CRP64 FWD/REV SWITCH 3. CRP129 TO MAIN HARNESS

2. CRS196 CLAMP COIL SWITCH

Figure 9030-03-13. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Manual
Hydraulics

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Electrical System General Maintenance and Diagnostic Data

1. CPS20 DISPLAY W/KEY SWITCH 4. CPS166 FRONT MARKER RH

2. CPS21 WIRE HARNESS TEMPERATURE SEN- 5. CRP180 MAIN LIGHTS HARNESS
SOR 6. CRP135 MAIN HARNESS
3. CPS103 RH FRONT WORK LIGHT

Figure 9030-03-14. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Display
Freezer

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General Maintenance and Diagnostic Data Electrical System

1. CPS35 TO TURN SIGNAL SWITCH HARNESS 4. CPS180A TO DISPLAY FREEZER HARNESS

2. CRP131 WIRE HARNESS LH -OHG W/TURN 5. CRP180A TO LIGHT MAIN HARNESS
SIGNALS
3. CRS220 FLASHER

Figure 9030-03-15. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Turn Wire Harness Signal

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Electrical System General Maintenance and Diagnostic Data

1. CPS128 STEER MAKEUP VALVE 2. CRP133 MAIN HARNESS

Figure 9030-03-16. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Synchro
Steer

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General Maintenance and Diagnostic Data Electrical System

1. CPS16 PARK BRAKE MODULE 3. CRP15 MAIN HARNESS

2. CRS17 PARK BRAKE SOLENOID

Figure 9030-03-17. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Park Brake

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Electrical System General Maintenance and Diagnostic Data

1. CPS106 TAIL LIGHT RH 6. CPS104 WORK LIGHT FRONT LH

2. CPS87 STROBE LIGHT 7. CRP34 LH FRONT MARKER
3. CPS116 REAR WORK LIGHT 8. CRP138 MAIN LIGHT HARNESS
4. CPS105 TAIL LIGHT LH 9. CPS131 TO TURN SIGNAL HARNESS
5. CPS107 DOME LIGHT
Figure 9030-03-18. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness - LH OHG w/
Turn Signals

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General Maintenance and Diagnostic Data Electrical System

1. TF15 HORN SWITCH NO 4. CPS28 DIAGNOSTIC CONNECTOR

2. TF14 HORN SWITCH C 5. CRP132 MAIN HARNESS
3. CPS78 STEER WHEEL POSITION SENSOR

Figure 9030-03-19. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Steering
Column

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Electrical System General Maintenance and Diagnostic Data

1. CPS103 WORK LIGHT FRONT RH 3. CRP135 DISPLAY HARNESS

2. CPS20 DISPLAY W/KEY SWITCH 4. CRP180 DISPLAY LIGHT HARNESS

Figure 9030-03-20. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Lights
w/OHG - RH

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-03-35
General Maintenance and Diagnostic Data Electrical System

1. TFK80 FUSE 2 6. CPS138 WIRE HARNESS LIGHTS LH - OHG

2. CPS112 BACK UP ALARM 7. CPS211 HARNESS LIGHT SWITCH
3. CPS90 DC - DC CONVERTER 8. CPS180 DISPLAY LIGHT HARNESS
4. CRS210 BRAKE LIGHT RELAY 9. CRP137 MAIN HARNESS
5. CRS110 REVERSE RELAY

Figure 9030-03-21. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Lights
Chassis Main

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Electrical System General Maintenance and Diagnostic Data

1. CRP54 MAIN HARNESS 3. CPS55 SEAT SENSOR

2. CPS52 MLM SEAT HARNESS

Figure 9030-03-22. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Seat E-
Hydraulic

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-03-37
General Maintenance and Diagnostic Data Electrical System

1. CRP54 MAIN HARNESS 2. CRP55 SEAT HARNESS

Figure 9030-03-23. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Seat
Manual-Hydraulic

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Electrical System General Maintenance and Diagnostic Data

Figure 9030-03-24. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Main w/
Manual – Hydraulic

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-03-39
General Maintenance and Diagnostic Data Electrical System

Legend for Figure 9030-03-24

1. CPS114 OHG HORN SWITCH 23. CPS154 TRACTION MOTOR TEMPERATURE

2. CPS54 SEAT HARNESS SENSOR
3. CPS157 CONTROLLER FAN 24. CPS152 TRACTION MOTOR SPEED SENSOR
4. CPS95 CONTROLLER FAN 25. CPS61 PUMP MOTOR TEMPERATURE SEN-
5. TFK78 FUI SOR
6. TF10 MAIN CONNECTOR COIL 26. CPS146 PUMP MOTOR SPEED SENSOR
7. TF11 MAIN CONNECTOR COIL 27. CRS212 SYNC. STEER VALVE RELAY
8. TR65 NEGATIVE TERMINAL TRACTION CON- 28. CRS208 KEY SWITCH RELAY
TROLLER 29. TF04 BRAKE FLUID LEVEL
9. CPS5 PUMP CONTROLLER 30. TF03 BRAKE FLUID LEVEL
10. CPS3 TRACTION MOTOR CONTROLLER 31. CPS11 SERVICE BRAKE PRESSURE SENSOR
11. CPS31 STEER AXLE SENSOR 32. CPS2 VSM
12. CPS102 BATTERY GATE MAGNETIC SWITCH 33. CSP1 VSM
13. CPS135 DISPLAY HARNESS 34. CPS151 HORN ASSEMBLY
14. CPS191 CLAMP COIL 35. CPS133 SYNC. STEER VALVE HARNESS
15. CPS161 MANUAL HYDRAULIC COIL 36. CPS142 TERMINATION RESISTOR
16. CPS160 MANUAL HYDRAULIC COIL 37. CPS512 PARK BRAKE POSITION
17. CPS137 LIGHT OPTION HARNESS 38. CPS132 STEER HARNESS
18. CPS29 ACCELERATOR PEDAL POSITION 39. CPS8 TILT POSITION SENSOR
SENSOR 40. CPS70 HYD. OIL LEVEL SENSOR
19. CPS65 DIRECTION SELECT SENSOR 41. CPS66 HYD. FILTER PRESSURE SWITCH
20. CPS10 LIFT PRESSURE 42. CPS14 HYD. OIL TEMPERATURE SENSOR
21. CPS162 MANUAL HYDRAULIC SPOOL POSI- 43. CPS192 MANUAL HYD. HARNESS
TION SENSOR
22. CPS15 PARK BRAKE

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Electrical System General Maintenance and Diagnostic Data

Figure 9030-03-25. E2.2-3.5XN (E45-70XN) (A268); J2.2-3.5XN (J40-70XN) (A276) Wire Harness Main w/E –
Hydraulic

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-03-41
General Maintenance and Diagnostic Data Electrical System

Legend for Figure 9030-03-25

1. CPS114 OHG HORN SWITCH 22. CRS212 SYNC. STEER VALVE RELAY
2. CPS54 SEAT HARNESS 23. CRS209 E-HYDRAULIC ENABLE RELAY
3. CPS157 CONTROLLER FAN 24. TF03 BRAKE FLUID LEVEL
4. CPS95 CONTROLLER FAN 25. TF04 BRAKE FLUID LEVEL
5. TFK78 FUI 26. CPS11 SERVICE BRAKE PRESSURE SENSOR
6. TFK67 ESD TRUCK FRAME 27. CPS2 VSM
7. TF10 MAIN CONNECTOR COIL 28. CSP1 VSM
8. TF11 MAIN CONNECTOR COIL 29. CPS151 HORN ASSEMBLY
9. TR65 NEGATIVE TERMINAL TRACTION CON- 30. CPS133 SYNC. STEER VALVE HARNESS
TROLLER 31. CPS142 TERMINATION RESISTOR
10. CPS3 TRACTION MOTOR CONTROLLER 32. CPS132 STEER HARNESS
11. CPS5 PUMP CONTROLLER 33. CPS512 PARK BRAKE POSITION
12. CPS31 STEER AXLE SENSOR 34. CPS70 HYD. OIL LEVEL SENSOR
13. CPS102 BATTERY GATE MAGNETIC SWITCH 35. CPS8 TILT POSITION SENSOR
14. CPS135 DISPLAY HARNESS 36. CPS66 HYD. FILTER PRESSURE SWITCH
15. CPS137 LIGHT OPTION HARNESS 37. CPS14 HYD. OIL TEMPERATURE SENSOR
16. CPS75 E-HYDRAULIC LOWER COIL 38. CPS146 PUMP MOTOR SPEED SENSOR
17. CPS74 E-HYDRAULIC UPPER COIL 39. CPS61 PUMP MOTOR TEMPERATURE SEN-
18. CPS10 LIFT PRESSURE SOR
19. CPS65 DIRECTION SELECT SENSOR 40. CPS152 TRACTION MOTOR SPEED SENSOR
20. CPS29 ACCELERATOR PEDAL POSITION 41. CPS154 TRACTION MOTOR TEMPERATURE
SENSOR SENSOR
21. CRS208 KEY SWITCH RELAY 42. CPS15 PARK BRAKE

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Electrical System General Maintenance and Diagnostic Data

Figure 9030-03-26. A1.3XNT, A1.5XNT (A25XNT, A30XNT) [D203] Main Harness Assembly

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-03-43
General Maintenance and Diagnostic Data Electrical System

Legend for Figure 9030-03-26

1. CPS114 OHG HORN SWITCH 24. TF04 BRAKE FLUID LEVEL

2. CRP54 PREMIUM SEAT HORN SWITCH 25. TF03 BRAKE FLUID LEVEL
3. CRP57 SEAT BELT SWITCH HARNESS 26. TS67 B(-) PUMP MOTOR
4. CPS154 TRACTION MOTOR TEMPERATURE 27. CPS146 PUMP MOTOR SOLENOID
SENSOR 28. CPS61 PUMP MOTOR TEMPERATURE SEN-
5. CPS152 TRACTION MOTOR SPEED SENSOR SOR
6. TF11 MAIN CONTACTOR COIL 29. CPS5 PUMP CONTROLLER
7. TF10 MAIN CONTACTOR COIL 30. CRP12 PARK BRAKE SWITCH CONNECTOR
8. CPS94 TRACTION CONTROLLER FAN 31. CPS12 PARK BRAKE SWITCH CONNECTOR
9. CPS3 TRACTION CONTROLLER 32. CRP132 STEER HARNESS CONNECTOR
10. B(-) STUD TRACTION CONTROLLER 33. CPS78 STEER WHEEL POSITION SENSOR
11. CPS87 STROBE CONNECTOR 34. TF15 / TF14 HORN SWITCH
12. TS65 FRAME GROUND B(-) 35. CPS28 DIAGNOSTIC CONNECTOR
13. TFK78 FUSE FU1 36. CPS29 ACC PEDAL POSITION SENSOR
14. CRS208 KEY SWITCH RELAY 37. CPS65 DIRECTION SELECTOR SENSOR
15. CPS31 STEER AXLE POSITION SENSOR 38. CPS160-161 HYDRAULIC COIL CONNECTORS
16. CRS210 REVERSE RELAY 39. CPS162 HYDRAULIC SPOOL SENSOR
17. CPS6 VSM CONNECTOR 40. CPS192 MANUAL LEVER HARNESS
18. CPS7 VSM CONNECTOR 41. CRP135 DISPLAY HARNESS
19. CPS1 VSM CONNECTOR 42. CRP136 SIG. DISPLAY HARNESS
20. CPS2 VSM CONNECTOR 43. CPS151 HORN CONNECTOR
21. CPS96 PUMP CONTROLLER FAN 44. B(-) HORN GND
22. CPS95 PUMP CONTROLLER FAN 45. CPS20 DISPLAY CONNECTOR
23. CPS14 HYDRAULIC OIL TEMPERATURE SEN- 46. KEY SWITCH
SOR

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Electrical System Principles of Operation

Group 10

Principles of Operation

Electrical System
GENERAL DESCRIPTION
The major components in the electrical system are
shown in Figure 9030-10-27, Figure 9030-10-28, Fig-
ure 9030-10-29, Figure 9030-10-30, and Fig-
ure 9030-10-32.

Figure 9030-10-27. J1.5-2.0XNT (J30-40XNT) (K160) and J1.6-2.0XN (J30-40XN) (A935)

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-10-1
Principles of Operation Electrical System

Legend for Figure 9030-10-27

NOTE: J1.5-2.0XNT (J30-40XNT) (K160) IS SHOWN AND THE J1.6-2.0XN (J30-40XN) (A935) IS SIMILAR.

1. VSM 7. PUMP MOTOR CONTROLLER

2. DC/DC CONVERTER 8. MINI-LEVER MODULE (MLM)
3. RELAYS 9. MAIN CHASSIS HARNESS
4. MAIN CONTACTOR AND FUSES 10. EMERGENCY STOP
5. DISPLAY 11. PUMP MOTOR
6. TRACTION MOTOR CONTROLLER 12. TRACTION MOTOR

1. VSM 7. PUMP MOTOR CONTROLLER

2. DC/DC CONVERTER 8. MINI-LEVER MODULE (MLM)
3. RELAYS 9. MAIN CHASSIS HARNESS
4. MAIN CONTACTOR AND FUSES 10. EMERGENCY STOP
5. DISPLAY 11. PUMP MOTOR
6. TRACTION MOTOR CONTROLLER 12. TRACTION MOTOR

Figure 9030-10-28. E2.2-3.5XN (E45-70XN) (A268)

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Electrical System Principles of Operation

NOTE: J2.2-3.5XN (J45-70XN) (A276) SHOWN. J4.0-5.0XN (J80-100 XN) (A970) IS SIMILAR.
1. VSM 7. PUMP MOTOR CONTROLLER
2. DC/DC CONVERTER 8. MINI-LEVER MODULE (MLM)
3. RELAYS 9. MAIN CHASSIS HARNESS
4. MAIN CONTACTOR AND FUSES 10. EMERGENCY STOP
5. DISPLAY 11. PUMP MOTOR
6. TRACTION MOTOR CONTROLLERS 12. TRACTION MOTORS
Figure 9030-10-29. J2.2-3.5XN (J40-70XN) (A276) and J4.0-5.0XN (J80-100 XN) (A970)

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-10-3
Principles of Operation Electrical System

NOTE: J1.6-2.0XN (J30-40XN) (A935) IS SHOWN AND J1.5-2.0XNT (J30-40XNT) (K160) IS SIMILAR.

1. DISPLAY 3. FUSE PANEL

2. VSM
Figure 9030-10-30. J1.6-2.0XN (J30-40XN) (A935) and J1.5-2.0XNT (J30-40XNT) (K160)

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Electrical System Principles of Operation

1. DISPLAY 3. VSM
2. TRACTION CONTROLLER 4. PUMP CONTROLLER
Figure 9030-10-31. A1.3XNT, A1.5XNT (A25XNT, A30XNT) [D203] Controller Locations

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Principles of Operation Electrical System

1. CONTACTOR AND FUSE PANEL 3. VSM

2. DISPLAY
Figure 9030-10-32. E2.2-3.5XN (E45-70XN) (A268)

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Electrical System Principles of Operation

The truck's electrical system directly controls and

monitors every electrical component in the truck. See
Figure 9030-10-33 which shows the interconnection
between various components in the system.

Figure 9030-10-33. System Block Diagram

The lift truck contains components as listed below; • The contactor and fuses are assembled to-
Component location on truck may vary with the differ- gether on a single bracket.
ent platforms. • Other fuses are located adjacent to the devices
they are protecting.
Battery
Relays
• Deep-cycle, multi-cell, lead acid battery.
• Voltage ranges 24/36/48/72/80 volts with differ- The relays used are 12V and 24V having high contact
ent Ah ratings based on customer applications. rating, high temperature and quick connect design.
• The battery is located below the hood in the Following are the relays provided in the truck:
battery compartment area. • Standard Relays:
- Key Switch Relay (12V)
Contactor
- E-Hyd Enable Relay (24V) (Only on E-
The contactors used are single pole single throw nor- Hydraulic Trucks)
mally open contactors. The contactors are available in • Optional Relays:
UL-E and UL-EE options. - Reverse Relay (24V)

Fuses - Brake Light Relay (24V)

- Flasher (Turn Signal Option) Relay
• The main fuses are 15 Amp fast acting ceramic (12V)
tubes with nickel plated brass end cap con-
struction.

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Principles of Operation Electrical System

Wire Harnesses Controllers

Fundamental to the operation of the truck, the wire Vehicle System Manager (VSM)
harnesses have been designed to ensure trouble free,
reliable electrical operation, and ease of service. This The Vehicle System Manager (VSM) is a microproc-
has been achieved through the following: essor powered controller which controls and monitors
• Harness retention clips and brackets used for directly or indirectly every electrical device on the
consistent routing and clean appearance. truck. The VSM power inputs are protected for over-
voltage, reverse polarity, electrostatic discharge and
• Constructed with ultrasonically welded splices short to battery. VSM outputs are protected for short
and protective conduit. to battery, short to ground, electro static discharge
• High quality sealed connectors with locks are and transients. There are two versions of the VSM.
used instead of spade type connectors and un- One is for Manual Hydraulics, and one is for the E-Hy-
sealed connections wherever possible. draulics configuration. See Figure 9030-10-35.
• Standardized wire colors and circuit identifica-
tion. Motor Controllers

DC/DC Converter Motor controllers are used to provide Traction and

Pump motors with power and control signals. Traction
The DC/DC converter is connected permanently to and Pump motors are controlled individually by sepa-
the batteries of the lift truck. rate controllers. These controllers are linked to VSM
via CANbus which provides control signals to control-
The DC/DC converter regulated voltage outputs. The lers. See Figure 9030-10-36 or Figure 9030-10-37.
DC/DC converter helps provide unmatched levels of
efficiency with thermal protection for lights, horns,
wipers, communication equipment, and charging aux-
iliary batteries.

Operator Interface

Display

The display panel is located on the upper portion of

the right front overhead guard leg. It is the main oper-
ator interface providing operator input through the
push buttons and outputs to the operator through
messages and warning icons. It also provides on-
board diagnostics and setup to a qualified technician
through password protection. See Figure 9030-10-34.
There are two display options available Standard
Temperature and Freezer (Arctic) Temperature.
Keyed and Keyless Power on is also an option.

Figure 9030-10-34. Display

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Electrical System Principles of Operation

Figure 9030-10-35. Vehicle System Manager (VSM) Figure 9030-10-37. Motor Controller for Three
Wheel Applications

Figure 9030-10-36. Motor Controller for Four

Wheel Applications

Figure 9030-10-38. Motor Controllers with

Integrated Heat Sink

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Principles of Operation Electrical System

E-Hydraulics Mini Levers Module (MLM) The truck utilizes CANopen communications, CAN
2.0B hardware, to link the control system compo-
The electro hydraulic systems for all electric rider fork- nents. Multiple packets of information can be sent on
lift trucks include a mini-lever module (MLM). The this bus, an operation commonly known as Multiplex-
MLM consists of analog (levers) and digital (switch) ing. See Figure 9030-10-39 which shows components
inputs that command various hydraulic and truck func- connected through CANbus.
tions. The hydraulic functions which are controlled by
the MLM are lift/lower, tilt and up to three auxiliary
functions. Auxiliary functions are used for operating
“forklift attachments” such as a sideshift, rotator,
clamp, push/pull, etc. See E-Hydraulic System Inter-
face.

Figure 9030-10-39. CAN Network Diagram

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Electrical System Principles of Operation

The CANbus consists of a twisted pair of wires. Each Valve Coils

of the twisted wires is uniquely color-coded.
There are two different valve options available E-Hy-
Yellow = CAN Hi draulic and Manual.
Green = CAN Lo • E-Hydraulic valve spool displacement is ac-
complished by applying an electrical signal to a
Typical characteristics of data on the CANbus are: solenoid located on either end of the valve sec-
• Each wire broadcasts a mirror image of the tion. These solenoids receive Pulse Width
other to insure signal integrity. Modulated (PWM) signals from the VSM which
provide proportional control of the spool. See
• Each CAN connected device receives and Figure 9030-10-41.
broadcasts messages.
• The message data, if viewed with an oscillo-
scope, would look like the signal trace shown
in Figure 9030-10-40.

Figure 9030-10-40. Typical CAN Signals

System Controlled Outputs

The various controllers provide electrical outputs to 1. E-HYDRAULIC SOLENOIDS

various devices to control variable functions; some of 2. E-HYDRAULIC VALVE
them are described below. Figure 9030-10-41. E-Hydraulic Valve

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Principles of Operation Electrical System

• In Manual valves the spool displacement is ac- Depending on your lift truck and further information
complished by manual levers. The position pertaining to lights and schematics, see Diagrams
sensors provided on the valve monitors the po- 8000SRM1341 or Diagrams 8000SRM1384.
sition of the valve spool and produce a variable
output signal relative to how far the spool has See Figure 9030-10-43, which shows general loca-
traveled from its neutral position. The output tions of different lights used. They may vary depend-
signal from the sensor is used by the VSM to ing upon your lift truck.
vary the hydraulic pump flow. The manual
valve is provided with Operator presence sole-
noids (OPS) which allows valve operation only
if operator is present on the seat. See Fig-
ure 9030-10-42.

1. FRONT WORK LIGHTS

2. RH FRONT MARKER LIGHTS
3. LH FRONT MARKER LIGHTS
4. LH TAIL LIGHT
5. REAR WORK LIGHT
1. OPS LOCKOUT SOLENOIDS 6. STROBE LIGHT
2. SPOOL POSITION SENSORS 7. RH TAIL LIGHT
3. MANUAL HYDRAULIC VALVE
Figure 9030-10-43. Light Location
Figure 9030-10-42. Manual Hydraulic Valve
Cab options
Lights and Backup Alarm
Some of the lift trucks are equipped with following op-
The work lights are 35/55 watt halogen lights. A pre- tions:
mium LED 37 or 55 watt work light package is also of-
fered. Tail lights, front-marker and strobe lights are all • Washer/ Front-Rear Wipers
LED lights and are used in both the incandescent and • Cab Heater
LED work light options. • Dome Light

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Electrical System Principles of Operation

PRINCIPLES OF OPERATION, Positive Temperature Coefficient (PTC)

COMPONENTS
The PTC thermistor ensures that the motor controller
Power Distribution drive capacitors are charged when the battery is con-
nected and prior to the contactor being operated. This
Contactor prevents damage to the contactor contacts due to
large capacitive inrush currents.
The Contactor is an electrically controlled switch used
to supply main power to the lift truck's motion system. Fuses
It consists of a set of high current contacts to carry
battery power. These contacts are closed by an elec- The fuses used are 15 Amp fuses. They are typically
tromagnetic coil which when energized by the control used to connect the Emergency Disconnect Switch
system sends battery power to the motor controllers circuits, Primary DC/DC converter and Auxiliary
and other battery operated devices. DC/DC converter to battery power. One 5 Amp fuse is
used for the Key Switch and E-Stop. See Fig-
One of the main terminals of the contactor is connec- ure 9030-10-45. See Figure 9030-10-46.
ted to battery power and the other terminal is connec-
ted to the motor controllers. In order for the coil to op-
erate there are certain interlock conditions which need
to be fulfilled. Once all conditions are met the VSM
provides a signal to the coil. When the operator turns
on the Key or Keyless Power to ON (both are located
on display), the key switch relay is energized on and
the main contactor coil is energized closing its con-
tacts. See Figure 9030-10-44.

1. CONTACTOR
2. FUSES

Figure 9030-10-45. Fuse and Contactor Assembly

1. CONTACTOR

Figure 9030-10-44. Contactor (EE Type Shown)

Figure 9030-10-46. Power Circuit Diagram

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Principles of Operation Electrical System

Relays Backup Light Relay (Optional): This device is control-

led by the VSM and gets activated after detecting the
Key Switch Relay: Upon turning on the key or keyless selection of reverse direction. See Figure 9030-10-49.
switch located on Display panel, key switch relay gets
energized and provides power to components to Brake Light Relay (Optional): This is controlled by the
which it is connected. See Figure 9030-10-47. VSM and gets activated after brake is applied. See
Figure 9030-10-50.
E-Hydraulic Enable Relay: This relay is available on
lift trucks with E-Hydraulic option and is controlled by Motion Relay (Optional): This relay is activated via the
the VSM and gets activated whenever operators send user interface with supervisor password and energi-
input to VSM via E-Hydraulic input device. It provides zes whenever lift truck is operational in any direction
12V power to E-Hyd coils. See Figure 9030-10-48. that is selected.

Figure 9030-10-47. Key Switch Relay Diagram

Figure 9030-10-48. E-Hyd Enable Relay Circuit

Figure 9030-10-49. Backup Light Relay Circuit

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Electrical System Principles of Operation

• Traction Controller
• Pump Controller
• Park Brake Controller (if equipped)
• Park Brake Solenoid (if equipped)
• Manual Hydraulic Clamp Coil (if equipped)
• Manual Hydraulic Interlock/E-Hydraulic Enable
Relay
• 5th Function Hydraulic Diverter Valve (if equip-
ped)
Figure 9030-10-50. Brake Light Relay Circuit
• Reverse/Backup Light Relay (if equipped)
Operator Interface • Brake Light Relay (if equipped)
• Accessory Relays (if equipped)
Display
After the key is switched on the display screen turns
The display is the most important operator interface in
on all pixels and blackens the screen for ½ second.
the lift truck. The display is protected for reverse volt-
After performing the screen check the system will
age up to -16 volts, short to 16 volts and battery nega-
transition to one of the following screens:
tive, transients, ESD up to 8,000 volts and electro-
magnetic interference (EMI) up to 100 volts/meter. • The Password screen if the Operator Pass-
The display gets 12V power from VSM; also it is words are enabled
linked to VSM via CANbus. The Display has two con- • If Operator Passwords are not enabled then
trolled outputs: the Buzzer and the Key Switch Relay. the system transitions to the Operator Check-
The following Figure 9030-10-51 shows how display list Screen if the Operator Checklist function is
is connected into the system. enabled and the system was not powered off
through the auto-power down feature.
Upon turning on the Key or Keyless switch which is
• If the Operator Checklist function is not ena-
located on display, the key switch relay gets ener-
bled (or the system was last powered off
gized and in turn provides power to following compo-
through the auto-power off function) and the
nents:
Operator Passwords function is not enabled
• Main Contactor Coil then the system transitions to the Operating
• Supplementary Contactor Coil (if equipped) Screen.

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Principles of Operation Electrical System

Figure 9030-10-51. Display CAN Connections

The operating Screen displays several warning and position sensor mounted on the steer motor. The E-
information icons, these include: Steer system uses this sensor to calibrate steer axle
• Performance Mode center point.

• Seat Belt Warning Steer Controller and Motor

• Low Brake Fluid Warning
• Thermal Management The steer axle in the E-Steer system is driven by an
AC induction motor coupled to the steer axle gearbox.
• Service Due (Optional) The steer motor controller is mounted directly to the
• Direction/Park Brake Indicator motor. The steer motor controller communicates to
• Steer Angle (Optional) the VSM on the CANbus network..

• Time of Day Position Sensor

• Battery Charge
• Diagnostic Trouble Codes The steer axle position sensor sends steer axle posi-
tion feedback to the E-Steer motor controller. The
E-Steer steer axle position sensor is mounted on the steer
motor.
Description
TFD (Tactile Feedback Device)
There is no mechanical linkage or hydraulic hose be-
tween the steering wheel and the steer axle of the E- The TFD steering unit provides bearing support,
Steer system. A sensor driven by the steering wheel steering position sensing, communication, and varia-
communicates operator input to the steer motor con- ble resistive steering torque. The TFD, located below
troller. The steer motor drives the steer axle in the di- the steering wheel, senses operation by a hall-effect
rection and to the position commanded by the steer steering sensor and transmits the steering position to
motor controller. Actual steer axle position feedback is the steer controller. The steer controller uses proxim-
input to the steer motor controller from the steer axle ity sensor input to determine the preferred steering re-
sponse.

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Electrical System Principles of Operation

1. TFD COIL CONNECTOR

2. TFD (TACTILE FEEDBACK DEVICE)
3. INPUT SHAFT

Figure 9030-10-53. TFD Assembly

2. This allows the VSM to analyze, and determine

the controls of most of the lift trucks electrically
controlled functions. The VSM is also program-
med to detect truck malfunctions and provide
feedback to the operator and service techni-
1. STEER CONTROLLER cian in the form of:
2. STEER MOTOR • Display Messages
3. STEER AXLE
• Display Warning Icons
Figure 9030-10-52. Steer Axle Assembly • Audible Warnings
The operator will experience torque feedback in re- • A Change in truck operations (Deceler-
sponse to steering input. The TFD will simulate steer ate, Shutdown)
resistance by energizing a magnetically responsive 3. The VSM can be viewed as a box containing
material against a fixed stator. This material is a mag- multiple inputs and outputs, see Ta-
neto rheological fluid, or MR fluid, providing a smooth ble 9030-10-3.
and quiet steering feel.
4. Inputs are connected to:
Controllers • Sensors
• Switches
Vehicle System Manager (VSM):
• Control lines from other devices
1. The VSM is the Master Controller of the truck. • Voltage supplies
It receives input from:
• The Operator (Via Display)
• Sensors
• Controlled Devices

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Principles of Operation Electrical System

5. Outputs are connected to: • Motor Controllers

• Contactor • Display
• Relays • MLM
• E-Hyd Valve coils • Impact Sensor
• Lights • PCST
• Solenoids
6. The VSM communicates to multiple devices
over CAN:

Table 9030-10-3. VSM Connection

CPS1 CPS2
Pin # Circuit Description Signal Pin # Circuit Description Signal
1 Foot brake pressure AI 1 Brake Light Relay PWM
2 Hydraulic Temperature AI 2 Battery - P
3 Brake Fluid Level AI 3
4 Lift Pressure AI 4 Aux 3 (Fifth Function) Diverter PWM
5 Hydraulic Oil Level AI 5 Manual Hydraulic Clamp PWM
6 Manual Hydraulic #3 AI 6 Manual RTST Valve PWM
7 Manual Hydraulic #1 AI 7 Hydraulic Enable PWM
8 Steering Wheel Position AI 8 Reverse Relay PWM
9 12V Supply LP 9 Motion Relay PWM
10 10 Main Contactor PWM
11 11 Battery - (if equipped) P
E-Hydraulic Only
12 12 Keyswitch Input DI-H
13 Accelerator Pedal Pos A AI 13 Synchronous Steering (if PWM-C
equipped)
E-Hydraulic Only
14 Analog Return LP 14 Tilt B (if equipped) PWM-C
E-Hydraulic Only
15 Tilt Position AI 15 Tilt A (if equipped) PWM-C
E-Hydraulic Only
16 Steer Axle Position AI 16 Lift (if equipped) PWM-C
E-Hydraulic Only
DI-L = Digital Input (Switch to B-); DI-H = Digital Input (Switch to B=); P= Power; PWM = Pulse Width Modulated Output;
PWM-C = Pulse Width Modulated Output with Current Feedback; AI = Analog Input; QI = Quadrature Input; CAN = CAN Bus;
F = Flyback; LP = Low Voltage Power

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Electrical System Principles of Operation

Table 9030-10-3. VSM Connection (Continued)

CPS1 CPS2
Pin # Circuit Description Signal Pin # Circuit Description Signal
17 Analog Return LP 17 Lower (if equipped) PWM-C
E-Hydraulic Only
18 Operator Presence Switch AI 18
19 Direction Select 2 AI 19 Aux 1A (if equipped) PWM-C
E-Hydraulic Only
20 Analog Return LP 20 Aux 1B (if equipped) PWM-C
E-Hydraulic Only
21 21 Aux 2A (if equipped) PWM-C
E-Hydraulic Only
22 12V Return LP 22 Aux 2B (if equipped) PWM-C
E-Hydraulic Only
23 Manual RTST Override DI-L 23 E-Hydraulic Flyback (if equipped) F
Input E-Hydraulic Only
24 Park Brake Position AI 24 Keyswitch Flyback F
25 Lift Height Position AI 25
26 Manual Hydraulic #4 AI 26 Battery Gate DI-L
27 27 Hydraulic Filter DI-L
28 Manual Hydraulic #2 AI 28 Seatbelt Switch DI-L
29 Direction Select 1 AI 29 Hydraulic Brake Pressure Switch DI-L
30 Accelerator Pedal Pos B AI 30 Traction/Hydraulic Enable DI-L
31 5V Supply LP 31 Speed Limit Override DI-L
32 5V Supply LP 32 Manual Hydraulic Clamp Switch DI-L
33 CAN Low CAN 33 Supplementary Contactor PWM
34 CAN High CAN 34 Switch Return LP
35 35 Battery + P
DI-L = Digital Input (Switch to B-); DI-H = Digital Input (Switch to B=); P= Power; PWM = Pulse Width Modulated Output;
PWM-C = Pulse Width Modulated Output with Current Feedback; AI = Analog Input; QI = Quadrature Input; CAN = CAN Bus;
F = Flyback; LP = Low Voltage Power

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Principles of Operation Electrical System

Motor Controller rameters of the motor. Both speed and winding tem-
perature are monitored and adjusted to provide opti-
The traction and Hydraulic pump motor controllers mum performance.
have been separated and provide power and control
signals to their respective motors. The accelerator pedal, directional switch, and brake
pressure sensor signals to the VSM which are sent by
Traction Motor Controller: Each traction motor is con- CAN to the motor controllers to provide speed, and di-
trolled by a separate controller which gets its power rectional control. In addition to this motor winding tem-
from the battery and provides power and control sig- perature and speed are inputs to the controllers. The
nals to the motor. The controller is also connected by diagram below shows interconnection between a trac-
CANbus to VSM which monitors various operating pa- tion motor and its controller. See Figure 9030-10-54.

Figure 9030-10-54. Traction Motor and Controller Connections

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Electrical System Principles of Operation

Hydraulic Pump Motor Controller: This motor is con- Inputs from the hydraulic control valves go to the VSM
trolled by a separate controller, which gets its power which then communicate what required flow is nee-
from the battery and provides power and control sig- ded to meet the requested function. This is communi-
nals to the hydraulic pump motor. In addition to the cated over the CAN to the controller to provide the
controller the VSM oversees motor configuration and needed motor speed for a given hydraulic flow. The
monitoring responsibilities to ensure the motor runs diagram below shows interconnection between pump
within given operating parameters. Both speed and motor and its controller. See Figure 9030-10-55.
winding temperature are monitored and adjusted to
provide optimum performance. The following diagram
shows interconnection between pump motor and its
controller.

Figure 9030-10-55. Hydraulic Pump Motor and Controller Connections

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Principles of Operation Electrical System

E-Hydraulics Mini Levers Module (MLM) 2. Upon satisfying above mentioned parameters
the following events take place:
The E-Hydraulic mini lever module is a controller as- • Contactor closes and provides power to
sembly that includes operator input levers and but- the system
ton(s). These levers and buttons provide analog and
digital inputs to the E-Hydraulic input device. The E- • Motor controllers become operational
Hydraulic input device then formats the information • Hydraulic system becomes operational
into a predefined protocol and broadcasts the opera- and begin to give hydraulic steering flow
tor inputs to the VSM via the CANbus. Inputs from the
hydraulic control valves go to the VSM which commu- Sensors
nicate what required flow is needed to meet the re-
quested function. This is communicated over the The sensors are divided into 5 functional groups.
CANbus to the pump controller to provide the needed Most are supplied from a VSM 5 volt sources. The ex-
pump motor speed. ception is the ultrasonic hydraulic level sensor which
operates on 12 volts. If a sensor signal falls below or
PRINCIPLES OF OPERATION, SYSTEM exceeds programmed values, a failure condition or a
warning will be given to the operator.
Battery (Plug-In)
The functional groups are:
The power is supplied to the system after connecting 1. Speed (Hall Sensor Technology):
the battery. The following components are connected
to the battery voltage • Pump motor

• The primary and auxiliary DC/DC converter • Traction motor

which in turn provides 12V power to compo- 2. Pressure :
nents to which they are connected • Service Brake Pressure
• The VSM which in turn provides 12V power to • Mast Pressure
display and E-Hydraulics Mini Levers Module
(MLM) 3. Position - Rotary and Linear:

• Various relays and contactor • Park brake

• The motor controllers are only connected to the • Accelerator Pedal Position
battery after the key is turned on. The system • Operator presence
is powered to an non-operational state until the • Return To Set Tilt (Tilt Position)
operator turns on the key.
• Mast height (Optional)
Key ON and Operation • Manual hydraulic spool position
• Steer wheel
When the key or keyless switch is turned ON, the dis-
play wakes up and initiates the power up sequence, • Steer axle (Optional)
as mentioned in Operator Interface. The VSM is pro- • Direction control selector
grammed and wired to detect certain conditions be- 4. Temperature:
fore allowing the vehicle to be started.
• Traction motor
1. Interlocks:
• Pump motor
• Operator presence in the seat
• Hydraulic oil (Optional)
• Accelerator pedal in released position
• Display temperature (Optional)
• All hydraulic controls must be in neutral
state 5. Level/Miscellaneous:

• Battery gate switch closed (If applicable) • Hydraulic filter (Optional)

• No other operational faults • Hydraulic oil level

• Impact sensor

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Electrical System Principles of Operation

These functional groups have common signal output from zero to maximum. The output is the same
characteristics: irrespective of the different application pres-
1. Speed (4-wire devices): sure ranges of the sensors.

• Operating voltage = 12 Volts 4. Temperature: These devices have the same

Negative Temperature Coefficient (NTC) Ther-
• Variable frequency (Zero to Max speed) mistor element in different packages. Heating
2. Pressure and Position (3-wire devices): of this element changes the element resist-
• Operating voltage = 5 Volts ance. Higher temperature = Lower Resistance.
These sensors are connected in series with a
• Variable output voltage, 0.5 volts to 4.5 pull up resistor connected to 5 volts. The other
volts, Zero to Full scale end of the sensor is connected to Battery neg-
3. Temperature (2-wire device): ative, effectively forming a variable voltage di-
• Operating voltage = 5 Volts vider that the VSM can read and then interpret
as a temperature reading.
• Variable resistance, NTC (Increase in
temperature results in decrease of re- 5. Ultrasonic: This device uses ultrasonic waves
sistance) which radiate out until they hit an object and re-
turn. The time of the cycle determines the dis-
4. Level/Miscellaneous: tance and/or level. See Diagrams
• Ultrasonic 8000SRM1528.
• Reed Switch
Switches
Sensor Operation Technology
The switches are used for following applications:
1. Hall Effect (Position): This technology uses a
sensor that can detect the strength of a mag- • Hydraulic filter pressure
netic field or in case of rotation, the angle of • Battery gate
the magnetic field in relative to the sensor. • Clamp solenoid
Moving the magnet closer or further away from
the sensor varies the output voltage. For rota- Depending on your lift truck and further information
tion the output varies based on magnetic field pertaining to switches and schematics, see Diagrams
angle. 8000SRM1341 or Diagrams 8000SRM1384.
2. Hall Effect (Speed): This uses the same princi-
ple as described in the position sensor but Outputs
uses the presence and absence of gear teeth
to change the strength of the magnetic field. Relays
This causes a variable voltage that is used to
operate a transistor switch output providing a 1. ON/OFF Operation
pulse train that is proportional to speed.
2. Programmed for a specific maximum current
3. Pressure: These devices use a strain gauge or
capacitive sense element that generates a mi- 3. The following faults are detectable
crovolt signal which is proportional to the pres- • Short to Battery
sure applied. This signal is amplified to provide
• Short to Ground
an output voltage that varies between 0.5 and
4.5 Vdc in proportion to pressure changing • Open circuit

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Principles of Operation Electrical System

Figure 9030-10-56. Switch Connections

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Electrical System Principles of Operation

Table 9030-10-4. Motor Temperature Sensor

(°C) (°F) Nominal Resistance (?)

-40 -40 359
-30 -22 391
-20 -4 424
-10 14 460
0 32 498
10 50 538
20 68 581
30 86 626
40 104 672
50 122 722
60 140 773
70 158 826
80 176 882
90 194 940
100 212 1000
110 230 1062
120 248 1127
130 266 1194
140 284 1262
150 302 1334
160 320 1407
170 338 1482
180 356 1560
190 374 1640
200 392 1722
NOTE: Measured resistance should be within ±5% of specified Nominal Resistance (?)

E-Hydraulic Valve • Short to Ground

• Open circuit
1. Valve coil is controlled in following manner
• Current above or below normal
a. Pulse Width Modulated (PWM) signal controls
the valve opening, and therefore flow. (Higher 2. Hydraulics operation is also disabled for the fol-
duty cycle results in higher fluid flow). lowing conditions:

b. Each E-Hydraulics valve is independently con- a. Operator presence in seat is not detected
trolled and current monitored
b. Circuit Failures in Valve Wiring/ Connectors/
c. The following faults are detectable: Valve coils and Valve coil drivers. See Fig-
ure 9030-10-57.
• Short to Battery

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Principles of Operation Electrical System

Cab Devices • Cab Heater

All CAB devices are operated from unswitched or Lights and Backup Alarm
switched battery circuits using the device’s own
ON/OFF switches 1. Tail Light/Front Work Lights
• Front/Rear Wiper a. The Tail light/front work lights can be turned
• Washer ON or OFF by using a switch which is located
on Dash panel. See Figure 9030-10-58.
• Cab light

Figure 9030-10-57. Hydraulic Valve Coil Diagram

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Electrical System Principles of Operation

Figure 9030-10-58. Work/Marker Lights Diagram

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Principles of Operation Electrical System

2. Rear Work Lights or automatically controlled by the reverse relay.

See Figure 9030-10-59.
a. The rear work lights can be turned ON or OFF
by using switch which is located on Dash panel

Figure 9030-10-59. Rear Work Lights Diagram

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Electrical System Principles of Operation

3. Strobe Light

a. The Strobe light becomes operational when-

ever key switch relay is turned on. See Fig-
ure 9030-10-60.

Figure 9030-10-60. Strobe Light Diagram

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Principles of Operation Electrical System

4. Backup Light and Alarm rection. The circuit is designed to allow a cus-
tomer to connect their desired audible warning
a. The Backup light and Alarm are controlled by device. See Figure 9030-10-61.
the VSM detecting the selection of reverse di-

Figure 9030-10-61. Backup Light Diagram

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Electrical System Principles of Operation

5. Brake Light when the brake is applied. See Fig-

ure 9030-10-62.
a. This light is controlled by the VSM detecting
the pressure in the brake pressure sensor

Figure 9030-10-62. Brake Light Diagram

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 NOTES

9030-10-32
Electrical System Diagnostic Trouble Codes

Group 20

Diagnostic Trouble Codes

Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL)

Fault Codes
DTC 12844 DTC 12836
Load Weigh Service Brake
Pressure Pressure

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

LOAD WEIGH PRESSURE CAUSES A B C D E > ?

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Diagnostic Trouble Codes Electrical System

Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL) (Cont)
SERVICE BRAKE PRESSURE CAUSES A B C D E > ?

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ ?

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Electrical System Diagnostic Trouble Codes

Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL) (Cont)
CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK For Service Brake Pressure, go
to Component Operational
Check.
Repair OPEN Circuit. See Electrical System For Load Weigh Pressure, go to
2200SRM1337/Electrical System 2200SRM1369. Component Operational Check.

Power OFF→ ?
CAUSE B CHECK RESISTANCE - Ω - OHMS

8 ? = Open circuit→ Find↑ OPEN circuit ˜ 4.7K? = OK Go to Component Operational

Check.
Repair OPEN circuit. See Electrical System ˜0?= ?
2200SRM1337/Electrical System 2200SRM1369.

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Diagnostic Trouble Codes Electrical System

Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL) (Cont)
CAUSE C CHECK RESISTANCE - Ω - OHMS

= 0 ? = Short circuit→ Find↑ Short circuit ˜ 4.7K? = OK For Service Brake Pressure, ?
Repair Short circuit. See Electrical System > 10K? = OK For Load Weigh Pressure, ?
2200SRM1337/Electrical System 2200SRM1369.
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ ?

sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old ?

present→ sensor→

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Electrical System Diagnostic Trouble Codes

Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL) (Cont)
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ ?

Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Diagnostic Trouble Codes Electrical System

Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH)

Fault Codes
DTC 12845 DTC 12837
Load Weigh Service Brake
Pressure Pressure

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

LOAD WEIGH PRESSURE CAUSES A B C C1 C2 D E > ?

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Electrical System Diagnostic Trouble Codes

Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH) (Cont)
SERVICE BRAKE PRESSURE CAUSES A B C C1 C2 D E > ?

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ ?

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK For Load Weigh Pressure, go to
Component Operational Check
Repair OPEN Circuit. See Electrical System For Service Brake Pressure, go to
2200SRM1337/Electrical System 2200SRM1369. Component Operational Check

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Diagnostic Trouble Codes Electrical System

Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH) (Cont)
CAUSE B CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check.
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE C

Power OFF→ Reconnect sensor→ Power ON→ ?

CAUSE C1 CHECK VOLTAGE

˜ 5 Volts = Short circuit→ Find↑ Short circuit. > 5.5 volts Go to Cause C2
Repair Short Circuit. See Electrical System < 4.5 volts OK Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. = Check

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Electrical System Diagnostic Trouble Codes

Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH) (Cont)
CAUSE C2 CHECK VOLTAGE

> 5.5 volts = Short circuit→ Find↑ Short circuit to an- < 4.5 volts OK Go to Component Operational
other voltage source. = Check.
Repair Short circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ ?

sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC present→ Old sensor OK/Reinstall old Go to Component Operational

sensor→ Check.

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Diagnostic Trouble Codes Electrical System

Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH) (Cont)
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Cause E1. Not OK Correct/

Repair→ Go to
Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Electrical System Diagnostic Trouble Codes

Accelerator Pedal Position A/B Out of Range Low (OORL)

Fault Codes
DTC 12808 DTC 12810
Accelerator Pedal Accelerator Pedal
Position A Position B

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

ACCELERATOR PEDAL POSITION A/B CAUSES A B C D E > ?

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Diagnostic Trouble Codes Electrical System

Accelerator Pedal Position A/B Out of Range Low (OORL) (Cont)

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ ?

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check.
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B CHECK RESISTANCE - Ω - OHMS

8 ? = Open circuit→ Find↑ OPEN circuit ˜ 4.7K? = OK Go to Component Operational

Check
Repair OPEN circuit. See Electrical System ˜0?= Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. Check

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Electrical System Diagnostic Trouble Codes

Accelerator Pedal Position A/B Out of Range Low (OORL) (Cont)

CAUSE C CHECK RESISTANCE - Ω - OHMS

0 ? = Short circuit→ Find↑ Short circuit

Repair Short circuit. See Electrical System

2200SRM1337/Electrical System 2200SRM1369.
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ ?

sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC present→ Old sensor OK/Reinstall old Go to Component Operational

sensor→ Check.

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Diagnostic Trouble Codes Electrical System

Accelerator Pedal Position A/B Out of Range Low (OORL) (Cont)

CAUSE E

Power OFF→ Inspect VSM Connec- OK - Go to Not OK →Correct/Repair Go to

tions→ Cause E1. Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Electrical System Diagnostic Trouble Codes

Accelerator Pedal Position A/B Out of Range High (OORH)

Fault Codes
DTC 12809 DTC 12811
Accelerator Pedal Accelerator Pedal

Position A Position B

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

ACCELERATOR PEDAL POSITION A/B CAUSES A B C C1 C2 D E > ?

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Diagnostic Trouble Codes Electrical System

Accelerator Pedal Position A/B Out of Range High (OORH) (Cont)

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ ?

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check.
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B
Not Applicable
CAUSE C

Power OFF→ Reconnect sensor→ Power ON→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-16 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Accelerator Pedal Position A/B Out of Range High (OORH) (Cont)

CAUSE C1 CHECK VOLTAGE

˜ 5 Volts = Short circuit→ Find↑ Short circuit. > 5.5 volts OK Go to Cause C2
Repair Short Circuit. See Electrical System < 4.5 volts Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. = Check
CAUSE C2 SWITCHED VOLTAGES

> 5.5 Volts = Short circuit→ Find↑ Short circuit. Power OFF ?

Repair Short Circuit. See Electrical System

2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-17
Diagnostic Trouble Codes Electrical System

Accelerator Pedal Position A/B Out of Range High (OORH) (Cont)

CAUSE C3 UNSWITCHED VOLTAGES

> 5.5 Volts = Short circuit→ Find↑ Short circuit. < 4.5 volts OK Go to Component Operational
= Check
Repair Short Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ ?

sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC present→ Old sensor OK/Reinstall old Go to Component Operational

sensor→ Check.

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9030-20-18 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Accelerator Pedal Position A/B Out of Range High (OORH) (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ OK - Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-19
Diagnostic Trouble Codes Electrical System

Accelerator Pedal Position A/B Data Incorrect

Fault Codes
DTC 12812
Accelerator Pedal
Position A to B

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-20 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Accelerator Pedal Position A/B Data Incorrect (Cont)

QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1 FAULT LOG CODE Review - Go to Display Menu
Note: DTC 12812 can be caused by the same conditions that caused DTCs 12808 to 12811
Check VSM Fault Logs→ Go to Check 1↑ Are these codes present?↓
YES→ See Accelerator Pedal Position A/B Out of Range Low (OORL) or Accelera- NO→ Go to Check 1↑
tor Pedal Position A/B Out of Range High (OORH)

Enter Service Password→ Diagnostic→ FAULT LOGs→ VSM/MLM Fault Logs→ View all VSM/MLM DTCs→ ?

3? All VSM/MLM DTCs Erase all VSM/MLM DTCs→ E Exit Fault Log→ ↑ ↓ Speedometer F*
Check 2

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-21
Diagnostic Trouble Codes Electrical System

Accelerator Pedal Position A/B Data Incorrect (Cont)

Does Sensor APS2 Volts = Sensor APS1 Volts = DTC 12812?

YES → Component Operational Check NO→ Resume Operation
Does (Sensor APS2 Volts x 2) - Sensor APS1 Volts = > 0.60 volts for more than 2 seconds = DTC 12812?
YES→ Component Operational Check NO→ Resume Operation
POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
ACCELERATOR PEDAL POSITION A/B CAUSES A B C D E > ?

CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C

If 2 = 1 = Short circuit→ Find↑ Short circuit If 2 = (2x1) = OK→ Component Operational Check ↓
Find/Repair Short circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.
Reconnect→ Use Display Diagnostics to validate→ Test OK→ YES→ Resume Operation NO→ Component Op-
erational Check ↓

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9030-20-22 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Accelerator Pedal Position A/B Data Incorrect (Cont)

CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ ?

sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC present→ Old sensor OK/Reinstall old Go to Component Operational

sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connec- OK - Go to Not OK →Correct/Repair Go to

tions→ Cause E1. Cause E1.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-23
Diagnostic Trouble Codes Electrical System

Accelerator Pedal Position A/B Data Incorrect (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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9030-20-24 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL)

Fault Codes
DTC 12820 DTC 12824
Steering Wheel Steering Axle
Position Position

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

STEERING WHEEL POSITION CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-25
Diagnostic Trouble Codes Electrical System

Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL) (Cont)
STEERING AXLE POSITION CAUSES A B C D E > ?

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ ?

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-26 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL) (Cont)
CAUSE B CHECK RESISTANCE - Ω - OHMS

8 ? = Open circuit→ Find↑ OPEN circuit ˜ 4.7K? = OK Go to Component Operational

Check
Repair OPEN circuit. See Electrical System ˜0?= Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. Check
CAUSE C CHECK RESISTANCE - Ω - OHMS

0 ? = Short circuit→ Find↑ Short circuit

Repair Short circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-27
Diagnostic Trouble Codes Electrical System

Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL) (Cont)
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ ?

sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ OK - Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

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9030-20-28 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL) (Cont)
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-29
Diagnostic Trouble Codes Electrical System

Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH)

Fault Codes
DTC 12821 DTC 12825
Steering Wheel Steering Axle
Position Position

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

STEERING WHEEL POSITION CAUSES A B C C1 C2 D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-30 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH) (Cont)
STEERING AXLE POSITION CAUSES A B C C1 C2 D E > ?

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next

step.
CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts OK Go to Component Operational

= Check
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B
Not Applicable

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-31
Diagnostic Trouble Codes Electrical System

Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH) (Cont)
CAUSE C

Power OFF→ Reconnect sensor→ Power ON→ Go to next

step.
CAUSE C1 CHECK VOLTAGE

= 5 Volts = Short circuit→ Find↑ Short circuit. > 5.5 volts, Go to Cause C2
Repair Short Circuit. See Electrical System < 4.5 volts OK Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. = Check
CAUSE C2 CHECK VOLTAGE

> 5.5 volts = Open circuit→ Find↑ OPEN circuit. < 4.5 Volts OK Go to Component Operational
= Check
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-32 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH) (Cont)
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next
sor.→ step.
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ OK - Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-33
Diagnostic Trouble Codes Electrical System

Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH) (Cont)
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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9030-20-34 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Steer Axle Calibration Required

Fault Codes
DTC 4098
Steer Axle Calibration

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

STEERING AXLE CALIBRATION CAUSES A B C D E > ?
Faulty Steer System/Faulty Sensor/New Sensor Installed
VSM

CAUSE A
Not Applicable
CAUSE B
Not Applicable

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-35
Diagnostic Trouble Codes Electrical System

Steer Axle Calibration Required (Cont)

CAUSE C
Not Applicable
CAUSE D
Calibration Process--Go to Display Menu

Enter SERVICE Password→ F* DDiagnostics→ F* ESteering Sensor

CAUSE D1
Steering Sensor Values

1. F*→Rotate steering wheel #Values vary>0.5V <4.5V = v→Proceed with Calibration→Cause D3↓

2. F*→Rotate steering wheel #Values =the same = X=Steer Mechanism/Faulty Sensor→Go to 3↓

3. Check Steer Mechanism Operation→Mechanism v→Cause D2↓Mechanism XGo to 4↓
4. See Steering System 1600SRM1331/Steering System 1600SRM1363 repair.
CAUSE D2
Steer Sensor(s) Replacement

1. Power OFF→Disconnect sensor Do not discard.→Install new sensor→Power ON→Go to 2↓

2. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.

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9030-20-36 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Steer Axle Calibration Required (Cont)

CAUSE D3

Enter SERVICE Password→ F* DCalibration→ F* ESteering Axle

F* Rotate Fully CCW F* Rotate Fully CW Cause D4 ↓

F*
CAUSE D4

Power OFF→ Power ON→ Cause D5 ↓

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-37
Diagnostic Trouble Codes Electrical System

Steer Axle Calibration Required (Cont)

CAUSE D5

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ OK - Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-38 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Temperature Sensor Out of Range High (OORL)

Fault Codes
DTC 12852
Hydraulic
Temperature

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

HYDRAULIC TEMPERATURE CAUSES A B C D E > ?

CAUSE A
Not Applicable
CAUSE B
Not Applicable

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-39
Diagnostic Trouble Codes Electrical System

Hydraulic Temperature Sensor Out of Range High (OORL) (Cont)

CAUSE C

Power OFF→ Disconnect sensor→ Power ON→ Go to next

step.
CAUSE C1 CHECK VOLTAGE

0 Volts = Short circuit→ Find↑ Short circuit. ˜ 5 Volts = OK Go to Component Operational

Check
Repair Short Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-40 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Temperature Sensor Out of Range High (OORL) (Cont)

CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next
sor.→ step.
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-41
Diagnostic Trouble Codes Electrical System

Hydraulic Temperature Sensor Out of Range High (OORL) (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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9030-20-42 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Temperature Sensor Out of Range High (OORH)

Fault Codes
DTC 12853
Hydraulic
Temperature

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

HYDRAULIC TEMPERATURE CAUSES A B C C1 C2 D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-43
Diagnostic Trouble Codes Electrical System

Hydraulic Temperature Sensor Out of Range High (OORH) (Cont)

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next

step.
CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-44 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Temperature Sensor Out of Range High (OORH) (Cont)

CAUSE C

Power OFF→ Reconnect sensor→ Power ON→ Go to next step.

CAUSE C1 CHECK VOLTAGE

= 5 Volts = Short circuit→ Find↑ Short circuit. > 5.5 volts Go to Cause C2
Repair Short Circuit. See Electrical System < 4.5 volts = OK Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. Check
CAUSE C2 CHECK VOLTAGE
Switched and Unswitched

> 5.5 volts = Short circuit→ Find↑ Short circuit to an- < 4.5 volts = OK Go to Component Operational
other voltage source. Check.
Repair Short circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-45
Diagnostic Trouble Codes Electrical System

Hydraulic Temperature Sensor Out of Range High (OORH) (Cont)

CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next
sor.→ step.
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Cause E1. Not OK Correct/

Repair→ Go to
Cause E1.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-46 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Temperature Sensor Out of Range High (OORH) (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-47
Diagnostic Trouble Codes Electrical System

Hydraulic Fluid Level Sensor Out Of Range Low (OORL)

Fault Codes
DTC 12872
Hydraulic Fluid Level

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

HYDRAULIC FLUID LEVEL CAUSES A B C D E > ?

NOTE: If the CDF setting is for a sensor but the sensor is not connected, then a DTC code will be displayed.
Check that the sensor is present and the harness connection is OK.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-48 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Fluid Level Sensor Out Of Range Low (OORL) (Cont)

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next

step.
CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ Open circuit. ˜ 12Volts OK → Go to Component Operational

= Check↓
Repair Open Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.

CAUSE B

Power OFF→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-49
Diagnostic Trouble Codes Electrical System

Hydraulic Fluid Level Sensor Out Of Range Low (OORL) (Cont)

CAUSE B1 CHECK RESISTANCE - Ω - OHMS

1. 8 ? = Open circuit→Find↑OPEN circuit→Go to 3↓ ˜ 4.7K? = OK Go to Component Operational

Check.↓
2. 0? = Short circuit→Go to Component Operational Check↓
3. Repair OPEN circuit. See Electrical System 2200SRM1337/Electrical System [Link] to 4↓
4. Repair @→Retest→Cause C1↓
CAUSE C CHECK RESISTANCE - Ω - OHMS

1. 0? = Short circuit→Find↑Short circuitGo to 2↓ ˜ 4.7K? = OK Go to Component Operational

Check.↓
2. Repair Short circuit. See Electrical System 2200SRM1337/Electrical System [Link] to 3↓
3. Repair @→Retest→Cause C1↓
CAUSE C1

Retest - Power ON→ NO → Go to Compo- Is fault DTC gone? Fault corrected→ Continue operation.
nent Operational
Check NO ← YES →

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-50 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Fluid Level Sensor Out Of Range Low (OORL) (Cont)

CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next
sor.→ step.
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-51
Diagnostic Trouble Codes Electrical System

Hydraulic Fluid Level Sensor Out Of Range Low (OORL) (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-52 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Fluid Level Sensor Out Of Range High (OORH)

Fault Codes
DTC 12873
Hydraulic Fluid Level

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

HYDRAULIC TEMPERATURE CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-53
Diagnostic Trouble Codes Electrical System

Hydraulic Fluid Level Sensor Out Of Range High (OORH) (Cont)

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to A1.↓

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 12 Volts OK Go to Component Operational

= Check
Repair OPEN Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.

CAUSE B
Not Applicable
CAUSE C

> 4.7 Volts = Short circuit→ Find↑ Short circuit. < /= 4.5 OK Go to Component Operational
Volts = Check
Repair OPEN Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-54 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Fluid Level Sensor Out Of Range High (OORH) (Cont)

CAUSE C1

Retest - Power ON→ NO → Go to Compo- Is fault DTC gone? Fault corrected→ Continue operation.
nent Operational
Check NO ← YES →
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next
sor.→ step.↓
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-55
Diagnostic Trouble Codes Electrical System

Hydraulic Fluid Level Sensor Out Of Range High (OORH) (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Cause E1. Not OK Correct/

Repair→ Go to
Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-56 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL)

Fault Codes DTC 12832 DTC 12840

Park Brake Position Mast Tilt Position

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

PARK BRAKE POSITION CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-57
Diagnostic Trouble Codes Electrical System

Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL) (Cont)
MAST TILT POSITION CAUSES A B C D E > ?

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next step.

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check.
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-58 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL) (Cont)
CAUSE B CHECK RESISTANCE - Ω - OHMS

8 ? = Open circuit→ Find↑ OPEN circuit ˜ 4.7K? = OK Go to Component Operational

Check
Repair OPEN circuit. See Electrical System ˜0?= Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. Check
CAUSE C CHECK RESISTANCE - Ω - OHMS

0 ? = Short circuit→ Find↑ Short circuit

Repair Short circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-59
Diagnostic Trouble Codes Electrical System

Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL) (Cont)
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next step.
sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

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9030-20-60 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL) (Cont)
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-61
Diagnostic Trouble Codes Electrical System

Park Brake/Mast Tilt Position Sensor Out of Range High (OORH)

Fault Codes DTC 12831 DTC 12841

Park Brake Position Mast Tilt Position

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

PARK BRAKE POSITION CAUSES A B C D E > ?

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9030-20-62 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Park Brake/Mast Tilt Position Sensor Out of Range High (OORH) (Cont)
MAST TILT POSITION CAUSES A B C D E > ?

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next step.

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check.
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B
Not Applicable

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-63
Diagnostic Trouble Codes Electrical System

Park Brake/Mast Tilt Position Sensor Out of Range High (OORH) (Cont)
CAUSE C

Power OFF→ Reconnect sensor→ Power ON→ Go to next step.

CAUSE C1 CHECK VOLTAGE

5 Volts = Short circuit→ Find↑ Short circuit. > 5.5 volts Go to Cause C2
Repair Short Circuit. See Electrical System < 4.5 volts OK Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. = Check
CAUSE C2 CHECK VOLTAGE
Switch and Unswitched

> 5.5 volts = Short circuit→ Find↑ Short circuit to an- < 4.5 volts OK Go to Component Operational
other voltage source. = Check.
Repair Short circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-64 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Park Brake/Mast Tilt Position Sensor Out of Range High (OORH) (Cont)
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next step.
sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-65
Diagnostic Trouble Codes Electrical System

Park Brake/Mast Tilt Position Sensor Out of Range High (OORH) (Cont)
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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9030-20-66 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL)

Fault Codes
DTC 12800 DTC 12804
Directional Select A Directional Select B

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

DIRECTIONAL SELECT A/B CAUSES A B C D E > ?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-67
Diagnostic Trouble Codes Electrical System

Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL) (Cont)
CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next step.

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check.
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B CHECK RESISTANCE - Ω - OHMS

8 ? = Open circuit→ Find↑ OPEN circuit ˜ 4.7K? = OK Go to Component Operational

Check
Repair OPEN circuit. See Electrical System ˜ 0? = Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. Check

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9030-20-68 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL) (Cont)
CAUSE C CHECK VOLTAGE

0 ? = Short circuit→ Find↑ Short circuit

Repair Short circuit. See Electrical System

2200SRM1337/Electrical System 2200SRM1369.
CAUSE D

Power OFF→ Disconnect Pedal or Hyd Lever.→ In- Power ON→ Go to next
stall new component.→ step.
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-69
Diagnostic Trouble Codes Electrical System

Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL) (Cont)
CAUSE E

Power OFF→ Inspect VSM Connections→ OK - Go to Not OK →Correct/Repair Go to

Cause E1. Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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9030-20-70 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH)

Fault Codes
DTC 12801 DTC 12805
Directional Select A Directional Select B

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

DIRECTIONAL SELECT A/B CAUSES A B C C1 C2 D E > ?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-71
Diagnostic Trouble Codes Electrical System

Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) (Cont)
CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ ?

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check.
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B
Not Applicable
CAUSE C

Power OFF→ Reconnect sensor→ Power ON→ ?

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9030-20-72 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) (Cont)
CAUSE C1 CHECK VOLTAGE

5 Volts = Short circuit→ Find↑ Short circuit. > 5.5 Volts Go to Cause C2

Repair Short Circuit. See Electrical System < 4.5 volts OK Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. = Check
CAUSE C2 CHECK VOLTAGE

> 5.5 Volts = Short circuit→ Find↑ Short circuit to an- < 4.5 volts OK Go to Component Operational
other voltage source. = Check.
Repair Short Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-73
Diagnostic Trouble Codes Electrical System

Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) (Cont)
CAUSE D

Power OFF→ Disconnect Pedal or Hyd Lever.→ In- Power ON→ Go to next
stall new component.→ step.
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

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9030-20-74 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) (Cont)
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-75
Diagnostic Trouble Codes Electrical System

Seat Sensor Out of Range Low (OORL)

Fault Codes
DTC 12816
Seat Sensor

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

SEAT SENSOR CAUSES A B C D E > ?

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9030-20-76 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Seat Sensor Out of Range Low (OORL) (Cont)

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next step.

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK For Service Brake Pressure, go to
Component Operational Check
Repair OPEN Circuit. See Electrical System For Load Weigh Pressure, go to
2200SRM1337/Electrical System 2200SRM1369. Component Operational Check
CAUSE B CHECK RESISTANCE - Ω - OHMS

8 ? = Open circuit→ Find↑ OPEN circuit ˜ 4.7K? = OK Go to Component Operational

Check
Repair OPEN circuit. See Electrical System ˜0?= Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. Check

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-77
Diagnostic Trouble Codes Electrical System

Seat Sensor Out of Range Low (OORL) (Cont)

CAUSE C CHECK RESISTANCE - Ω - OHMS

0 ? = Short circuit→ Find↑ Short circuit

Repair Short circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next step.
sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC present→ Old sensor OK/Reinstall old Go to Component Operational

sensor→ Check.

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9030-20-78 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Seat Sensor Out of Range Low (OORL) (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-79
Diagnostic Trouble Codes Electrical System

Seat Sensor Out of Range High (OORH)

Fault Codes
DTC 12819
Seat Sensor

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

LOAD WEIGH PRESSURE CAUSES A B C C1 C2 D E > ?

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9030-20-80 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Seat Sensor Out of Range High (OORH) (Cont)

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next step.

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B
Not Applicable
CAUSE C

Power OFF→ Reconnect sensor→ Power ON→ Go to next

step.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-81
Diagnostic Trouble Codes Electrical System

Seat Sensor Out of Range High (OORH) (Cont)

CAUSE C1 CHECK VOLTAGE

5 Volts = Short circuit→ Find↑ Short circuit. > 5.5 volts OK Go to Cause C2
=
Repair Short Circuit. See Electrical System < 4.5 volts Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. = Check
CAUSE C2 CHECK VOLTAGE

> 5.5 volts = Short circuit→ Find↑ Short circuit to an- < 4.5 volts OK Go to Component Operational
other voltage source. = Check
Repair Short circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-82 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Seat Sensor Out of Range High (OORH) (Cont)

CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next step.
sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-83
Diagnostic Trouble Codes Electrical System

Seat Sensor Out of Range High (OORH) (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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9030-20-84 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Battery OORH/OORL

Fault Codes DTC 12545 DTC 12546

Battery OORH Battery OORL

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

CBB 4 WHEEL CAUSES A B C D E > ?
Possible Causes (OORL) Wrong Battery/Discharged Battery/Faulty Battery/ ® = High Resistance
Possible Causes (OORH) Wrong Battery Installed/ ® = High Resistance

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-85
Diagnostic Trouble Codes Electrical System

Battery OORH/OORL (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
A935 K160 HIGH RESISTANCE CONNECTIONS CAUSES A B C D E > ?

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

CBB 3 WHEEL HIGH RESISTANCE CONNECTIONS CAUSES A B C D E > ?

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9030-20-86 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Battery OORH/OORL (Cont)

CAUSE A
Battery OORH/OORL

Check that correct voltage battery is instal- Perform battery maintenance, see Operating Man- ?
led → ual→
STEP A1
OORH/OORL

Power ON→ Go to Diagnostic→ Battery/Supply→ View Bat- ?

tery Value
See Display Menu Flowchart
STEP A2
Battery OORL
NOTE: OOR Code is set if OOR condition is present for longer than 1 second.
Battery Voltage
Nominal 36 48 72 80
Fully Charged 39.6 52.8 79.2 88
˜< OORL 18 24 36 40
˜ OORH 48.6 57.6 97.2 108
Is battery voltage ˜ < OORL value for correct battery→ ?
STEP A3
Battery OORL

NO (v)→ ? YES (X) Recharge bat- See Operating Manual for ?

tery→ charge time

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-87
Diagnostic Trouble Codes Electrical System

Battery OORH/OORL (Cont)

STEP A4
Battery OORL/OORH
Battery Voltage
Nominal 36 48 72 80
Fully Charged 40 53 79 88

˜< OORL 18 24 36 40
˜> OORH 48.6 57.6 97.2 108
Operate truck→ All functions

Monitor battery voltage→ Is battery voltage going?↓ < OORL or ↑ > OORH value for correct battery→ ?
STEP A5
Battery OORH/OORL

YES (X) Inspect All Battery Connections for Corrosion/ High Resistance→ ?
NO (v) → Go to Step B4
CAUSE B
NOTE: High Resistance in Wiring and Connections will cause High Voltage drops (OORL) when subjected to
High Current Draw
NOTE: High Resistance in Wiring and Connections will cause High Voltage peaks (OORH) when subjected to
High Current Regen

Disconnect battery→ Set meter to lowest ? scale→ Check lead resistance < 0.01? ?

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9030-20-88 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Battery OORH/OORL (Cont)

STEP B1 CHECK RESISTANCE - Ω - OHMS
Battery OORH/OORL

Check resistance between the Battery (+) and (-) terminals and the Battery Connector (+) and (-) Terminals
1. > 0.01? Replace battery leads/connector terminal↓
2. > 0.01? Replace battery leads/connector terminal→ < 0.01? Connection OK→ ?
STEP B2

Check Resistance between the Bat (+) Connector and the Contactor Stud/Bat (-) Connector and Bat (-) to Sys-
tem
1. > 0.01? →Replace battery leads/connector terminal↓
2. > 0.01? →Replace battery leads/connector terminal→ < 0.01? → Connection OK ?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-89
Diagnostic Trouble Codes Electrical System

Battery OORH/OORL (Cont)

STEP B3
Battery OORH/OORL

Reconnect battery Retest Power ON NO → ? Is DTC gone? Fault Correc- Continue opera-
NO YES → ted→ tion
STEP B4
Battery OORH/OORL

Possible Battery Cell Failure→ Perform Battery Cell Test→ See Electrical System 2200SRM1337/Electrical
System 2200SRM1369.
If a cell failure is detected replace Battery→ ?
STEP B5

Retest Power ON NO → ? Is DTC gone? Fault Corrected→ Continue operation

NO YES →
CAUSE C
Not Applicable
CAUSE D
Not Applicable

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9030-20-90 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Battery OORH/OORL (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to Cause E1

Cause E1
CAUSE E1

Retest - Power ON→ NO → Is DTC gone? Fault corrected→ Continue operation.

Go to VSM Controller NO YES

Check
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-91
Diagnostic Trouble Codes Electrical System

VSM 5 Volt Supply (OORL) (OORH)

DTC 13056 DTC 13057

5V OORL 5V OORH

Fault Codes

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

WARNING
Any VSM 5 volt powered Device will be damaged by a Short to Battery (+) condition and possibly by a
Short to 12 volts (+).

WARNING
All VSM 5 volt powered devices will need to be checked for correct operation and probably replaced.

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9030-20-92 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

VSM 5 Volt Supply (OORL) (OORH) (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
DBB/CBB 4 WHEEL 5 VOLT SUPPLY CAUSES A B C D E > ?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-93
Diagnostic Trouble Codes Electrical System

VSM 5 Volt Supply (OORL) (OORH) (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
CBB 3 WHEEL 5 VOLT SUPPLY CAUSES A B C D E > ?

CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C

Power OFF→ Disconnect Accelerator Pedal sen- Go to Cause C1

sor→

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9030-20-94 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

VSM 5 Volt Supply (OORL) (OORH) (Cont)

CAUSE C1 UNSWITCHED VOLTAGES
5 Volt OORH

˜ 0 Volts = OK → Go to Cause C2→ Power ON→ Go to Cause C2

> 0 Volts = Short Circuit→ Bat (+) or 12v (+) Find ↑ Short circuit.
Repair Short circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369. Check all 5 volt
devices → Go to Component Operational Check
CAUSE C2 SWITCHED VOLTAGES
5 Volt OORH

˜ 0 Volts = Short to bat (-) → Go to Cause C3→ ˜ 5 Volts = Faulty Accelerator Pedal → Go Compo-
nent Operational Check↓
> 5.5 Volts = Short Circuit→ Bat (+) or 12v (+) Find ↑ Short circuit↓
Repair Short circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369. Check all 5 volt
devices → Go to Component Operational Check

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-95
Diagnostic Trouble Codes Electrical System

VSM 5 Volt Supply (OORL) (OORH) (Cont)

CAUSE C3
5 Volt OORL

˜ 0 Volts = Short circuit → Bat (-) → Find ↑ Short circuit ˜ 5 Volts = Faulty Accelerator Pedal → Replace – Go
Component Operational Check↓
Repair Short circuit, See Electrical System Go Component Operational Check↓
2200SRM1337/Electrical System 2200SRM1369.→
Check all 5 volt devices →
Reconnect Accelerator Pedal→ Go Component Operational Check↓
CAUSE D

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9030-20-96 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

VSM 5 Volt Supply (OORL) (OORH) (Cont)

CAUSE D1

Power OFF→ Disconnect next 5 volt Sensor→ Do Not Dis- Go to Cause D2.
card
CAUSE D2

? Power ON→ 5 Volt Fault DTC Old sensor faulty→ Install New sen- Resume operation
gone→ sor→

Original Fault DTC Old sensor OK/Reinstall Go to Next Sensor. Repeat Component
present→ old sensor→ Operational Check
All Sensors tested OK.
Go to Component Operational Check
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-97
Diagnostic Trouble Codes Electrical System

VSM 5 Volt Supply (OORL) (OORH) (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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9030-20-98 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Manual Hydraulic Position Sensors Out Of Range Low (OORL)

DTC 12860 DTC 12864 DTC 12868

Manual Hyd 2 Manual Hyd 3 Manual Hyd 4

Fault Codes
DTC 12856
Manual Hyd 1

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

MANUAL HYDRAULIC POSITION SENSOR CAUSES A B C D E > ?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-99
Diagnostic Trouble Codes Electrical System

Manual Hydraulic Position Sensors Out Of Range Low (OORL) (Cont)

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next step.

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B CHECK RESISTANCE - Ω - OHMS

8 ? = Open circuit→ Find↑ OPEN circuit ˜ 4.7K? = OK Go to Component Operational

Check
Repair OPEN circuit. See Electrical System ˜0?= Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. Check

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Electrical System Diagnostic Trouble Codes

Manual Hydraulic Position Sensors Out Of Range Low (OORL) (Cont)

CAUSE C

0 ? = Short circuit→ Find↑ Short circuit

Repair Short circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next step.
sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-101
Diagnostic Trouble Codes Electrical System

Manual Hydraulic Position Sensors Out Of Range Low (OORL) (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ OK - Go to Not OK →Correct/Repair Go to

Cause E1. Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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9030-20-102 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Manual Hydraulic Position Sensor Out Of Range High (OORH)

DTC 12861 DTC 12865 DTC 12869

Manual Hyd 2 Manual Hyd 3 Manual Hyd 4

Fault Codes
DTC 12857
Manual Hyd 1

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit

ACCELERATOR PEDAL POSITION A/B CAUSES A B C C1 C2 D E > ?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-103
Diagnostic Trouble Codes Electrical System

Manual Hydraulic Position Sensor Out Of Range High (OORH) (Cont)

CAUSE A

Power OFF→ Disconnect sensor→ Power ON→ Go to next step.

CAUSE A1 CHECK VOLTAGE

0 Volts = Open circuit→ Find↑ OPEN circuit. ˜ 5 Volts = OK Go to Component Operational

Check
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE B
Not Applicable
CAUSE C

Power OFF→ Reconnect sensor→ Power ON→ Go to next step.

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Electrical System Diagnostic Trouble Codes

Manual Hydraulic Position Sensor Out Of Range High (OORH) (Cont)

CAUSE C1 CHECK VOLTAGE

5 Volts = Short circuit→ Find↑ Short circuit. > 5.5 Volts Go to Cause C2.

Repair Short Circuit. See Electrical System < 4.5 volts OK Go to Component Operational
2200SRM1337/Electrical System 2200SRM1369. = Check.
CAUSE C2 CHECK VOLTAGE
Switched and Unswitched

> 5.5 Volts = Short circuit→ Find↑ Short circuit to an- < 4.5 volts OK Go to Component Operational
other voltage source. = Check.

Repair Short Circuit. See Electrical System

2200SRM1337/Electrical System 2200SRM1369.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-105
Diagnostic Trouble Codes Electrical System

Manual Hydraulic Position Sensor Out Of Range High (OORH) (Cont)

CAUSE D

Power OFF→ Disconnect sensor.→ Install new sen- Power ON→ Go to next step.
sor.→
Do not discard

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC Old sensor OK/Reinstall old Go to Component Operational

present→ sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

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Electrical System Diagnostic Trouble Codes

Manual Hydraulic Position Sensor Out Of Range High (OORH) (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-107
Diagnostic Trouble Codes Electrical System

E-Hydraulic Enable System Data Incorrect

Fault Codes
DTC 12332
Data Incorrect

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

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Electrical System Diagnostic Trouble Codes

E-Hydraulic Enable System Data Incorrect (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
E-HYDRAULIC ENABLE SYSTEM DATA INCORRECT CAUSES A A1 A2 A3 B B1 C C1 C2 D E > ?

CAUSE A
Not Applicable
CAUSE A1 CHECK VOLTAGE
NOTE: Locate DC/DC Convertor - Check DC/DC Voltage Input

0 Volts = Open circuit/Blown fuse↑ → ˜ Bat Volts OK Go to Cause A2

=
Find OPEN circuit or SHORT circuit that blew the fuse.
Repair OPEN Circuit/SHORT Circuit. See Electrical System 2200SRM1337/Electrical System
2200SRM1369.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-109
Diagnostic Trouble Codes Electrical System

E-Hydraulic Enable System Data Incorrect (Cont)

CAUSE A2 CHECK VOLTAGE
NOTE: Check DC/DC Voltage Output

0 Volts = Open circuit/DC/DC failure↑ → Find OPEN cir- ˜ 12 Volts OK Go to Cause A3

cuit. =
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
No wiring OPEN circuit.→ Replace DC/DC convertor.
CAUSE A3 CHECK VOLTAGE
NOTE: Occupy Seat - Operate any Hyd Function - Check Voltage out on Enable Relay

0 Volts = Open circuit/Relay Contacts↑ → Find OPEN ˜ 12 Volts = OK Go to Component Operational

circuit. Check
Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
No Wiring OPEN Circuit.→ Replace Enable Relay.
CAUSE B

Power OFF→ Disconnect Coil Connector→ Disconnect VSM Connector CPS2→ Go to next step.

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Electrical System Diagnostic Trouble Codes

E-Hydraulic Enable System Data Incorrect (Cont)

CAUSE B1 CHECK RESISTANCE - Ω - OHMS

8 ? = Open circuit→ Find↑ OPEN circuit.→ ˜0?= OK Go to Cause C1

Repair OPEN Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE C
Not Applicable
CAUSE C1 CHECK RESISTANCE - Ω - OHMS

0 ? to 1 ? = Short circuit→ Find↑ Short circuit.→ >1?= OK Reconnect all connections, go to

Component Operational Check
Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-111
Diagnostic Trouble Codes Electrical System

E-Hydraulic Enable System Data Incorrect (Cont)

CAUSE C2 CHECK RESISTANCE - Ω - OHMS

0 ? = Short circuit→ Find↑ Short circuit.→ 8?= OK Reconnect all connections, go to

Component Operational Check
Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.
CAUSE D
Not Applicable
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Electrical System Diagnostic Trouble Codes

E-Hydraulic Coils Short To Battery Positive (STBP)

DTC 8964 DTC 8968 DTC 8972

Lower Tilt Forward Tilt Back

Fault Codes
DTC 8960
Lift

DTC 8978 DTC 8980 DTC 8984 DTC 8988

Aux 1A Aux 1B Aux 2A Aux 2B

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-113
Diagnostic Trouble Codes Electrical System

E-Hydraulic Coils Short To Battery Positive (STBP) (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
E-HYDRAULIC ENABLE SYSTEM DATA INCORRECT CAUSES A B C C1 C2 C3 C4 C5 C6 D E > ?

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Electrical System Diagnostic Trouble Codes

E-Hydraulic Coils Short To Battery Positive (STBP) (Cont)

CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C

Power OFF→ Disconnect coil connectors→ Go to next step.

CAUSE C1 UNSWITCHED VOLTAGES
NOTE: Coil Driver Short to Unswitched Battery

Bat Volts = Short circuit→ Find↑ SHORT circuit.→ ˜ 0 Volts = OK Go to Cause C2

Repair SHORT Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE C2 SWITCHED VOLTAGES
NOTE: Coil Driver Short to Switched Battery

Power ON→ Go to next step.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-115
Diagnostic Trouble Codes Electrical System

E-Hydraulic Coils Short To Battery Positive (STBP) (Cont)

CAUSE C3 SWITCHED VOLTAGES
NOTE: Coil Driver Short to Switched Battery

Bat Volts = Short circuit→ Find↑ SHORT circuit → ˜ 0 Volts = OK Go to Cause C4

Repair SHORT Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE C4 SWITCHED VOLTAGES
NOTE: Short to Switched Battery

Bat Volts = Short circuit→ Find↑ SHORT circuit → ˜ 0 Volts = OK Go to Cause C5

Repair SHORT Circuit. See Electrical System

2200SRM1337/Electrical System 2200SRM1369.
CAUSE C5 UNSWITCHED VOLTAGES
NOTE: Short to Unswitched Battery

Power OFF→ ?

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Electrical System Diagnostic Trouble Codes

E-Hydraulic Coils Short To Battery Positive (STBP) (Cont)

CAUSE C6 UNSWITCHED VOLTAGES
NOTE: Short to Unswitched Battery

Bat Volts = Short circuit→ Find↑ SHORT circuit → ˜ 0 Volts = OK Go to Component Operational
Check
Repair Open Circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE D
Not Applicable
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Diagnostic Trouble Codes Electrical System

E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC)

DTC 13316 DTC 13320 DTC 13324

Lower Tilt Forward Tilt Back

Fault Codes
DTC 13312
Lift

DTC 13328 DTC 13332 DTC 13336 DTC 13340

Aux 1A Aux 1B Aux 2A Aux 2B

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

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Electrical System Diagnostic Trouble Codes

E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC) (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
E-HYDRAULIC COILS (STBN)/(OC) CAUSES A B C E > ?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-119
Diagnostic Trouble Codes Electrical System

E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC) (Cont)

CAUSE A
For causes A1, A2, and A3, go to DTC 12332 in E-Hydraulic Enable System Data Incorrect.
CAUSE B

Power OFF→ Disconnect coil connectors→ Go to next step.

CAUSE B1 CHECK RESISTANCE - Ω - OHMS
NOTE: Open Circuit - Coil Connector To VSM

8Ω = Open circuit→ Find↑ OPEN circuit→ ˜ 90kΩ = OK Go to Cause B2

Repair OPEN circuit. See Electrical System ˜ 0Ω = Go to Cause C3
2200SRM1337/Electrical System 2200SRM1369.

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Electrical System Diagnostic Trouble Codes

E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC) (Cont)

CAUSE B2 CHECK RESISTANCE - Ω - OHMS
NOTE: Open Circuit - Coil Connections To Coil

8Ω = Open circuit→ Find↑ OPEN circuit→ ˜4.5Ω ± OK Go to Cause C2

1.5Ω =
Repair OPEN circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
> 6Ω < 3Ω = Faulty Coil→ ReplaceCoil→

Repair OPEN circuit. See Electrical System

2200SRM1337/Electrical System 2200SRM1369.
CAUSE C
Go to Cause C1
CAUSE C1 CHECK RESISTANCE - Ω - OHMS
For DC/DC volt Short to Battery, go to DTC 12332 in E-Hydraulic Enable System Data Incorrect.
CAUSE C2 CHECK RESISTANCE - Ω - OHMS
For DC/DC volt Short to Battery, go to DTC 12332 in E-Hydraulic Enable System Data Incorrect.
CAUSE C3 CHECK RESISTANCE - Ω - OHMS
NOTE: Short to Bat (-) Coil Driver Connectional

0 Ω = Short circuit→ Find↑ Short circuit→ ˜ 90kΩ = OK Go to Component Operational

Check
Repair Short circuit. See Electrical System
2200SRM1337/Electrical System 2200SRM1369.
CAUSE D
Not Applicable

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-121
Diagnostic Trouble Codes Electrical System

E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC) (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.
CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Electrical System Diagnostic Trouble Codes

A935 – K160 CAN Communication Failure

DTC 33025 DTC 33026 DTC 33027 DTC 33029

VSM to Display VSM to Traction VSM to Traction 2 VSM to Pump
1 (Right) (Left)
Fault Codes
DTC 33034 DTC 33035 DTC 33036 DTC 33037
VSM to MLM (DCS) VSM to Impact VSM to CAN Re- VSM to CAN Re-
served 1 served 2

DTC 33038 DTC 33057

VSM to CAN Re- Display to VSM
served 3

Power OFF→ Wait 30 sec- Power ON→ Fault remains. Service re- No fault→ Resume Operation
onds→ quired. Go to Quick Check.
FAULT LOG DTC Review – Go to Display Menu

Enter SERVICE Diagnostics→ Fault Logs→ VSM Fault Logs→ View all VSM DTCs→ ?
Password→

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-123
Diagnostic Trouble Codes Electrical System

A935 – K160 CAN Communication Failure (Cont)

3? all VSM DTCs Multiple VSM DTCs→ Erase VSM DTCs→ Exit Fault Log→ Power OFF→ Quick Check ↓
Single DTC→ Specific Device Fault Log→ 3? Device DTCs→ Erase Device DTCs↓
Emergency Stop Switch→ OFF → Wait 30 seconds→ ON → ?↓ Recheck Single Device Fault Logs↓
DTCs Present→ 3? DTCs→ Power OFF→ Go to Single DTCs Gone→ Resume Operation
Device TSP↓

QUICK CHECK X Open Circuit/Fail ) = Short Circuit

Disconnect Battery Disconnect Battery and Locate Diagnostic Connec- Service Connection
Sound Horn to Discharge tor CPS 28
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.

Short Circuit CAN Hi/CAN Open Circuit CAN Hi/CAN Open Circuit CAN Hi/ CAN Circuit OK
Lo Lo Lo Termination Resistor Go to Step A2,
Go to Step C1, Go to Component Opera- Go to Component Opera- Single CAN Device DTC
All CAN Device DTCs tional Check, tional Check,
Multiple CAN Device DTCs Intermittent DTCs

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Electrical System Diagnostic Trouble Codes

A935 – K160 CAN Communication Failure (Cont)

CAN Hi Short Circuit Bat CANbus Circuit OK CAN Hi Short Circuit Bat CANbus Circuit OK
(-) Go to Step A2, (+) Go to Step A2,
Go to Step C2, Single CAN Device DTC All CAN Device DTCs Single CAN Device DTC
All CAN Device DTCs Go to Step C3,

CAN Lo STB (-), No DTC CAN Hi Short to 12/5 (+)

Go to Step C2, No DTC
No DTC
CAN Lo Short Circuit Bat
(+)
All CAN Device DTCs
Go to Step C3,
SINGLE DEVICE DTC→ Fault is isolated to a SINGLE CANbus Connected Device and its Supply Connections
MULTIPLE DEVICE DTCs → Faults that affect some but not all CANbus Devices→ Typically Open Circuits
ALL DEVICE DTCs→ Faults that affect all of the CANbus connected devices→ Typically Short Circuits

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-125
Diagnostic Trouble Codes Electrical System

A935 – K160 CAN Communication Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
CAUSES A B C D E > ?
Table 9030-20-5. Main Schematic

Open Circuit – Termination Resistor/CAN Hi/CAN Lo/Key Switch Supply/Device Supply/ CAUSES A, B
CAN Short to – Bat (-)/12volt Bat (+)/Shorted CAN Hi to CAN Lo/Device Failure CAUSES C, D, E

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Electrical System Diagnostic Trouble Codes

A935 – K160 CAN Communication Failure (Cont)

CONNECTORS
Table 9030-20-6. Device Connectors

VSM Cxx 1 and Cxx 2 Main Seat Cxx 52 Impact Device Cxx Service Connector Cxx
and 54 148 28

Traction/Pump Controller Cxx 3, 4, and 5 MLM Cxx 52 Display Harness Cxx Display Cxx 20
135

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-127
Diagnostic Trouble Codes Electrical System

A935 – K160 CAN Communication Failure (Cont)

CAUSE A
CAN Hi/CAN Lo Single Device DTC (Black X) vs Multiple DTCs (Red X)

1, 2, and 3 are examples of possible Causes

1. Single DTC→Indicated Device Connections/Device Fail→Step A1
1. Single DTC above →Open Circuit on Device Supply (+) or Bat (-) or Open Circuit on Sub Circuit Wir-
ing→Step A3
2. Multiple DTCs→Fault Log→DTC/Device closest to VSM↑→= Open circuit between DTC Device and
VSM→Step B3
3. All DTCs above→Open Circuit on Device Supply (+) Bat (-)→= Supply Failure/Open Circuit Main Supply Cir-
cuit→Step A3
3. All DTCs above→Open/Short Circuit on VSM CANbus→= Open Circuit→Step B3 – Short Circuit→Component
Operational Check
STEP A1
CAN Hi/ CAN Lo Single Device DTC - Locate Device

1. Example Only→ Single DTC→ Indicated Device Connections/Device Fail→ of Step A2

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Electrical System Diagnostic Trouble Codes

A935 – K160 CAN Communication Failure (Cont)

STEP A2

Power ON→ Step A3

STEP A3
Single Device DTC Open Circuit Supply Voltage

1. Locate Device→Check connection→Not OK, Go to 1. Connection OK→Go to 2↓

4↓
2. = 0 Volts = Open Circuit Supply/(+) or (-) →Go to 4↓ 2. =Supply Volts = OK→Step B1↓
3. > Supply Volts →Check for Shorts to a higher supply source→Repair→Component Operational Check as
CAN Device may be damaged
4. Reference Main Schematic - Find/Repair Open Circuit See Electrical System 2200SRM1337/Electrical
System 2200SRM1369→Recheck Voltage↑→Step A4↓
STEP A4

Retest - Power OFF NO → Component Op- Is fault DTC gone? Fault corrected→ Continue operation
Power ON erational Check
NO YES ← →

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-129
Diagnostic Trouble Codes Electrical System

A935 – K160 CAN Communication Failure (Cont)

CAUSE B

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ Go to Step B1
Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP B1
Single Device DTC Open Circuit CAN Hi or CAN Lo

Locate Device→ Check Connection→ Not OK, Go to 4↓ Connections OK→ Reconnect→ Go to Step B2
Device with Termination Resistor→ Locate and Discon- See Device Connectors
nect ↓
1. > 120? = Open Circuit Termination Resistor →Go to 1. ˜ 120? = OK Go to 2 ↓
3↓
2. = 8? = Open Circuit →Go to 4↓ 2. ˜ 0? = OK Go to 3 ↓
3. Replace Device→Component Operational Check↓
4. Find/Repair Open Circuit, See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Re-
check?↑→Reconnect→Step B2↓
STEP B2

Reconnect Battery Retest - Power ON NO → Step B3, Is fault DTC gone? Fault correc-
ted→ Continue
NO YES operation

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Electrical System Diagnostic Trouble Codes

A935 – K160 CAN Communication Failure (Cont)

STEP B3

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ De- Go to Step B4
pending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP B4
Multi CAN Device DTCs Display > Open Circuit CAN Hi to CAN Lo

Example Only→ Multiple DTCs→ Fault Log→ DTC/Device closest to VSM

Open circuit is between DTC Device and VSM→ , Step B5↓

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-131
Diagnostic Trouble Codes Electrical System

A935 – K160 CAN Communication Failure (Cont)

STEP B5
Multi Device DTCs Open Circuit CAN Hi or CAN Lo

The above is an Example Only

Disconnect VSM CPS1→ Measure ? See Device Connectors
> 60? to 8? = CAN Hi/Lo Open Circuit Step B6↓ ˜ 0? → Component Operational Check ↓
˜ 60? = OK→ Component Operational Check ↓
STEP B6

The above is an Example Only

Locate Device to Right or Left of Indicated Open Cir- Disconnect → See Device Connectors↓
cuit→
1. 8? = CAN Hi Open Circuit→Go to 3↓ 1. ˜ 0? = OK →Component Operational Check↓
2. 8? = CAN Lo Open Circuit→Go to 3↓ 2. ˜ 0? = OK →Component Operational Check↓
3. Find/Repair Short Circuit, See Electrical System 2200SRM1337/Electrical System 2200SRM1369Re-
check ?→Reconnect→Retest→Component Operational Check↓

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Electrical System Diagnostic Trouble Codes

A935 – K160 CAN Communication Failure (Cont)

CAUSE C
All CAN Device DTCs Displayed > CAN Hi/CAN Lo Short Circuit together/Supply (+) or (-)

All DTCs→ Open Circuit to VSM → Step B5 ↑

All DTCs→ Short Circuit CAN Hi to CAN Lo → Step C1 ↓
All DTCs→ Short Circuit CAN Hi to (-) Supply Sources → Step C2 ↓ No DTCs→ Short Circuit CAN Lo to (–-)
Supply Sources
All DTCs→ Short Circuit CAN Lo to (+) Supply Sources→ Step C3 ↓ No DTCs→ Short Circuit CAN Hi to (+)
Supplies (5, 12 volt)
STEP C1
All Device DTCs Short Circuit CAN Hi to CAN Lo

Locate Service Connection → Measure ? See Device Connectors↓

1. = 0? CAN Hi/Lo Short Circuit→Go to 2↓ 1. ˜ 60? = OK →Step C2↓
2. Inspect Accessible Harness Areas for Insulation Damage then Inaccessible Harness Areas. Focus on Bend
Edges and Pinch Points, Go to 3↓
3. Find/Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369 Re-
check ?→Reconnect→Retest→Step C5↓

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-133
Diagnostic Trouble Codes Electrical System

A935 – K160 CAN Communication Failure (Cont)

STEP C2
All Device DTCs Short Circuit CAN Hi to Bat (-) CAN Lo to Bat (-) will not Produce a DTC

1. 0? = CAN Hi Short Circuit. Go to 3↓ 1. > 50K? = OK, Go to 3↓

2. 0? = CAN Lo Short Circuit. Go to 3↓ 2. > 50K? = OK, Go to 3 ↓
3. Find/Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369 Re-
check ?→Reconnect→Retest, →Step C5
STEP C3
Multiple CAN Device DTCs Displayed > (+) Supply Short Circuit to CAN Hi or CAN Lo

All DTCs→ Short Circuit CAN Lo to (+) Supply Sources.

All DTCs→ Short Circuit CAN Hi to (+) Supply Sources. No DTCs for a Short to (+)12 Volts or (+) 5 Volts

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Electrical System Diagnostic Trouble Codes

A935 – K160 CAN Communication Failure (Cont)

STEP C4
All Device DTCs Short Circuit Supply (+) to CAN Hi or CAN Lo

1. A, B, C, D, and E = 0? = CAN Hi Short Circuit, Go to 1. A, B, C, D, and E > 50K? = OK→, Step C5↓
3↓
2. A, B, C, D, and E = 0? = CAN Lo Short Circuit, Go to 2. A, B, C, D, and E > 50K? =OK→Step C5↓
3↓
3. Find/Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369 Re-
check ?→Reconnect→Retest→Step C5↓
STEP C5

Reconnect Battery Retest - Power ON NO → Go to Compo- Is fault DTC gone? Fault correc-
nent Operational ted→ Continue
Check NO YES operation
CAUSE D

Disconnect Battery To Power OFF Disconnect CAN De- Install New CAN De- Power ON→
Replace Motor Control- vice→ vice Go to Step D1
ler
Do Not Discard

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Diagnostic Trouble Codes Electrical System

A935 – K160 CAN Communication Failure (Cont)

STEP D1

? Fault DTC gone→ Old device faulty→ Resume operation

Fault DTC present→ Old Device OK/Reinstall Old Go to Component Operational

Device→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Step E1 Step E1
STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation
troller Check
NO YES
END FAULT

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Electrical System Diagnostic Trouble Codes

CBB 4 Wheel CAN Communication

DTC 33025 DTC 33026 DTC 33027 DTC 33029

VSM to Display VSM to Traction VSM to Traction 2 VSM to Pump
1 (Right) (Left)
Fault Codes
DTC 33034 DTC 33035 DTC 33036 DTC 33037
VSM to MLM (DCS) VSM to Impact VSM to CAN Re- VSM to CAN Re-
served 1 served 2

DTC 33038 DTC 33057

VSM to CAN Re- Display to VSM
served 3

Power OFF→ Wait 30 sec- Power ON→ Fault remains. Service re- No fault→ Resume Operation
onds→ quired. Go to Quick Check.
FAULT LOG DTC Review – Go to Display Menu

Enter SERVICE Diagnostics→ Fault Logs→ VSM Fault Logs→ View all VSM DTCs→ ?
Password→

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Diagnostic Trouble Codes Electrical System

CBB 4 Wheel CAN Communication (Cont)

3? all VSM DTCs Multiple VSM DTCs→ Erase VSM DTCs→ Exit Fault Log→ Power OFF→ Quick Check ↓
Single DTC→ Specific Device Fault Log→ 3? Device DTCs→ Erase Device DTCs↓
Emergency Stop Switch→ OFF → Wait 30 seconds→ ON → ?↓ Recheck Single Device Fault Logs↓
DTCs Present→ 3? DTCs→ Power OFF→ Go to Single DTCs Gone→ Resume Operation
Device TSP↓

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Electrical System Diagnostic Trouble Codes

CBB 4 Wheel CAN Communication (Cont)

QUICK CHECK X Open Circuit/Fail ) = Short Circuit

Disconnect Battery Disconnect Battery and Locate Diagnostic Connec- Service Connection
Sound Horn to Discharge tor CPS 28
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.

Short Circuit CAN Hi/CAN Open Circuit CAN Hi/CAN Open Circuit CAN Hi/ CAN Circuit OK
Lo Lo Lo Termination Resistor Go to Step A2,
Go to Step C1, Go to Component Opera- Go to Component Opera- Single CAN Device DTC
All CAN Device DTCs tional Check, tional Check,
Multiple CAN Device DTCs Intermittent DTCs

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-139
Diagnostic Trouble Codes Electrical System

CBB 4 Wheel CAN Communication (Cont)

CAN Hi Short Circuit Bat CANbus Circuit OK CAN Hi Short Circuit Bat CANbus Circuit OK
(-) Go to Step A2, (+) Go to Step A2,
Go to Step C2, Single CAN Device DTC All CAN Device DTCs Single CAN Device DTC
All CAN Device DTCs Go to Step C3,

CAN Lo STB (-), No DTC CAN Hi Short to 12/5 (+)

Go to Step C2, No DTC
No DTC
CAN Lo Short Circuit Bat
(+)
All CAN Device DTCs
Go to Step C3,
SINGLE DEVICE DTC→ Fault is isolated to a SINGLE CANbus Connected Device and its Supply Connections
MULTIPLE DEVICE DTCs → Faults that affect some but not all CANbus Devices→ Typically Open Circuits
ALL DEVICE DTCs→ Faults that affect all of the CANbus connected devices→ Typically Short Circuits

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Electrical System Diagnostic Trouble Codes

CBB 4 Wheel CAN Communication (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
CAUSES A B C D E > ?
Table 9030-20-7. Main Schematic

Open Circuit – Termination Resistor/CAN Hi/CAN Lo/Key Switch Supply/Device Supply/ CAUSES A, B
CAN Short to > Bat (-)/12volt Bat (+)/Shorted CAN Hi to CAN Lo/Device Failure CAUSES C, D, E >?

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Diagnostic Trouble Codes Electrical System

CBB 4 Wheel CAN Communication (Cont)

CONNECTORS
Table 9030-20-8. Device Connectors

VSM Cxx 1 and Cxx 2 Main Seat Cxx 52 and Impact Device Cxx 148 Service Connector Cxx
54 28

Traction/Pump Controller Cxx 3, 4, and 5 MLM Cxx 52 Display Harness Cxx Display Cxx 20
135

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Electrical System Diagnostic Trouble Codes

CBB 4 Wheel CAN Communication (Cont)

CAUSE A
CAN Hi/CAN Lo Single Device DTC (Black X) vs Multiple DTCs (Red X)

1, 2, and 3 are examples of possible Causes

1. Single DTC→Indicated Device Connections/Device Fail→Step A1
1. Single DTC above →Open Circuit on Device Supply (+) or Bat (-) or Open Circuit on Sub Circuit Wir-
ing→Step A3
2. Multiple DTCs→Fault Log→DTC/Device closest to VSM↑→= Open circuit between DTC Device and
VSM→Step B3
3. All DTCs above→Open Circuit on Device Supply (+) Bat (-)→= Supply Failure/Open Circuit Main Supply Cir-
cuit→Step A3
3. All DTCs above→Open/Short Circuit on VSM CANbus→= Open Circuit→Step B3 – Short Circuit→Component
Operational Check
STEP A1
CAN Hi/ CAN Lo Single Device DTC - Locate Device

1. Example Only→Single DTC→Indicated Device Connections/Device Fail→Step A2↓

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Diagnostic Trouble Codes Electrical System

CBB 4 Wheel CAN Communication (Cont)

STEP A2

Power ON→ Step A3

STEP A3
Single Device DTC Open Circuit Supply Voltage

NOTE: Motor Controllers Require Battery Removal. Only do this if either or both Motor Controller DTCs as Dis-
played
NOTE: If Fault Log shows Multiple DTCs = Possible Open Circuit Supply (+) (-) other than at the Device
1. Locate Device→Check connection→Not OK, Go to 1. Connection OK→Go to 2↓
4↓
2. = 0 Volts = Open Circuit Supply/(+) or (-) →Go to 4↓ 2. =Supply Volts = OK→Step B1↓
3. > Supply Volts →Check for Shorts to a higher supply source→Repair→Component Operational Check as
CAN Device may be damaged
4. Reference Main Schematic - Find/Repair Open Circuit See Electrical System 2200SRM1337/Electrical
System 2200SRM1369→Recheck Voltage↑→Step A4↓
STEP A4

Retest - Power OFF NO → Component Op- Is fault DTC gone? Fault corrected→ Continue operation
Power ON erational Check
NO YES ← →

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Electrical System Diagnostic Trouble Codes

CBB 4 Wheel CAN Communication (Cont)

CAUSE B

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ Go to Step B1
Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP B1
Single Device DTC Open Circuit CAN Hi or CAN Lo – Motor Devices, See Step B2.

Locate Device→ Disconnect→ Check Connection→ Measure ? → Go to 1↓

1. 8? = Open Circuit CAN Device to Harness→Go to 2↓ 1. ˜ 60? = OK →CAN Device FaultyGo to Component
Operational Check↓
2. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 3↓
3. Recheck ?↑→Reconnect→Step B2↓

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-145
Diagnostic Trouble Codes Electrical System

CBB 4 Wheel CAN Communication (Cont)

STEP B2
Single Device DTC Open Circuit CAN Hi or CAN Lo – Motor Device with Termination Resistor shown

Locate Device→ Disconnect→ Check Connection→ Measure ? → Go to 1↓

1. 8? = Open Circuit CAN Device to Harness→Go to 3↓ 1. ˜ 60?/120? = OK →CAN Device FaultyGo to Com-
ponent Operational Check↓
2. 8? = Open Circuit →Go to 3↓ 2. ˜ 0? = OK Reconnect Device →Go to 3↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 4↓
4. Recheck ?↑→Reconnect→Step B2↓

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Electrical System Diagnostic Trouble Codes

CBB 4 Wheel CAN Communication (Cont)

STEP B3
Single Device DTC Open Circuit CAN Hi or CAN Lo – Motor Device with Termination Resistor shown

Locate Device→ Disconnect→ Check Connection→ Measure ? → Go to 1↓

1. 8? = Open Circuit Motor Controller Loop(s)→Go to 1. ˜ 0? = OK →Go to 3↓
5↓
2. 8? = Open Circuit Motor Controller Loop(s)→Go to 2. ˜ 0? = OK →Go to 3↓
5↓
3. 8? = Open Circuit →Go to Component Operational 3. ˜ 0? = OK Reconnect Device →Go to 4↓
Check↓
4. > 120? = Open Circuit Termination Resistor→Go to 4. ˜ 120? = OK Reconnect Device →Go to Step B4↓
Component Operational Check↓
5. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 6↓
6. Recheck ?↑→Reconnect→Step B4↓
STEP B4

Reconnect Battery Retest - Power ON NO → ? Is fault DTC gone? Fault correc-

ted→ Continue
NO YES operation

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Diagnostic Trouble Codes Electrical System

CBB 4 Wheel CAN Communication (Cont)

STEP B5

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ De- Go to Step B4
pending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP B6
Multi CAN Device DTCs Display > Open Circuit CAN Hi to CAN Lo

Example Only→ Multiple DTCs→ Fault Log→ DTC/Device closet to VSM

Open circuit is between DTC Device and VSM→ Step B5 ↓

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Electrical System Diagnostic Trouble Codes

CBB 4 Wheel CAN Communication (Cont)

STEP B7
Multi Device DTCs Open Circuit CAN Hi or CAN Lo

The above is an Example Only

Disconnect VSM CPS1→ Measure ? See Device Connectors
> 60? to 8? = Termination Resistor/CAN Hi/Lo Open ˜ 60? = OK→ Component Operational Check ↓
Circuit Step B6↓
> 60? to 8? = Termination Resistor/CAN Hi/Lo Open
Circuit Step B6↓ ˜ 0?→ Component Operational Check ↓
STEP B8

Disconnect Termination Resistor Connector Cxx 42

1. = 120? = Faulty Connections/Wiring/ to Termination Resistor or Faulty Termination Resistor→Go to 3↓
2. >120? = Faulty Connections/Wiring/ Pump Controller→Step B7↓
3. Measure Termination Resistor ?
4. >120? = Faulty Resistor→Replace→Recon- 4. = 120?→Step B7↓
nect→Retest ?→

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Diagnostic Trouble Codes Electrical System

CBB 4 Wheel CAN Communication (Cont)

STEP B9

The above is an Example Only

Locate Device to Right or Left of Indicated Open Cir- Disconnect → See Device Connectors↓
cuit→
1. 8? = CAN Hi Open Circuit→Go to 3↓ 1. ˜ 0? = OK →Component Operational Check↓
2. 8? = CAN Lo Open Circuit→Go to 3↓ 2. ˜ 0? = OK →Component Operational Check↓
3. Find/Repair Short Circuit, See Electrical System 2200SRM1337/Electrical System 2200SRM1369Re-
check ?→Reconnect→Retest→Component Operational Check↓
CAUSE C
All CAN Device DTCs Displayed > CAN Hi/CAN Lo Short Circuit together/Supply (+) or (-)

All DTCs→ Open Circuit to VSM → Step B5 ↑

All DTCs→ Short Circuit CAN Hi to CAN Lo → Step C1 ↓
All DTCs→ Short Circuit CAN Hi to (-) Supply Sources → Step C2 ↓ No DTCs→ Short Circuit CAN Lo to (–-)
Supply Sources
All DTCs→ Short Circuit CAN Lo to (+) Supply Sources→ Step C3 ↓ No DTCs→ Short Circuit CAN Hi to (+)
Supplies (5, 12 volt)

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Electrical System Diagnostic Trouble Codes

CBB 4 Wheel CAN Communication (Cont)

STEP C1
All Device DTCs Short Circuit CAN Hi to CAN Lo

Locate Service Connection → Measure ? See Device Connectors↓

1. = 0? CAN Hi/Lo Short Circuit→Go to 2↓ 1. ˜ 60? = OK →Step C2↓
2. Inspect Accessible Harness Areas for Insulation Damage then Inaccessible Harness Areas. Focus on Bend
Edges and Pinch Points, Go to 3↓
3. Find/Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369 Re-
check ?→Reconnect→Retest→Step C5↓
STEP C2
All Device DTCs Short Circuit CAN Hi to Bat (-) CAN Lo to Bat (-) will not Produce a DTC

1. 0? = CAN Hi Short Circuit. Go to 3↓ 1. > 50K? = OK, Go to 3↓

2. 0? = CAN Lo Short Circuit. Go to 3↓ 2. > 50K? = OK, Go to 3 ↓
3. Find/Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369 Re-
check ?→Reconnect→Retest, →Step C5

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-151
Diagnostic Trouble Codes Electrical System

CBB 4 Wheel CAN Communication (Cont)

STEP C3
Multiple CAN Device DTCs Displayed > (+) Supply Short Circuit to CAN Hi or CAN Lo

All DTCs→ Short Circuit CAN Lo to (+) Supply Sources.

All DTCs→ Short Circuit CAN Hi to (+) Supply Sources. No DTCs for a Short to (+)12 Volts or (+) 5 Volts
STEP C4
All Device DTCs Short Circuit Supply (+) to CAN Hi or CAN Lo

1. A, B, C, D, and E = 0? = CAN Hi Short Circuit, Go to 1. A, B, C, D, and E > 50K? = OK→, Step C5↓
3↓
2. A, B, C, D, and E = 0? = CAN Lo Short Circuit, Go to 2. A, B, C, D, and E > 50K? =OK→Step C5↓
3↓
3. Find/Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369 Re-
check ?→Reconnect→Retest→Step C5↓

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Electrical System Diagnostic Trouble Codes

CBB 4 Wheel CAN Communication (Cont)

STEP C5

Reconnect Battery Retest - Power ON NO → Go to Compo- Is fault DTC gone? Fault correc-
nent Operational ted→ Continue
Check NO YES operation
CAUSE D

Disconnect Battery To Power OFF Disconnect CAN De- Install New CAN De- Power ON→
Replace Motor Control- vice→ vice Go to Step D1
ler
Do Not Discard
STEP D1

? Fault DTC gone→ Old device faulty→ Resume operation

Fault DTC present→ Old Device OK/Reinstall Old Go to Component Operational

Device→ Check.

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Diagnostic Trouble Codes Electrical System

CBB 4 Wheel CAN Communication (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Step E1 Step E1
STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation
troller Check
NO YES
END FAULT

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Electrical System Diagnostic Trouble Codes

DBB 4 Wheel CAN Communication

DTC 33025 DTC 33026 DTC 33027 DTC 33029

VSM to Display VSM to Traction VSM to Traction 2 VSM to Pump
1 (Right) (Left)
Fault Codes
DTC 33034 DTC 33035 DTC 33036 DTC 33037
VSM to MLM (DCS) VSM to Impact VSM to CAN Re- VSM to CAN Re-
served 1 served 2

DTC 33038 DTC 33057

VSM to CAN Re- Display to VSM
served 3

Power OFF→ Wait 30 sec- Power ON→ Fault remains. Service re- No fault→ Resume Operation
onds→ quired. Go to Quick Check.
FAULT LOG DTC Review – Go to Display Menu

Enter SERVICE Pass- Diagnos- Fault Logs→ VSM Fault Logs→ View all VSM DTCs→ ?
word→ tics→

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Diagnostic Trouble Codes Electrical System

DBB 4 Wheel CAN Communication (Cont)

3? all VSM DTCs Multiple VSM DTCs→ Erase VSM DTCs→ Exit Fault Log→ Power OFF→ Quick
Check ↓
Single DTC→ Specific Device Fault Log→ 3? Device DTCs→ Erase Device DTCs↓
Emergency Stop Switch→ OFF → Wait 30 seconds→ ON → ? Recheck Single Device Fault Logs↓
DTCs Present→ 3? DTCs→ Power OFF→ Go to Single DTCs Gone→ Resume Operation
Device TSP↓

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Electrical System Diagnostic Trouble Codes

DBB 4 Wheel CAN Communication (Cont)

QUICK CHECK X Open Circuit/Fail ) = Short Circuit

Disconnect Battery Disconnect Battery and Locate Diagnostic Connec- Service Connection
Sound Horn to Discharge tor CPS 28
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.

Short Circuit CAN Hi/CAN Open Circuit CAN Hi/CAN Open Circuit CAN Hi/ CAN Circuit OK
Lo Lo Lo Termination Resistor Go to Step A2,
Go to Step C1, Go to Component Opera- Go to Component Opera- Single CAN Device DTC
All CAN Device DTCs tional Check, tional Check,
Multiple CAN Device DTCs Intermittent DTCs

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Diagnostic Trouble Codes Electrical System

DBB 4 Wheel CAN Communication (Cont)

CAN Hi Short Circuit Bat CANbus Circuit OK CAN Hi Short Circuit Bat CANbus Circuit OK
(-) Go to Step A2, (+) Go to Step A2,
Go to Step C2, Single CAN Device DTC All CAN Device DTCs Single CAN Device DTC
All CAN Device DTCs Go to Step C3,

CAN Lo STB (-), No DTC CAN Hi Short to 12/5 (+)

Go to Step C2, No DTC
No DTC
CAN Lo Short Circuit Bat
(+)
All CAN Device DTCs
Go to Step C3,
SINGLE DEVICE DTC→ Fault is isolated to a SINGLE CANbus Connected Device and its Supply Connections
MULTIPLE DEVICE DTCs → Faults that affect some but not all CANbus Devices→ Typically Open Circuits
ALL DEVICE DTCs→ Faults that affect all of the CANbus connected devices→ Typically Short Circuits

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Electrical System Diagnostic Trouble Codes

DBB 4 Wheel CAN Communication (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
CAUSES A B C D E > ?
Table 9030-20-9. Main Schematic

Open Circuit – Termination Resistor/CAN Hi/CAN Lo/Key Switch Supply/Device Supply/ CAUSES A, B
CAN Short to – Bat (-)/12volt Bat (+)/Shorted CAN Hi to CAN Lo/Device Failure CAUSES C, D, E

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Diagnostic Trouble Codes Electrical System

DBB 4 Wheel CAN Communication (Cont)

CONNECTORS
Table 9030-20-10. Device Connectors

VSM Cxx 1 and Cxx 2 Main Seat Cxx 52 Impact Device Cxx Service Connector Cxx
and 54 148 28

Traction/Pump Controller Cxx 3, 4, and 5 MLM Cxx 52 Display Harness Cxx Display Cxx 20
135

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Electrical System Diagnostic Trouble Codes

DBB 4 Wheel CAN Communication (Cont)

CAUSE A
CAN Hi/CAN Lo Single Device DTC (Black X) vs Multiple DTCs (Red X)

1, 2, and 3 are examples of possible Causes

1. Single DTC→Indicated Device Connections/Device Fail→Step A1
1. Single DTC above →Open Circuit on Device Supply (+) or Bat (-) or Open Circuit on Sub Circuit Wir-
ing→Step A3
2. Multiple DTCs→Fault Log→DTC/Device closest to VSM↑→= Open circuit between DTC Device and
VSM→Step B3
3. All DTCs above→Open Circuit on Device Supply (+) Bat (-)→= Supply Failure/Open Circuit Main Supply Cir-
cuit→Step A3
3. All DTCs above→Open/Short Circuit on VSM CANbus→= Open Circuit→Step B3 – Short Circuit→Component
Operational Check
STEP A1
CAN Hi/ CAN Lo Single Device DTC - Locate Device

1. Example Only→Single DTC→Indicated Device Connections/Device Fail→?

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Diagnostic Trouble Codes Electrical System

DBB 4 Wheel CAN Communication (Cont)

STEP A2

Power ON→ ?
STEP A3
Single Device DTC Open Circuit Supply Voltage

1. Locate Device→Check connection→Not OK, Go to 1. Connection OK→Go to 2↓

4↓
2. = 0 Volts = Open Circuit Supply/(+) or (-) →Go to 4↓ 2. =Supply Volts = OK→Step B1↓
3. > Supply Volts →Check for Shorts to a higher supply source→Repair→Component Operational Check as
CAN Device may be damaged
4. Reference Main Schematic - Find/Repair Open Circuit See Electrical System 2200SRM1337/Electrical
System 2200SRM1369→Recheck Voltage↑→Step A4↓
STEP A4

Retest - Power OFF NO → ? Is fault DTC gone? Fault corrected→ Continue oper-
Power ON ation
NO YES

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Electrical System Diagnostic Trouble Codes

DBB 4 Wheel CAN Communication (Cont)

CAUSE B

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ ?

Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP B1
Single Device DTC Open Circuit CAN Hi or CAN Lo

Locate Device→ Check Connection→ Not OK, Go to 6↓ Connections OK→ Reconnect→ Go to Step B2
Device with Termination Resistor→ Locate and Discon- See Device Connectors
nect ↓
1. > 120? = Open Circuit Termination Resistor →Go to 1. ˜ 120? = OK Go to 2 ↓
5↓
2. = 8? = Open Circuit →Go to 5↓ 2. ˜ 0? = OK Go to 3 ↓
3. = 8? = Open Circuit →Go to 6↓ 3. ˜ 0? = OK Reconnect Device↓
4. Motor Controller ID Loop(s) = 8? = Open Circuit→Go 4. Reference Main Schematic ˜ 0? = OK Reconnect
to 6↓ Device ↓
5. Replace Device→Component Operational Check↓
6. Find/Repair Open Circuit, See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Re-
check?↑→Reconnect→?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-163
Diagnostic Trouble Codes Electrical System

DBB 4 Wheel CAN Communication (Cont)

STEP B2

Reconnect Battery Retest - Power ON NO → ? Is fault DTC gone? Fault correc-

ted→ Continue
NO YES operation
STEP B3

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ De- ?
pending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP B4
Multi CAN Device DTCs Display > Open Circuit CAN Hi to CAN Lo

Example Only→ Multiple DTCs→ Fault Log→ DTC/Device closet to VSM

Open circuit is between DTC Device and VSM→ ?

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Electrical System Diagnostic Trouble Codes

DBB 4 Wheel CAN Communication (Cont)

STEP B5
Multi Device DTCs Open Circuit CAN Hi or CAN Lo

The above is an Example Only

Disconnect VSM CPS1→ Measure ? See Device Connectors
> 60? to 8? = CAN Hi/Lo Open Circuit ? ˜ 0? = → Component Operational Check ↓ ˜ 60? =
OK→ Component Operational Check ↓
STEP B6

The above is an Example Only

Locate Device to right or Left of Indicated Open Circuit
1. 8? = CAN Hi Open Circuit→Go to 3↓ 1. ˜0? = OKComponent Operational Check↓
2. 8? = CAN Hi Open Circuit→Go to 3↓ 2. ˜0? = OKComponent Operational Check↓
4. Find/Repair Short Circuit, See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Re-
check?→→Reconnect→Retest→?

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Diagnostic Trouble Codes Electrical System

DBB 4 Wheel CAN Communication (Cont)

CAUSE C
All CAN Device DTCs Displayed > CAN Hi/CAN Lo Short Circuit together/Supply (+) or (-)

All DTCs→ Open Circuit to VSM → Step B5 ↑

All DTCs→ Short Circuit CAN Hi to CAN Lo → Step C1 ↓
All DTCs→ Short Circuit CAN Hi to (-) Supply Sources → Step C2 ↓ No DTCs→ Short Circuit CAN Lo to (–)
Supply Sources
All DTCs→ Short Circuit CAN Lo to (+) Supply Sources→ Step C3 ↓ No DTCs→ Short Circuit CAN Hi to (+)
Supplies (5, 12 volt)
STEP C1
All Device DTCs Short Circuit CAN Hi to CAN Lo

Locate Service Connection → Measure ? See Device Connectors↓

1. = 0? CAN Hi/Lo Short Circuit→Go to 2↓ 1. ˜ 60? = OK →Step C2↓
2. Inspect easily Accessible Harness Areas for Insulation Damage then Inaccessible Harness Areas. Focus on
Bend Edges and Pinch Points, ?
3. Find/Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369 Re-
check ?→Reconnect→Retest→?

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Electrical System Diagnostic Trouble Codes

DBB 4 Wheel CAN Communication (Cont)

STEP C2
All Device DTCs Short Circuit CAN Hi to Bat (-) CAN Lo to Bat (-) will not Produce a DTC

1. 0? = CAN Hi Short Circuit. Go to 3↓ 1. > 50K? = OK, Go to 3↓

2. 0? = CAN Lo Short Circuit. Go to 3↓ 2. > 50K? = OK, Go to 3 ↓
3. Find/Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369 Re-
check ?→Reconnect→Retest, →Step C5
STEP C3
Multiple CAN Device DTCs Displayed > (+) Supply Short Circuit to CAN Hi or CAN Lo

All DTCs→ Short Circuit CAN Lo to (+) Supply Sources.

All DTCs→ Short Circuit CAN Hi to (+) Supply Sources. No DTCs for a Short to (+)12 Volts or (+) 5 Volts

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-167
Diagnostic Trouble Codes Electrical System

DBB 4 Wheel CAN Communication (Cont)

STEP C4
All Device DTCs Short Circuit Supply (+) to CAN Hi or CAN Lo

1. A, B, C, D, and E = 0? = CAN Hi Short Circuit, Go to 1. A, B, C, D, and E > 50K? = OK→?

3↓
2. A, B, C, D, and E = 0? = CAN Lo Short Circuit, Go to 2. A, B, C, D, and E > 50K? =OK→?
3↓
3. Find/Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369 Re-
check ?→Reconnect→Retest→?
STEP C5

Reconnect Battery Retest - Power ON NO → Go to ? Is DTC gone? Fault correc-

ted→ Continue
NO YES → operation
CAUSE D

Disconnect Battery To Power OFF Disconnect CAN De- Install New CAN De- Power ON→ ?
Replace Motor Con- vice→ vice
troller
Do Not Discard

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Electrical System Diagnostic Trouble Codes

DBB 4 Wheel CAN Communication (Cont)

STEP D1

? Fault DTC gone→ Old device faulty→ Resume operation

Fault DTC present→ Old Device OK/Reinstall Old ?

Device→
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Step E1 Step E1
STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation
troller Check
NO YES ← →
END FAULT

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Diagnostic Trouble Codes Electrical System

MLM Failure

DTC 21830 DTC 21834 DTC 21835 DTC 21836

MLM EEPROM Write MLM Sensor 1 MLM Sensor 2 MLM Sensor 3 Out of
Error Out of Range Out of Range Range

DTC 21837 DTC 25344

MLM Sensor 4 Out of MLM Checksum Error
Range
Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
DTC 21834 MLM Sensor 1 Out of → Component Operational
Range Check ↓
DTC 21835 MLM Sensor 2 Out of → Component Operational
Range Check ↓
DTC 21836 MLM Sensor 3 Out of → Component Operational
Range Check ↓
DTC 21837 MLM Sensor 4 Out of → Component Operational
Range Check ↓
DTC 25344 MLM Checksum Error DTC 33034 Display → Component Operational
Check ↓
DTC 21830 MLM EEPROM Write Error DTC 33034 Display → Component Operational
Check ↓
Check 1

Push in Emergency Stop Disconnect Battery and Wait 30 seconds Release Emergency Stop
Sound Horn to Discharge
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.
FAULT LOG CODE Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ VSM/MLM Fault Logs→ View all VSM/MLM DTCs→ ?

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Electrical System Diagnostic Trouble Codes

MLM Failure (Cont)

3? All VSM/MLM DTCs Erase all VSM/MLM DTCs→ E Exit Fault Log Power OFF↓

Check 2

Push in Emergency Stop Disconnect Battery and Wait 30 seconds Release Emergency Stop
Sound Horn to Discharge
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.

Enter Service Password→ Diagnostic→ FAULT LOGs→ VSM/MLM Fault Logs→ View all VSM/MLM DTCs→ ?

3? VSM/MLM DTCs→ Compare VSM/MLM DTCs Check 1 & 2→ Erase all VSM/MLM DTCs→ Exit Fault Log↓
MLM 21834, 21835, 21836, & 21837→ Power OFF→ Component Operational Check

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Diagnostic Trouble Codes Electrical System

MLM Failure (Cont)

33034 VSM DTC Only→ Power OFF→ Component Operational Check

No DTCs→ ?

No Fault→ Resume Operation

CAUSE A
Table 9030-20-11. Main Schematic

STEP A1
MLM Open Circuit Supply Voltage

1. Locate Device→Check Connections→Not OK Go to 1. Connections OK→Go to 2↓

4↓
2. =0 Volts = Open Circuit→Supply/(+) or (-)→Go to 4↓ 2. = Supply Volts= OK→Step A2↓
3. > Supply Volts→Check for Shorts to a Higher Supply Source→Repair→Component Operational Check as
MLM may be damaged.
4. Reference Table 9030-20-11→ - Find/Repair OPEN Circuit See Electrical System 2200SRM1337/Electrical
System 2200SRM1369→ReCheck Voltage↑

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Electrical System Diagnostic Trouble Codes

MLM Failure (Cont)

STEP A2
MLM Open Circuit CAN Hi/CAN Lo

1. Locate Device→Check Connections→Not OK Go to 1. Connections OK→Go to 2↓

4↓
2. > 60? = Open Circuit→CAN Hi/CAN Lo→Go to 4↓ 2. CAN Hi/CAN Lo Connections = OK→Component
Operational Check↓
3. Reference Table 9030-20-11→ - Find/Repair OPEN Circuit See Electrical System 2200SRM1337/Electrical
System 2200SRM1369→Go to 4↓
4. ReCheck ?↑→Repeat Check 2↑?
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D

Power OFF→ Remove and Replace MLM PCB Cassette Assembly→ See Electrical System 2200SRM1337/
Electrical System 2200SRM1369↓
Check Replacement MLM < Version→ See Label Information→ Step D2 ↓

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Diagnostic Trouble Codes Electrical System

MLM Failure (Cont)

STEP D1

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Cassette Software Version the Latest Version
2. NO→Download the latest Application <→Install on truck→See 4↓→Step D2↓
3. YES→Test New Installation→Step D2↓
4. WARNING: Keyswitch must be OFF during reprogramming
STEP D2

Power ON→ ? DTCs gone→ Original MLM Cassette faulty→ Resume operation

DTCs Still Present→ Original MLM Cassette OK/Reinstall Original Cas-

sette→ ?
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

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Electrical System Diagnostic Trouble Codes

MLM Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
END FAULT

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Diagnostic Trouble Codes Electrical System

MLM Incorrect Lever Installed

DTC 4112 DTC 4113 DTC 4114 DTC 4115

Incorrect Incorrect Lever 2 In- Incorrect Lever 3 In- Incorrect
Lever 1 Instal- stalled stalled Lever 4 Instal-
led led

DTC 4116
Incorrect Lever 5 Installed
Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1
Is Truck Lever Hardware Configuration Correct With Software Configuration?
Standard↓ Dual Function↓ Clamp↓ Monentary↓ (RTST)

Remove Lever(s)→ Check Base Information

If Incorrect Install Correct Lever(s)
Check 2
?DTC for Lever 1 or Lever 2→ Truck Setup→ Review RTST Setup Procedures
Standard Lever Installation→ Timer should be set to zero?

Enter Service Password→ Truck Setup→ RTST→ ? Timer Value = 0 for Standard Levers→ NO ↓
→ Reset Timer to Zero→ See Display Menu Flowchart for next step

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Electrical System Diagnostic Trouble Codes

MLM Incorrect Lever Installed (Cont)

Check 3

Push in Emergency Stop Disconnect Battery and Wait 30 seconds Release Emergency Stop
Sound Horn to Discharge
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.
DTC FAULT LOG CODE Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ VSM/MLM Fault Logs→ View all VSM/MLM DTCs→ ?

Erase all VSM/MLM DTCs→ Exit Fault Log→ Power OFF/Power ON→ No DTCs→ Resume Operation
Same DTCs Return→ Configuration File Incorrect→ Go to Component Operational Check
CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D
Not Applicable

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Diagnostic Trouble Codes Electrical System

MLM Incorrect Lever Installed (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
END FAULT

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Electrical System Diagnostic Trouble Codes

VSM 12 Volts Supply OORL/OORH

DTC 13060 DTC 13061

VSM 12V OORL VSM 12V OORH

Fault Codes

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

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Diagnostic Trouble Codes Electrical System

VSM 12 Volts Supply OORL/OORH (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
DBB/CBB 4 WHEEL VSM 12 VOLT SUPPLY CAUSES A B C D E > ?

The addition of Non Approved 12 Volt Devices other than those listed on the schematics may cause an OORL
condition

WARNING
No Display Fault Code will be visible for a Short To Battery(+) [STB(+)] OORH condition as the Display
will be Inoperative
For a STB (+) Fault Codes will only be visible on the PC Service Tool
Any VSM 12 volt powered Device that is turned on, will be damaged by a STB(+) condition, except for the
Display
All VSM 12 volt powered devices will need to be checked for correct operation and probably replaced

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Electrical System Diagnostic Trouble Codes

VSM 12 Volts Supply OORL/OORH (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
CBB 3 WHEEL VSM 12 VOLT SUPPLY CAUSES A B C D E > ?

WARNING
No Display Fault Code will be visible for a Short To Battery(+) [STB(+)] OORH condition as the Display
will be Inoperative
For a STB (+) Fault Codes will only be visible on the PC Service Tool
Any VSM 12 volt powered Device that is turned on, will be damaged by a STB(+) condition, except for the
Display
All VSM 12 volt powered devices will need to be checked for correct operation and probably replaced
A Breakout Connection for Cxx 135 is recommended for this TSP. See Table 9030-20-12 for Connector location

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Diagnostic Trouble Codes Electrical System

VSM 12 Volts Supply OORL/OORH (Cont)

CONNECTORS
Table 9030-20-12. Device Connectors

VSM Cxx 1 & 2 Display Cxx 20 &135 MLM Cxx 52

Hydraulic Level Cxx 70 Cxx 94 & 156 Cxx 95 & 157 Impact Device Cxx 148

CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C

Power OFF→ Disconnect Connector Cxx 135 Go to Step C1

and Install Breakout→

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Electrical System Diagnostic Trouble Codes

VSM 12 Volts Supply OORL/OORH (Cont)

STEP C1 UNSWITCHED VOLTAGES

1. ˜ 0 Volts→Step C4↓
2. ˜ 12 Volts→ Power ON→ Go to 2↓
3. ˜ Bat Volts = Short Circuit to Unswitched Bat (+)→Go to 4↓
4. Find/Repair Short Circuit, See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
ReCheck Voltage↑→Reconnect Go to 5↓
5. Check correct operation of all 12 volt Devices except Display→Component Operational Check↓
STEP C2 SWITCHED VOLTAGES

1. ˜ 12 Volts→ ˜ 12 Volts → Step C3, Component Operational Check↓

2. ˜ Bat Volts = Short Circuit to Switch Bat (+)→Go to 3↓
3. Find/Repair Short Circuit, See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
ReCheck Voltage↑→Reconnect Go to 4↓
4. Check correct operation of all 12 volt Devices except Display→Component Operational Check↓

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Diagnostic Trouble Codes Electrical System

VSM 12 Volts Supply OORL/OORH (Cont)

STEP C3

1. Disconnect VSM CPS1

2. ˜ 12 Volts = Short Circuit→DC/DC 12 Volts (+), Go to 3↓
3. Find/Repair Short Circuit, See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
ReCheck Voltage↑Fault Remains →Reconnect→Go to 4↓
Check correct operation of all 12 volt Devices except Display→ Component Operational Check ↓
STEP C4
OORL

1. ˜ 0 Volts = Short Circuit→Bat (-)→Find/Repair Short Circuit→Go to 2↓

2. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
ReCheck Voltage↑Fault Remains →Reconnect Cxx 135 →Component Operational Check↓

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Electrical System Diagnostic Trouble Codes

VSM 12 Volts Supply OORL/OORH (Cont)

STEP C5
OORL – No 12 volt Device Operation→No Fault Code

1. ˜ 0 Volts = No 12 volt Device operation→This will not Cause a Fault Code

2. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
ReCheck Voltage↑Fault Remains →Reconnect Cxx 135 →Component Operational Check↓
CAUSE D

1. Shorted Devices that are switched on by a control device will not cause a problem until operated by the control device. E,g.. Motor Controller Fans
2. 3 Wheel Fans are not supplied with 12 volts
3. Only approved 12 volt devices are allowed to be connected to this supply

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Diagnostic Trouble Codes Electrical System

VSM 12 Volts Supply OORL/OORH (Cont)

STEP D1

Power OFF→ Disconnect 12 volt Device→ Do Not Discard Go to Step D2, Component Operational
Check
STEP D2

? 12 Volt Fault DTC gone→ Old device faulty→ Old device faulty→In- Resume operation
stall New Device

Original Fault DTC Old Device OK/Reinstall Go to Next Device, Repeat

present→ Old Device→ Component Operational Check

All Devices Tested OK, go to

Component Operational Check
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Step E1. Step E1.

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Electrical System Diagnostic Trouble Codes

VSM 12 Volts Supply OORL/OORH (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Diagnostic Trouble Codes Electrical System

Display Internal Failure

DTC 22032 DTC 22033 DTC 33056 DTC 33057

Display EEPROM Display Cell Write Display Internal Display Communi-
Checksum Error Error CAN Failure cations Error with
VSM

DTC 8704 DTC 12934 DTC 12935 DTC 8705

Display Internal Display Internal Display Internal Display Internal
Fault Codes LCD Backlight LCD Backlight LCD Backlight LCD Heater

DTC 12936 DTC 12937 DTC 22528 DTC 22529

Display Internal Display Internal Display Button * Display Button #
LCD Heater LCD Heater

DTC 22530 DTC 22531 DTC 22532 DTC 22533

Display \ Arrow Display ] Arrow Display Button 1 Display Button 2

DTC 22534 DTC 22535 DTC 22536 DTC 22537

Display Button 3 Display Button 4 Display Button 5 Display Button 6

DTC 22538 DTC 22539 DTC 22540 DTC 22541

Display Button 7 Display Button 8 Display Button 9 Display Button 0

FAULT LOG CODE Review - Go To Display Review

QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Table 9030-20-13. Display Internal Failure Fault DTCs

DTC 22032 Display EEPROM Checksum Er- → Component Operational

ror Check ↓
DTC 22033 Display Cell Write Error → Component Operational
Check ↓
DTC 33056 Display Internal CAN Failure → Component Operational
Check ↓
DTC 33057 Display Communications Error → See CAN Communication TSPs
with VSM
DTC 8704 Display Internal LCD Backlight STB (-)/Current OORH → Component Operational
Check ↓
DTC 12934 Display Internal LCD Backlight STB (+) → Component Operational
Check ↓
DTC 12935 Display Internal LCD Backlight Open Circuit → Component Operational
Check ↓
DTC 8705 Display Internal LCD Heater STB (-)/Current OORH → Component Operational
Check ↓

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Electrical System Diagnostic Trouble Codes

Display Internal Failure (Cont)

Table 9030-20-13. Display Internal Failure Fault DTCs (Continued)

DTC 12936 Display Internal LCD Heater STB (+) → Component Operational
Check ↓
DTC 12937 Display Internal LCD Heater Open Circuit → Component Operational
Check ↓
DTC 22528 Display Button * Button Stuck → Component Operational
Check ↓
DTC 22529 Display Button # Button Stuck → Component Operational
Check ↓
DTC 22530 Display \Arrow Button Stuck → Component Operational
Check ↓
DTC 22531 Display ] Arrow Button Stuck → Component Operational
Check ↓
DTC 22532 Display Button 1 Button Stuck → Component Operational
Check ↓
DTC 22533 Display Button 2 Button Stuck → Component Operational
Check ↓
DTC 22534 Display Button 3 Button Stuck → Component Operational
Check ↓
DTC 22535 Display Button 4 Button Stuck → Component Operational
Check ↓
DTC 22536 Display Button 5 Button Stuck → Component Operational
Check ↓
DTC 22537 Display Button 6 DTC 33034 Display → Component Operational
Check ↓
DTC 22538 Display Button 7 Button Stuck → Component Operational
Check ↓
DTC 22539 Display Button 8 Button Stuck → Component Operational
Check ↓
DTC 22540 Display Button 9 Button Stuck → Component Operational
Check ↓
DTC 22541 Display Button 0 Button Stuck → Component Operational
Check ↓
Note: No Display Visible→ Use PC Service Tool→ Component Operational
Check ↓
Note: No DTC on PC Service Tool→ Possible Key Switch Failure→ Component Operational
Check ↓

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Diagnostic Trouble Codes Electrical System

Display Internal Failure (Cont)

QUICK CHECK X = Open Circuit/Fail ) = Short Circuit

Check 1

Power OFF→ Wait 30 sec- Power ON→ Fault remains Service re- No fault→ Resume opera-
onds→ quired tion

Go to Check 2↓

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Electrical System Diagnostic Trouble Codes

Display Internal Failure (Cont)

QUICK CHECK X = Open Circuit/Fail ) = Short Circuit

Check 2

Disconnect Battery Disconnect Battery and Wait 30 seconds Reconnect Battery

Sound Horn to Discharge
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.

Power ON→ Fault Remains Service Required→ No Fault→ Resume Oper-

ation

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-191
Diagnostic Trouble Codes Electrical System

Display Internal Failure (Cont)

QUICK CHECK X = Open Circuit/Fail ) = Short Circuit

Check 3

Enter SERVICE Password→ Diagnostics→ FAULT LOGs→ Display FAULT View all Display
LOGs→ DTCs→ ?

3? all Display DTCs→ Erase all Display DTCs→ Exit Fault Power OFF→
Log Component Op-
erational Check

CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D

1. No Display/No PC DTCs→Possible Keyswitch Failure↓

2. Keyswitch Mechanical Operation Indicates Binding/No Turn↓
3. YES→Replace Keyswitch Barrel↓NO→Step D1↓
4. See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓

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Electrical System Diagnostic Trouble Codes

Display Internal Failure (Cont)

STEP D1

Retest - Power ON→ NO → Step D2 Does Display Turn On? Fault corrected→ Continue operation.

Is DTC gone?

NO YES ← →
STEP D2

Power OFF→ Disconnect Display→ Do not Dis- Step D3 ↓

card→

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Diagnostic Trouble Codes Electrical System

Display Internal Failure (Cont)

STEP D3

1. Download the latest Display Application Version→Install NEW Display→Install NEW Application →Go to 2↓
2. See Hypass Online, Software Resources for your truck, (Installing Display Application Software)↓

Power ON→ ? DTC Gone→ Original Display Faulty→ Resume Operation

New DTC Present→ DTC TSP↓

Return Faulty Display→ Dealer→ Factory→ Failure Analysis→ ?? Reprogramming

END FAULT

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Electrical System Diagnostic Trouble Codes

Display Failure – Keyswitch Relay Output

DTC 9041 DTC 12940 DTC 12941 DTC 13070

Display Keyswitch Display Keyswitch Display Keyswitch Keyswitch Data
Output Output Output Incorrect

Fault Codes
FAULT LOG CODE Review - Go To Display Review
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
DTC 9041 Display Keyswitch Output STB (-)/Current OORH → Component Operational
Check ↓
DTC 12940 Display Keyswitch Output STB (+) → Component Operational
Check ↓
DTC 12941 Display Keyswitch Output Open Circuit → Component Operational
Check ↓
DTC 13070 Display Keyswitch Data Incorrect STB (+) → Component Operational
Check ↓
Note: No Display Visible→ Use PC Service Tool→ Component Operational
Check ↓
Note: No DTC on PC Service Tool→ Possible Key Switch Failure→ Component Operational
Check ↓
QUICK CHECK X = Open Circuit/Fail ) = Short Circuit

Check 1

Power OFF→ Wait 30 sec- Power ON→ Fault remains Service re- No fault→ Resume opera-
onds→ quired tion

Go to Check 2↓

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Diagnostic Trouble Codes Electrical System

Display Failure – Keyswitch Relay Output (Cont)

QUICK CHECK X = Open Circuit/Fail ) = Short Circuit

Check 2

Disconnect Battery Disconnect Battery and Wait 30 seconds Reconnect Battery

Sound Horn to Discharge
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.

Power ON→ Fault Remains Service Required→ No Fault→ Resume Oper-

ation

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Electrical System Diagnostic Trouble Codes

Display Failure – Keyswitch Relay Output (Cont)

QUICK CHECK X = Open Circuit/Fail ) = Short Circuit

Check 3

Enter SERVICE Pass- Diagnostics→ FAULT LOGs→ Display FAULT View all Display
word→ LOGs→ DTCs→ ?

3? all Display DTCs→ Erase all Display DTCs→ Exit Fault Log Power OFF→ Com-
ponent Operational
Check

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Diagnostic Trouble Codes Electrical System

Display Failure – Keyswitch Relay Output (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Display Cxx 20

Key Switch Relay Connector Cxx 208 Display Cxx 135

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Electrical System Diagnostic Trouble Codes

Display Failure – Keyswitch Relay Output (Cont)

CAUSE A
DTC 12941 Key Switch Relay OC

Remove Display and Disconnect Display Connector→ Measure ?→ Go to 1↓

1. > 100? to 8? = High Resistance/Open Circuit→Go to 1. ˜80? = OK→Step A5↓
Step A2↓
2. < ˜60? to 0? = Short Circuit→Component Opera- 2. ˜80? = OK→Step A5↓
tional Check↓
STEP A1

Remove 12 Volt Relay→ Measure ?→ Go to 1↓

1. > 100? to 8? = High Resistance/Open Circuit→Go to 1. ˜80? = OK→Step A3↓
3↓
2. < ˜60? to 0? = Short Circuit→Go to 3↓ 2. ˜80? = OK→Step A3↓
3. Relay Coil OPEN/SHORT Circuit→Replace Relay→ReCheck ?↑Step A1→Reconnect Display→Step A4↓

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Diagnostic Trouble Codes Electrical System

Display Failure – Keyswitch Relay Output (Cont)

STEP A2

Measure ?→ Go to 1↓
1. 8? = High Resistance/Open Circuit→Go to 2↓ 1. ˜0? = OK→Step A4↓
2. Find/Repair OPEN Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Re-
Check ?↑Step A1→Reconnect→Step A4↓
STEP A3

Retest - Power OFF NO → Step A4 Is fault DTC gone? Fault corrected→ Continue operation
Power ON
NO YES

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Electrical System Diagnostic Trouble Codes

Display Failure – Keyswitch Relay Output (Cont)

STEP A4

CAUTION
Do not backprobe VSM connector if Breakout Connectors are available. See Step A6 for Alternative to 3.
1. Turn Key Switch ON→Measure Volts at 1, 2, and 3→Go to 2↓
2. 0 Volts→Open Circuit Fuse/Wiring/Relay Con- 2. ˜ Bat (+) Volts = OK→Step A6↓
tacts→Go to 3↓
3. Find/Repair OPEN Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Re-
Check Volts↑Step A5→Reconnect→Step A6↓
STEP A5

Turn Key Switch OFF→ Disconnect Relay and VSM CPS 2→ Measure ?→ Go to 1↓
1. = 8?→Open Circuit Wiring→Go to 2↓ 1. ˜ 0? = OK→Step A6↓
2. Find/Repair OPEN Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Re-
Check ?↑Step A1→Reconnect→Step A6↓

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-201
Diagnostic Trouble Codes Electrical System

Display Failure – Keyswitch Relay Output (Cont)

STEP A6

Retest - Power OFF NO → Component Op- Is fault DTC gone? Fault corrected→ Continue operation
Power ON erational Check
NO YES →
CAUSE B
Not Applicable
CAUSE C

1. Turn Key Switch OFF→Push Emergency Stop→Remove Display and Disconnect→Measure Volts→Go to 2↓
2. ˜ Bat (+) Volts = Short to Unswitched Bat (+) →Go to 2. 0 Volts = OK→Go to 3↓
6↓
3. Release Emergency Stop→Go to 4↓
4. ˜ 12 Volts = Short to VSM 12 Volt Supply→Go to 6↓ 4. 0 Volts = OK→Step C1↓
5. ˜ Bat (+) Volts = Short to Switched Bat (+) →Go to 6↓
6. Find/Repair Short Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Re-
Check Volts↑→Reconnect→↓

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Electrical System Diagnostic Trouble Codes

Display Failure – Keyswitch Relay Output (Cont)

STEP C1

1. Turn Key Switch OFF→Measure ?→Go to 2↓

2. < ˜60? = Short Circuit →Go to 3↓ 2. ˜ 80? = OK→Component Operational Check↓
3. Find/Repair Short Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Re-
Check ?↑→Reconnect→Component Operational Check↓
CAUSE D

1. No Display/No PC DTCs→Possible Keyswitch Failure↓

2. Keyswitch Mechanical Operation Indicates Binding/No Turn↓
3. YES→Replace Keyswitch Barrel↓NO→Step D1↓
4. See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓

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Diagnostic Trouble Codes Electrical System

Display Failure – Keyswitch Relay Output (Cont)

STEP D1

Retest - Power ON→ NO → Step D2 Does Display Turn On? Fault corrected→ Continue operation.

Is DTC gone?

NO YES ← →
STEP D2

Power OFF→ Disconnect Display→ Do not Dis- Step D3 ↓

card→

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Electrical System Diagnostic Trouble Codes

Display Failure – Keyswitch Relay Output (Cont)

STEP D3

1. Download the latest Display Application Version→Install NEW Display→Install NEW Application →Go to 2↓
2. See Hypass Online, Software Resources for your truck, (Installing Display Application Software)↓

Power ON→ ? DTC Gone→ Original Display Faulty→ Resume Operation

New DTC Present→ DTC TSP↓

Return Faulty Display→ Dealer→ Factory→ Failure Analysis→ ?? Reprogramming

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Diagnostic Trouble Codes Electrical System

Display Failure – Keyswitch Relay Output (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Step E1. Step E1.
STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
END FAULT

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Electrical System Diagnostic Trouble Codes

VSM Controller Check

DTC 21760 DTC 21761 DTC 21762 DTC 21764

VSM BOOT_BLOCK CDF_Check- VSM APPLICA- VSM EEPROM
sum_failure TION_SOFT- Checksum
Fault Codes Checksum failure WARE Checksum
failure/Error failure/Error

DTC 21766 DTC 21792

VSM EEPROM Cell fail- VSM Serial Num-
ure ber Error

Write Error

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Quick
Check.

QUICK CHECK X Open Circuit/Fail ) = Short Circuit

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Diagnostic Trouble Codes Electrical System

VSM Controller Check (Cont)

Check 1

Disconnect Battery Disconnect Battery and Wait 30 seconds Reconnect Battery

Sound Horn to Discharge
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.

Power ON→ Fault remains, Service required→ Go to Check 2↓ No fault→ Resume opera-
tion
Check 2

Enter Service Password→ Diagnostic→ FAULT VSM Fault Logs View all VSM DTCs→ Go to next step↓
LOGs→

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Electrical System Diagnostic Trouble Codes

VSM Controller Check (Cont)

3? all VSM DTCs Erase all VSM DTCs→ EExit Fault Log→ Truck Status

VSM Versions→ 3? Hardware/Software Versions→ EExit Versions Power OFF→ Go to Next

Step↓

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Diagnostic Trouble Codes Electrical System

VSM Controller Check (Cont)

QUICK CHECK X = Open Circuit/Fail ) = Short Circuit

DTCs 21792→ Step 1 VSM has been installed from another truck
DTCs 21792→ Step 1 Display has been installed from another truck
DTCs 21761→ Step 3, Step 1→ Reprogram CDF
DTCs 21762→ Step 4, Step 1→ Reprogram Application Software
DTCs 21760, 21764, 21766→ Step 4, Step 1→ Factory Issued VSM Required

STEP 1

Scroll to Password symbol→ Enter 5 Digit Password → Press Scroll to Truck Symbol. Press *→
*→

Press *→ Scroll to Truck Serial #→ Press *→

? Displayed Serial Number = the YES → Step 2 ↓ NO → Find/Replace with Correct VSM.
Truck Serial Number?→ See Electrical System 2200SRM1337/
Electrical System 2200SRM1369.
Repair Complete.→ Step 2 ↓
? Displayed Serial Number for
VSM and Display are BLANK?→

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Electrical System Diagnostic Trouble Codes

VSM Controller Check (Cont)

STEP 2

Retest - Power ON→ NO → Go to Step 3. Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
STEP 3

1. DTC 21761↓
2. Go to Hypass Online→Software→Download new CDF→Install on Truck→Go to 3↓
3. Test→Step 6↓→OK→Resume Operation – Not OK Step 5↓
STEP 4

1. DTC 21761↓
2. Go to Hypass Online→Software→Download the latest Application Software→Install on Truck→Go to 3↓
3. Test→Step 6↓→OK→Resume Operation – Not OK Step 5↓

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Diagnostic Trouble Codes Electrical System

VSM Controller Check (Cont)

STEP 5

DTCs 21760, 21762, 21764, and 21766→

1. Replacement Approval –Contact Hyster Resident Service.
2. Remove and replace faulty VSM with new VSM. See Electrical System 2200SRM1337 or
Electrical System 2200SRM1369.
3. Return faulty VSM to dealer.
4. Retest new installed VSM. Go to Step 6.
STEP 6

Retest - Power NO → Go to Is DTC gone? NO ← YES → Fault corrected→ Continue opera-

ON→ Step 3. tion.
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart – Clearing DTCs.
END FAULT

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Electrical System Diagnostic Trouble Codes

Controller Logic Failure

DTC 65299
Controller Logic Failure

Fault Codes

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

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Diagnostic Trouble Codes Electrical System

Controller Logic Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
CBB 4 WHEEL CAUSES A B C D E > ?
Possible Causes Battery Voltage Below Input Threshold/ ® = High Resistance
Possible Causes Battery Voltage Above Input Threshold/ ® = High Resistance

DBB 4 WHEEL CAUSES A B C D E > ?

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Electrical System Diagnostic Trouble Codes

Controller Logic Failure (Cont)

A935 K160 HIGH RESISTANCE CONNECTIONS CAUSES A B C D E > ?

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Diagnostic Trouble Codes Electrical System

Controller Logic Failure (Cont)

CAUSE A
Controller Detected Voltage OOR

Check that correct voltage battery is instal- Perform battery maintenance, see Operating Man- ?
led → ual→
STEP A1

Power ON→ Go to Diagnostic→ Battery/Supply→ View Bat- ?

tery Value
See Display Menu Flowchart
STEP A2
Controller Detected Voltage OOR
NOTE: OOR Code is set if OOR condition is present for longer than 1 second.
Controller Threshold
24v 48v
< OORL 9 11
< OORH 45 65
Is battery voltage ˜ < OORL value for correct battery→ ?
STEP A3

NO (v)→ ? YES (X) Recharge bat- See Operating Manual for ?

tery→ charge time

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Electrical System Diagnostic Trouble Codes

Controller Logic Failure (Cont)

STEP A4
Battery OORL/OORH
Battery Voltage
Nominal 36 48 72 80
Fully Charged 40 53 79 88

˜< OORL 18 24 36 40
˜> OORH 48.6 57.6 97.2 108
Operate truck→ All functions

Monitor battery voltage→ Is battery voltage going?↓ < OORL or ↑ > OORH value for correct battery→ ?
STEP A5

YES (X) Inspect All Battery Connections for Corrosion/ High Resistance→
NO (v) → Go to Step B4
CAUSE B
NOTE: High Resistance in Wiring and Connections will cause High Voltage drops (OORL) when subjected to
High Current Draw
NOTE: High Resistance in Wiring and Connections will cause High Voltage peaks (OORH) when subjected to
High Current Regen

Disconnect battery→ Set meter to lowest ? scale→ Check lead resistance < 0.01? ?

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Diagnostic Trouble Codes Electrical System

Controller Logic Failure (Cont)

STEP B1 CHECK RESISTANCE - Ω - OHMS
Battery OORH/OORL

Check resistance between the Battery (+) and (-) terminals and the Battery Connector (+) and (-) Terminals
1. > 0.01? Replace battery leads/connector terminal↓
2. > 0.01? Replace battery leads/connector terminal→ < 0.01? Connection OK→ ?
STEP B2

Check Resistance between the Bat (+) Connector and the Contactor Stud/Bat (-) Connector and Bat (-) to Sys-
tem
1. > 0.01? →Replace battery leads/connector terminal↓
2. > 0.01? →Replace battery leads/connector terminal→ < 0.01? → Connection OK ?

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Electrical System Diagnostic Trouble Codes

Controller Logic Failure (Cont)

STEP B3
Battery OORH/OORL

Reconnect battery Retest Power ON NO → ? Is DTC gone? Fault Correc- Continue opera-
NO YES → ted→ tion
STEP B4
Battery OORH/OORL

Possible Battery Cell Failure→ Perform Battery Cell Test→ See Electrical System 2200SRM1337/Electrical
System 2200SRM1369.
If a cell failure is detected replace Battery→ ?
STEP B5

Retest Power ON NO → ? Is DTC gone? Fault Corrected→ Continue operation

NO YES →
CAUSE C
Not Applicable
CAUSE D
Not Applicable

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Diagnostic Trouble Codes Electrical System

Controller Logic Failure (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to Cause E1

Cause E1
CAUSE E1

Retest - Power ON→ NO → Is DTC gone? Fault corrected→ Continue operation.

Go to VSM Controller NO YES

Check
END FAULT

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Electrical System Diagnostic Trouble Codes

Display Failure – Temperature/Buzzer

DTC 12928 DTC 12929 DTC 9040 DTC 12938

Display Tempera- Display Temperature Display Buzzer Display
ture Sensor Sensor (Freezer Option Output Buzzer Out-
(Freezer Option Only) put
Only)

DTC 12939
Fault Codes Display Buzzer Output

QUICK CHECK X Open Circuit/Fail ) = Short Circuit

DTC 12928 Display Temperature Sensor OORL Open Circuit → Component Operational
(Freezer Option Only) Check ↓
DTC 12929 Display Temperature Sensor OORH → Component Operational
(Freezer Option Only) Check ↓
DTC 9040 Display Buzzer Output STB (-)/Current OORH Code Not Active
DTC 12938 Display Buzzer Output STB (+) Code Not Active
DTC 12939 Display Buzzer Output Open Circuit Code Not Active
QUICK CHECK X = Open Circuit/Fail ) = Short Circuit

Check 1

Power OFF→ Wait 30 sec- Power ON→ Fault remains Service re- No fault→ Resume opera-
onds→ quired tion

Go to ↓

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Diagnostic Trouble Codes Electrical System

Display Failure – Temperature/Buzzer (Cont)

QUICK CHECK X = Open Circuit/Fail ) = Short Circuit

FAULT LOG CODE Review – Go to Display Menu

Enter SERVICE Password→ Diagnostics→ FAULT LOGs→ Display FAULT View all Display
LOGs→ DTCs→ ?

3? all Display DTCs→ Erase all Display DTCs→ Exit Fault Power OFF→ ?
Log

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC

CAUSES A B C D > ?

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Electrical System Diagnostic Trouble Codes

Display Failure – Temperature/Buzzer (Cont)

CAUSE A
DTC 12929 Temperature Sensor OORH

Remove Display and Disconnect Temperature Sensor→ Measure Volts→ Go to 1↓

1. > 5 volts = Short to→Go to 2↓ 1. < 5 volts = OK→Step A1↓
2. Find/Repair Short Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
ReCheck ?↑Component Operational Check→Reconnect Display→Step A3↓
STEP A1
DTC 12928 Temperature Sensor STB (-) OORL

Disconnect connector 135→ Measure ?→ Go to 1↓

1. ˜0? = Short Circuit to Bat (-)→Go to 2↓ 1. =8? = OK→Step A2↓
2. Find/Repair Short Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
ReCheck ?↑Reconnect→Step A3↓

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Diagnostic Trouble Codes Electrical System

Display Failure – Temperature/Buzzer (Cont)

STEP A2
DTC 12928 Temperature Sensor Open Circuit OORL

Remove Display and Disconnect Display Connector→ Disconnect Temperature Sensor→ Measure ? at 1 and
2→ Go to 1↓
1. =8? = Open Circuit→Go to 2↓ 1. ˜0? = OK→Component Operational Check↓
2. Find/Repair OPEN Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
ReCheck ?↑Component Operational Check→Reconnect →?
STEP A3

Retest - Power OFF NO → ? Is fault DTC gone? ?

Power ON
NO ← YES →
CAUSE B
There are no active DTCs displayed for Buzzer Failure. Please refer to the Troubleshooting Electrical
Symptoms for Diagnostics.
CAUSE C
Not Applicable

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Electrical System Diagnostic Trouble Codes

Display Failure – Temperature/Buzzer (Cont)

CAUSE D
Device Failure

NOTE: The Temperature Sensor is Only used on Freezer configured Displays.

NOTE: The Temperature Sensor is tied to the wiring Harness behind the Display.

NOTE: The Temperature Sensor is NOT RESISTIVE and cannot be analyzed using a DMM.

Power OFF→ Remove Display→ Disconnect sensor.→ Install new sen- Power ON→ ?
sor.→
Do not discard

? Fault DTC gone→ Original sensor faulty→ Resume operation

Fault DTC Original sensor OK/Reinstall old Go to Step D1.

present→ sensor→
STEP D1

Power OFF→ Disconnect Display→ Do not Dis- Step D2 ↓

card→

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Diagnostic Trouble Codes Electrical System

Display Failure – Temperature/Buzzer (Cont)

STEP D2

1. Download the latest Display Application Version→Install NEW Display→Install NEW Application →Go to 2↓
2. See Hypass Online, Software Resources for your truck, (Installing Display Application Software)↓
STEP D3

Power ON→ ô DTC Gone→ Original Display Faulty→ Resume Operation

New DTC Present→ DTC TSP↓

Return Faulty Display→ Dealer→ Factory→ Failure Analysis→ ?? Reprogramming

END FAULT

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Electrical System Diagnostic Trouble Codes

Contactor/Relay/Valve Coil Short to Battery Positive (STBP)

DTC 9000 DTC 9004 DTC 9008 DTC 9012

Diverter Valve E Hyd Enable Clamp Solenoid (Optional) Acc 2 Relay

DTC 9016 DTC 9020 DTC 9026 DTC 9028

Forward Relay Reverse Relay Spare 1 Relay Spare 2 Relay

DTC 9032 DTC 9036

Fault Codes Main Contactor 2nd Contactor

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

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Diagnostic Trouble Codes Electrical System

Contactor/Relay/Valve Coil Short to Battery Positive (STBP) (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
CONTACTOR/RELAY/VALVE COIL (STBP) CAUSES A B C D E > ?

CAUSE A
Not Applicable
CAUSE B
Not Applicable

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Electrical System Diagnostic Trouble Codes

Contactor/Relay/Valve Coil Short to Battery Positive (STBP) (Cont)

CAUSE C

Power OFF→ Unplug/Disconnect Contactor/Relay/Valve Coil Indicated DTC Connection to

VSM→ ?
STEP C1 UNSWITCHED VOLTAGES
NOTE: Short Circuit to Unswitched Bat (+) Contactor/Relay/Valve Coil Connection to VSM

Bat Volts = Short circuit→ Find↑ SHORT circuit.→ ˜ 0 Volts = OK ?

Repair SHORT Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.
See Schematic for Connection information
STEP C2

Power ON→ ?

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Diagnostic Trouble Codes Electrical System

Contactor/Relay/Valve Coil Short to Battery Positive (STBP) (Cont)

STEP C3 SWITCHED VOLTAGES
NOTE: Short Circuit to Switched Bat (+) – Contactor/Relay/Valve Coil Connection to VSM

Bat Volts = Short circuit→ Find↑ SHORT circuit → ˜ 0 Volts = OK ?

Repair SHORT Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.
See Schematic for Connection information
STEP C4

Power OFF→ Reconnect Contactor/Relay/Valve Coil Connections to ?

VSM→
CAUSE D
Not Applicable
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

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Electrical System Diagnostic Trouble Codes

Contactor/Relay/Valve Coil Short to Battery Positive (STBP) (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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Diagnostic Trouble Codes Electrical System

Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC)

DTC 13352 DTC 13356 DTC 13360 DTC 13364

Diverter Valve Hyd Enable Acc 1 Relay Acc 2 Relay

DTC 13368 DTC 13372 DTC 13376 DTC 13380

Motion Relay Reverse Relay Spare 1 Relay Brake Light Relay Short to B(-)
or Open
Fault Codes DTC 13384 DTC 13388
Main Contactor 2nd Contactor

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

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Electrical System Diagnostic Trouble Codes

Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
CONTACTOR/RELAY/VALVE COILS STBN/(OC) CAUSES A B C D E > ?

Relay/Coil Function Coil Voltage Coil Resistance (?)

Key Switch 12 80
Motion Direction 24 320
Reverse Direction 24 320
Brake Light 24 320
Diverter Valve 24 320

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Diagnostic Trouble Codes Electrical System

Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont)

Relay/Coil Function Coil Voltage Coil Resistance (?)

E Hyd Enable 24 320
Man Hyd Enable x 2 24 33
Clamp 24 33
CAUSE A
NOTE: Prior to performing any checks, Service Technician should verify to see if the Motion relay option or
Diverter valve option is activated. (See Truck Setup Display menu- Motion Alarm/Diverter Valve). If neither de-
vice is part of the truck hardware then the function should be TURNED OFF to prevent false DTC conditions.

Power OFF→ Unplug/Disconnect Contactor/Relay/Valve Coil Indicated DTC Connection to

VSM→ ?
STEP A1 CHECK RESISTANCE - Ω - OHMS
Open Circuit – Contactor/Relay/Valve Coil Connection to VSM

8 ? = Open Circuit→ Find↑ Open circuit→ ˜ Function K? = OK ?

˜ 0? Go to Component Operational
Check
Repair OPEN Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.

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Electrical System Diagnostic Trouble Codes

Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont)

CAUSE B CHECK RESISTANCE - Ω - OHMS
NOTE: Open Circuit – Contactor/Relay/Valve Coil Connections to Coil

8 ? = Open Circuit→ Find↑ Open circuit→ ˜ xx? =→ See Schematics =OK→ ?

Repair OPEN Circuit in wiring or Replace Open Circuit Coil/Relay ↓
See Electrical System 2200SRM1337/Electrical System 2200SRM1369.
> xx ? = Faulty Coil→ Replace Coil↓
See Electrical System 2200SRM1337/Electrical System 2200SRM1369.
STEP B1 CHECK RESISTANCE - Ω - OHMS
Open Circuit – Bat (+) Connections to Contactor/Relay/Valve Coil

8 ? = Open Circuit→ Find↑ Open circuit→ ˜ 0? = OK Go to Component Operational Check↓

Repair OPEN Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-235
Diagnostic Trouble Codes Electrical System

Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont)

CAUSE C
NOTE: STBN – Contactor/Relay/Valve Coil Connection to VSM

˜ 0 ? = Short Circuit→ Find↑ Short circuit→ ˜ Function K? = OK Go to Component Operational

Check↓
Repair Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.
STEP C1

Power OFF→ Reconnect Contactor/Relay/Valve Coil Connections to ?

VSM→
CAUSE D
Not Applicable
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

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9030-20-236 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont)

CAUSE E1

Retest – Power ON→ NO → Go to VSM Con- Is DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-237
Diagnostic Trouble Codes Electrical System

Motor Controller Contactor Failure

DTC 21569 DTC 21570 DTC 65318 DTC 65317

Contactor Open Contactor Closed Contactor Open Contactor Closed

DTC 65354 DTC 65355

Driver Shorted High Driver Shorted Low

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? No Operation?
POSSIBLE CAUSES
DTC 21569 Contactor Open Low Battery/Open Circuit Connections Go to 1, 2, → Component Op-
and 3↓ erational Check ↓
DTC 21570 Contactor Closed Short Circuit Connections Go to 2 and 3↓ → Component Op-
erational Check ↓
DTC 21569/21570 Contactor Coil Open/Short Circuit Connections Go to 2 and 3↓ → Component Op-
erational Check/
Component Opera-
tional Check↓
1. Go to Battery OORH/OORL
2. Go to Contactor/Relay/Valve Coil Short to Battery Positive (STBP)
3. Go to Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC)

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9030-20-238 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Motor Controller Contactor Failure (Cont)

Check 2

Disconnect Battery Disconnect Battery and Wait 30 seconds Reconnect Battery

Sound Horn to Discharge
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.
Check 3

Power ON→ Fault Remains Service Required ? No Fault→ Resume Operation

Check 4

Power ON→ Go to Diagnostics→ Battery/Supply→ View Bat Value→ Go to Display Menu Flowchart↓

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-239
Diagnostic Trouble Codes Electrical System

Motor Controller Contactor Failure (Cont)

Check 5
Battery OORL
NOTE: OOR Code is set if OOR condition is present for longer than 1 second.
Battery Voltage
Nominal 36 48 72 80
Fully Charged 39.6 52.8 79.2 88
˜< OORL 18 24 36 40
˜ OORH 48.6 57.6 97.2 108
Is battery voltage ˜ < OORL value for correct battery→ Is Bat Voltage ˜< OORL value for Correct Battery→
YES → Battery OORH/OORL → NO ?
FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostics→

Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

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9030-20-240 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Motor Controller Contactor Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-241
Diagnostic Trouble Codes Electrical System

Motor Controller Contactor Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
MOTOR CONTROLLER CONTACTOR FAILURE CAUSES A B C D E > ?

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9030-20-242 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Motor Controller Contactor Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx 3, 4, and 5

CAUSE A

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ ?

Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP A1
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-243
Diagnostic Trouble Codes Electrical System

Motor Controller Contactor Failure (Cont)

STEP A2

1. Inspect Contactor Top and Bottom Contacts for Pitting/Corrosion/Dirt Build-Up→Go to 2↓

2. Replace Contactor if Pitting/Corrosion is Observed→↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 4↓
4. Check all Connections→Reconnect Battery→Step A3↓
STEP A3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
STEP A4 CHECK RESISTANCE - Ω - OHMS

Disconnect Battery and Sound Horn to Discharge Capacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→ ?
Set DMM to Lowest ?→ Check Lead Resistance < 0.01?
Note: If the Resistance is > 0.01? then record this as the Zero ? Value→ ↓

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9030-20-244 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Motor Controller Contactor Failure (Cont)

STEP A5 CHECK RESISTANCE - Ω - OHMS
Contactor Open

1. >10 ? @ 25 °C (77 °F) = Faulty PTC→5↓0 ?→Com- 1. <10 ? >4 ? = OK→Go to 2↓

ponent Operational Check↓
2. > Zero Value +0.01 = High Resistance→Go to 5↓ 2. ˜0 ? = OK→Go to 4↓
3. 8 ? = Open Circuit→Go to 5↓ 3. ˜0 ? = OK→Go to 4↓
4. Repeat 2 & 3 on other Motor Controllers↑→Go to 5↓
5. Find/Repair High Resistance Open Circuit→Go to 7↓
6. Replace PTC(s)→Go to 7↓
7. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
8. Recheck ?↑→ Reconnect→Test→Component Operational Check↓
CAUSE B
Not Applicable

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-245
Diagnostic Trouble Codes Electrical System

Motor Controller Contactor Failure (Cont)

CAUSE C
Contactor Closed

1. 0 ? = Shorted PTC/Welded Contacts→Go to 2↓ 1. >4 ? <10 ? = OK→Component Operational Check↓

2. Disconnect PTC→Recheck ?↓
3. 8 ? = Shorted PTC Go to 4↓0 ? = Welded Contacts→Go to 5↓
4. Replace PTC(s)→Go to 6↓
5. Replace Contactor→Go to 6↓
6. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
7. Recheck ?↑→ Reconnect→Test↓
STEP C1

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →

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9030-20-246 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Motor Controller Contactor Failure (Cont)

CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ ?

Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓
STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-247
Diagnostic Trouble Codes Electrical System

Motor Controller Contactor Failure (Cont)

STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

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9030-20-248 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller Capacitor Failure

DTC 12592
Capacitor Charge

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? Function Failure/Reduced Performance/Uncommanded Continuous Operation?

POSSIBLE CAUSES
1. Motor Controller Connections/Wiring High Resistance?→ → Component Opera-
tional Check ↓
2. Motor Controller(s) Failure?→ → Component Opera-
tional Check ↓
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-249
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller Capacitor Failure (Cont)

Check 3

Power ON→ Fault Remains Service Re- No Fault→ Resume Operation

quired ?
FAULT LOG Review - Go to Display Menu

Enter SERVICE Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

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9030-20-250 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller Capacitor Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection
Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-251
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller Capacitor Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
MOTOR CONTROLLER CAPACITOR FAILURE CAUSES A B C D E > ?

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9030-20-252 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller Capacitor Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx 3, 4, and 5

CAUSE A

Power OFF→ ?
STEP A1
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections See Diagnostic Trouble Codes, Page
9030-20-238

CAUSE B
Not Applicable
CAUSE C
Not Applicable

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-253
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller Capacitor Failure (Cont)

CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→

Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓
STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming

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9030-20-254 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller Capacitor Failure (Cont)

STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-255
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Speed Sensor Failure

DTC 29456
Sensor Fault

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

?No Traction/Hydraulic Operation?

POSSIBLE CAUSES
1. Speed Sensor/Motor Controller Connections/Wiring?→
2. Speed Sensor Failure?→
3. Brake Drag and/or Axle Lockup?→Go to Brake and Axle Drag Check, Operational Checkout.↓
4. Motor Controller(s) Failure ?→
5. Motor Failure ?→
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-256 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

Check 3

Power ON→ Fault Remains No Fault→ Resume Operation

Service Required ?
Check 4
FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-257
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection
Diagnostics Speed Sensor Analysis – Use to Validate Correct Sensor Operation after Repairs

NOTE: If Motor Operation is Disabled then no speed will be displayed

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-258 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
WHEEL MOTOR SPEED SENSOR FAILURE CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-259
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx Speed Sensor Motor Connector Cxx
3, 4, and 5 146, 152, and 153
CAUSE A

Power OFF→ ?
STEP A1
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections

Disconnect Cxx XXX as indicated from the Fault Logs→ Power ON↓

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9030-20-260 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

STEP A2 CHECK VOLTAGE
Speed Sensor Supply

1. 0 Volts = Open/Short Circuit→Step A3↓ 1 ˜ 12 Volts = OK→Step A3↓Step A5↓

2. Bat Volts = Short to Bat (+)→Component Operational 2. ˜ 12 Volts = OK→Step A3↓Step A5↓
Check↓
STEP A3 CHECK RESISTANCE - Ω - OHMS

Power OFF→ Disconnect Cxx 3, 4, or 5 as indicated from the Fault Logs→

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-261
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

STEP A4 CHECK RESISTANCE - Ω - OHMS
Speed Sensor Connections

1. 0? = Short Circuit→Go to 4↓ 1 ˜ 8? = OK→Go to 2↓

2. 8? = Open Circuit→Go to 4↓ 2. ˜ 0? = OK→Go to 3↓
3. 8? = Open Circuit→Go to 4↓ 3. ˜ 0? = OK→Component Operational Check↓
4. Find/Repair Short/Open Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
5. Recheck ?↑→ Reconnect→Use Display Diagnostics to validate→Test OK→YES→Resume Opera-
tionNo→Component Operational Check↓
STEP A5 CHECK RESISTANCE - Ω - OHMS
Speed Sensor Connections

1. 8? = Open Circuit→Go to 3↓ 1. ˜ 0? = OK→Go to 2↓

2. 8? = Open Circuit→Go to 3↓ 2. ˜ 0? = OK→Component Operational Check↓
3. Find/Repair Open Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
4. Recheck ?↑→ Reconnect→Use Display Diagnostics to validate→Test OK→YES→Resume Opera-
tionNo→Component Operational Check↓

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9030-20-262 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

CAUSE B CHECK RESISTANCE - Ω - OHMS
Speed Sensor Connections

1. 0? = Short Circuit→Go to 6↓ 1. ˜ 8? = OK→Go to 2↓

2. 0? = Short Circuit→Go to 6↓ 2. ˜ 8? = OK→Go to 3↓
3. 0? = Short Circuit→Go to 6↓ 3. ˜ 8? = OK→Go to 4↓
4. 0? = Short Circuit→Go to 6↓ 4. ˜ 8? = OK→Go to 5↓
5. 0? = Short Circuit→Go to 6↓ 5. ˜ 8? = OK→Component Operational Check↓
6. Find/Repair Short Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 7↓
7. Recheck ?↑→ Reconnect→Use Display Diagnostics to validate→Test OK→YES→Resume Opera-
tionNo→Component Operational Check↓
CAUSE C CHECK RESISTANCE - Ω - OHMS
Sensor Failure

Power OFF→ Remove/Replace Motor Speed Sensor↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369→ Step C1 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-263
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

STEP C1

Power ON→ ô DTCs Gone→ Original Sensor Faulty→ Resume Operation

DTCs Present→ Original Sensor OK/Reinstall Original Sensor→ Com-

ponent Operational Check ↓
CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-264 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming
STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-265
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Speed Sensor Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-266 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Speed Sensor Failure

DTC 25104 DTC 29456

Sensor Fault Sensor Fault

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

?No Traction/Hydraulic Truck Operation?

POSSIBLE CAUSES
1. Speed Sensor/Motor Controller Connections/Wiring?→
2. Speed Sensor Failure?→
3. Motor Controller(s) Failure ?→
4. Motor Failure ?→

WARNING
The CBB Truck requires the removal of the battery to access the Controllers and Motors
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-267
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Speed Sensor Failure (Cont)

Check 3

Power ON→ Fault Remains No Fault→ Resume Operation

Service Required ?
Check 4
FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-268 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Speed Sensor Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection
Diagnostics Speed Sensor Analysis – Use to Validate Correct Sensor Operation after Repairs

NOTE: If Motor Operation is Disabled then no speed will be displayed

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-269
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Speed Sensor Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
1.5 – 2.0 TON CBB SCHEMATIC CAUSES A B C D E > ?

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9030-20-270 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Speed Sensor Failure (Cont)

2.2 – 3.5 TON DBB SCHEMATIC CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-271
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Speed Sensor Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx Speed Sensor Motor Connector Cxx
3, 4, and 5 146, 152, and 153
CAUSE A

Power OFF→ ?
STEP A1
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections

Disconnect Cxx XXX as indicated from the Fault Logs→ Power ON↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-272 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Speed Sensor Failure (Cont)

STEP A2 CHECK VOLTAGE
Speed Sensor Supply

1. 0 Volts = Open/Short Circuit→Step A3↓ 1 ˜ 12 Volts = OK→Step A3↓Step A5↓

2. Bat Volts = Short to Bat (+)→Component Operational 2. ˜ 12 Volts = OK→Step A3↓Step A5↓
Check↓
STEP A3

Power OFF→ Disconnect Cxx 3, 4, or 5 as indicated from the Fault Logs→

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-273
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Speed Sensor Failure (Cont)

STEP A4 CHECK RESISTANCE - Ω - OHMS
Speed Sensor Connections

1. 0? = Short Circuit→Go to 4↓ 1 ˜ 8? = OK→Go to 2↓

2. 8? = Open Circuit→Go to 4↓ 2. ˜ 0? = OK→Go to 3↓
3. 8? = Open Circuit→Go to 4↓ 3. ˜ 0? = OK→Component Operational Check↓
4. Find/Repair Short/Open Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
5. Recheck ?↑→ Reconnect→Use Display Diagnostics to validate→Test OK→YES→Resume Opera-
tionNO→Component Operational Check↓
STEP A5 CHECK RESISTANCE - Ω - OHMS
Speed Sensor Connections

1. 8? = Open Circuit→Go to 3↓ 1. ˜ 0? = OK→Go to 2↓

2. 8? = Open Circuit→Go to 3↓ 2. ˜ 0? = OK→Component Operational Check↓
3. Find/Repair Open Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
4. Recheck ?↑→ Reconnect→Use Display Diagnostics to validate→Test OK→YES→Resume Opera-
tionNO→Component Operational Check↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-274 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Speed Sensor Failure (Cont)

CAUSE B CHECK RESISTANCE - Ω - OHMS
Speed Sensor Connections

1. 0? = Short Circuit→Go to 6↓ 1. ˜ 8? = OK→Go to 2↓

2. 0? = Short Circuit→Go to 6↓ 2. ˜ 8? = OK→Go to 3↓
3. 0? = Short Circuit→Go to 6↓ 3. ˜ 8? = OK→Go to 4↓
4. 0? = Short Circuit→Go to 6↓ 4. ˜ 8? = OK→Go to 5↓
5. 0? = Short Circuit→Go to 6↓ 5. ˜ 8? = OK→Component Operational Check↓
6. Find/Repair Short Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 7↓
7. Recheck ?↑→ Reconnect→Use Display Diagnostics to validate→Test OK→YES→Resume Opera-
tionNO→Component Operational Check↓
CAUSE C CHECK RESISTANCE - Ω - OHMS
Sensor Failure

Power OFF→ Remove/Replace Motor Speed Sensor↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369→ Step C1 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-275
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Speed Sensor Failure (Cont)

STEP C1

Power ON→ ô DTCs Gone→ Original Sensor Faulty→ Resume Operation

DTCs Present→ Original Sensor OK/Reinstall Original Sensor→ Com-

ponent Operational Check ↓
CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-276 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Speed Sensor Failure (Cont)

STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming
STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-277
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Speed Sensor Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-278 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 Motor Auto Brake Failure

DTC 8786 DTC 12834 DTC 12835

Brake Coil Shorted Aux Driver Short to Bat (-) Aux Driver Open Circuit
Brake Coil Open Circuit Excess Current

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

?Brake does not Release when Traction is Commanded?

POSSIBLE CAUSES
DTC 12834 Aux Driver Short to Bat (-) → Component Operational
Brake Coil Open Circuit Check ↓
DTC 12835 Aux Driver Open Circuit No Current/> 5 amps driver → Component Operational
Excess Current current Check ↓
DTC 8786 Brake Coil Shorted > 5.3 amps driver current → Component Operational
Check ↓
Motor Controllers Fail- Driver Failure → Component Operational
ure?→ Check ↓
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-279
Diagnostic Trouble Codes Electrical System

A935 – K160 Motor Auto Brake Failure (Cont)

Check 3

Power ON→ Fault Remains No Fault→ Resume Operation

Service Required ?
Check 4
FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-280 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 Motor Auto Brake Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection
Diagnostics Speed Sensor Analysis – Use to Validate Correct Sensor Operation after Repairs

Note: If Motor Operation is Disabled then no speed will be displayed

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-281
Diagnostic Trouble Codes Electrical System

A935 – K160 Motor Auto Brake Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
WHEEL MOTOR AUTO BRAKE FAILURE CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-282 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 Motor Auto Brake Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx Auto Brake Motor Connectors Cxx 24
3, 4, and 5 and 26
CAUSE A
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections

Disconnect Cxx and Cxx 3 or 4 as indicated from the Fault Logs→ Power ON↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-283
Diagnostic Trouble Codes Electrical System

A935 – K160 Motor Auto Brake Failure (Cont)

STEP A1
Auto Brake Short Circuit to Bat (+)

1. Short to Bat (+)→Go to 2↓ 1 0 Volts = OK→Go to 2↓

2. Short to Bat (+)→Go to 3↓ 2. 0 Volts = OK→Step A2↓
3. Recheck ?↑→ Reconnect→Test→No DTCs→YES→Resume OperationNo→Step A2↓
STEP A2

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-284 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 Motor Auto Brake Failure (Cont)

STEP A3 CHECK RESISTANCE - Ω - OHMS
Auto Brake Coil Open/Short Circuit

1. <15 ? > 45 ?= Faulty Coil→Go to 2↓ 1 >15 ? < 45 ?= OK Coil→Go to Step A4↓

2. Replace Auto Brake→See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
3. Recheck ?↑→ Reconnect→Test→No DTCs→YES→Resume OperationNo→Step A4↓
STEP A4 CHECK RESISTANCE - Ω - OHMS
Auto Brake Connections Open/Short Circuit

1. 0? = Short Circuit→Go to 4↓ 1. ˜ 8? = OK→Go to 2↓

2. 8? = Open Circuit→Go to 4↓ 2. ˜ 0? = OK→Go to 3↓
3. 8? = Open Circuit→Go to 4↓ 3. ˜ 0? = OK→Component Operational Check↓
4. Find/Repair Short/Open Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
5. Recheck ?↑→ Reconnect→Test→No DTCs→YES→Resume OperationNo→Component Operational Check↓
CAUSE B
Not Applicable
CAUSE C
Not Applicable

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-285
Diagnostic Trouble Codes Electrical System

A935 – K160 Motor Auto Brake Failure (Cont)

CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓
STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Controller→Dealer→Factory→Failure Analysis→?? Reprogramming

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-286 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 Motor Auto Brake Failure (Cont)

STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-287
Diagnostic Trouble Codes Electrical System

A935 – K160 D203Motor Controller Power Mosfet Failure

DTC 65513
Power MOS Shorted

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? No Traction/Hydraulics Truck Operation ?

Possible Causes
Motor Controller(s) Failure ?→ → Component Operational
Check ↓
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-288 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203Motor Controller Power Mosfet Failure (Cont)

Check 3

Power ON→ Fault Remains Service Re- No Fault→ Resume Operation

quired ?
FAULT LOG Review - Go to Display Menu

Enter SERVICE Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-289
Diagnostic Trouble Codes Electrical System

A935 – K160 D203Motor Controller Power Mosfet Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-290 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203Motor Controller Power Mosfet Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
MOTOR CONTROLLER POWER MOSFET FAILURE CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-291
Diagnostic Trouble Codes Electrical System

A935 – K160 D203Motor Controller Power Mosfet Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx 3, 4, and 5

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-292 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203Motor Controller Power Mosfet Failure (Cont)

CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-293
Diagnostic Trouble Codes Electrical System

A935 – K160 D203Motor Controller Power Mosfet Failure (Cont)

STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming
STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-294 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203Motor Controller Power Mosfet Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-295
Diagnostic Trouble Codes Electrical System

A935 – K160 D203Motor/Motor Controller Failure

DTC 12576
Motor Voltage Not OK

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? No Traction/Hydraulic Truck Operation ?

POSSIBLE CAUSES
Motor to Motor Controller Connections/Wiring→ High Resistance?→ → Component Operational
Check ↓
Motor Windings Failure Open Circuit?→ → Component Operational
Check ↓
Motor Windings Short to Frame?→ → Component Operational
Check ↓
Motor Controller(s) Failure?→ → Component Operational
Check ↓
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-296 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203Motor/Motor Controller Failure (Cont)

Check 3

Power ON→ Fault Remains Service Required ? No Fault→ Resume Operation

FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-297
Diagnostic Trouble Codes Electrical System

A935 – K160 D203Motor/Motor Controller Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the Faulty Component/Connection

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-298 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203Motor/Motor Controller Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
MOTOR/MOTOR CONTROLLER FAILURE CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-299
Diagnostic Trouble Codes Electrical System

A935 – K160 D203Motor/Motor Controller Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2

CAUSE A

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ ?

Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP A1

For any Fault DTC→ Locate Device↓

Inspect ALL Wiring/Connections for Open Circuits/Corrosion/Bridging between adjacent Terminals

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-300 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203Motor/Motor Controller Failure (Cont)

STEP A2

1. Set DMM to Lowest ?→Check Lead Resistance <0.01?

Note: If the Resistance is >0.01? then record this as the Zero ? Value → Step A3 ↓
STEP A3 CHECK RESISTANCE - Ω - OHMS
Motor Coils

Disconnect Motor connections W, V, U on Motor System indicated in Fault Log↓

1. Measure ?→Go to 2↓
2. Measure ?→Go to 3↓
3. Measure ?→Go to 4↓
4. 1 ? 2 ? 3 = > 0.01? + Zero Value→Go to 5↓ 4. 1 = 2 = 3 < 0.01? + Zero Value→Step A4↓
5. Motor Faulty→Replace MotorGo to 6↓
6. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
7. Recheck ?↑→ Reconnect→Test→?DTCs? YES→Step A4↓ NO→Resume Operation

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-301
Diagnostic Trouble Codes Electrical System

A935 – K160 D203Motor/Motor Controller Failure (Cont)

STEP A4 CHECK RESISTANCE - Ω - OHMS
Motor Coils

Disconnect Motor connections W, V, U on Controller↓

1. Measure ?→Go to 2↓
2. Measure ?→Go to 3↓
3. Measure ?→Go to 4↓
4. 1 ? 2 ? 3 > 0.01? + Zero Value→Go to 5↓ 4. 1 = 2 = 3 < 0.01? + Zero Value→Component Opera-
tional Check↓
5. Wiring/Connector(s) Faulty→ReplaceGo to 6↓
6. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
7. Recheck ?↑→ Reconnect→Test→?DTCs? YES→Component Operational Check↓ NO→Resume Operation
CAUSE B
Not Applicable

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-302 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203Motor/Motor Controller Failure (Cont)

CAUSE C
Motor Windings to Motor Case

Measure ? between Case and any Motor Terminal

1. < 500K?→Go to 2↓ 1. > 500K?→Component Operational Check↓
2. Short to Case→Replace Motor→Go to 3↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
4. Recheck ?↑→ Reconnect→Test→?DTCs? YES→Component Operational Check↓ NO→Resume Operation
CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-303
Diagnostic Trouble Codes Electrical System

A935 – K160 D203Motor/Motor Controller Failure (Cont)

STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming
STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-304 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203Motor/Motor Controller Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-305
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller Failure

DTC 65280
Controller Failure

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? Function Failure/Reduced Performance/Uncommanded Continuous Operation?

POSSIBLE CAUSES
1. Motor Controller Connections/Wiring High Resistance?→ → Component Opera-
tional Check ↓
2. Motor Controller(s) Failure?→ → Component Opera-
tional Check ↓
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-306 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller Failure (Cont)

Check 3

Power ON→ Fault Remains Service Re- No Fault→ Resume Operation

quired ?
FAULT LOG Review - Go to Display Menu

Enter SERVICE Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-307
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection
Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-308 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
MOTOR CONTROLLER CAPACITOR FAILURE CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-309
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx 3, 4, and 5

CAUSE A

Power OFF→ ?
STEP A1
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections See Diagnostic Trouble Codes, Page
9030-20-238

CAUSE B
Not Applicable
CAUSE C
Not Applicable

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-310 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller Failure (Cont)

CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓
STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-311
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller Failure (Cont)

STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-312 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Failure

DTC 8976 DTC 9024

AC Current – Over Current AC Current – Short Circuit

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? No Traction/Hydraulic Truck Operation ?

POSSIBLE CAUSES
Motor to Motor Controller Connections/Wiring→ High Resistance?→ → Component Operational
Check ↓
Motor Windings Failure Open Circuit?→ → Component Operational
Check ↓
Motor Windings Short to Frame?→ → Component Operational
Check ↓
Motor Controller(s) Failure?→ → Component Operational
Check ↓

WARNING
The CBB Truck requires the removal of the battery to access the Controllers and Motors
Check 2

Disconnect Battery Sound Horn to Discharge Wait 30 seconds Reconnect Battery

Capacitors

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-313
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Failure (Cont)

Check 3

Power ON→ Fault Remains Service Required ? No Fault→ Resume Operation

FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-314 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the Faulty Component/Connection

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-315
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
1.5 – 2.0 TON CBB SCHEMATIC CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-316 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Failure (Cont)

2.2 – 3.0 TON DBB SCHEMATIC CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-317
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2

CAUSE A

Power OFF→ Disconnect Battery→ Sound Horn to Discharge Capacitors→ ?

STEP A1

For any Fault DTC→ Locate Device↓

Inspect ALL Wiring/Connections for Open Circuits/Corrosion/Bridging between adjacent Terminals

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-318 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Failure (Cont)

STEP A2

1. Set DMM to Lowest ?→Check Lead Resistance <0.01?

Note: If the Resistance is >0.01? then record this as the Zero ? Value → Step A3 ↓
STEP A3 CHECK RESISTANCE - Ω - OHMS
Motor Coils

Disconnect Motor connections W, V, U on Motor System indicated in Fault Log↓

1. Measure ?→Go to 2↓
2. Measure ?→Go to 3↓
3. Measure ?→Go to 4↓
4. 1 ? 2 ? 3 = > 0.01? + Zero Value→Go to 5↓ 4. 1 = 2 = 3 < 0.01? + Zero Value→Component Opera-
tional Check↓
5. Motor Faulty→Replace MotorGo to 6↓
6. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 7↓
7. Recheck ?↑→ Reconnect→Test→?DTCs? YES→Component Operational Check↓ NO→Resume Operation

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-319
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Failure (Cont)

CAUSE B CHECK RESISTANCE - Ω - OHMS
Motor/Controller Connections

Disconnect Motor connections W, V, U on Controller↓

1. Measure ?→Go to 2↓
2. Measure ?→Go to 3↓
3. Measure ?→Go to 4↓
4. 1./2./3. 0?→Go to 5↓ 4. 1./2./3. 8?→Component Operational Check↓
5. Wiring/Connector(s) Faulty→ReplaceGo to 6↓
6. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 7↓
7. Recheck ?↑→ Reconnect→Test→?DTCs? YES→Component Operational Check↓ NO→Resume Operation

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-320 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Failure (Cont)

CAUSE C
Motor Windings to Motor Case

Measure ? between Case and any Motor Terminal

1. < 500K?→Go to 2↓ 1. > 500K?→Component Operational Check↓
2. Short to Case→Replace Motor→Go to 3↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 4↓
4. Recheck ?↑→ Reconnect→Test→?DTCs? YES→Component Operational Check↓ NO→Resume Operation
CAUSE D

Power OFF→ Disconnect Battery Sound Horn to Discharge

Capacitors
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-321
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Failure (Cont)

STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming
STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-322 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-323
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller CAN Communication Failure

DTC 65527
No CAN Communication

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? No Traction/Hydraulic Truck Operation ?

POSSIBLE CAUSES
Motor Controller Connections/Wiring Open/ A935 – K160 CAN Communication Failure
Short Circuit→
Motor Controller(s) Failure?→ → Component Operational Check ↓
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-324 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller CAN Communication Failure (Cont)

Check 3

Power ON→ Fault Remains Service Required ? No Fault→ Resume Operation

FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-325
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller CAN Communication Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the Faulty Component/Connection

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-326 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller CAN Communication Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
MOTOR CONTROLLER CAN COMMUNICATION FAILURE CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-327
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller CAN Communication Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx 3, 4, and 5

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-328 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller CAN Communication Failure (Cont)

CAUSE A
See A935 – K160 CAN Communication Failure
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D

WARNING
Do not do Component Operational Check until Component Operational Check is complete.

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-329
Diagnostic Trouble Codes Electrical System

A935 – K160 D203 Motor Controller CAN Communication Failure (Cont)

STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming
STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-330 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

A935 – K160 D203 Motor Controller CAN Communication Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-331
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller CAN Communication Failure

DTC 33024
CAN Communication Failure

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? No Traction/Hydraulic Truck Operation ?

POSSIBLE CAUSES
1. Motor Controller Connections/Wiring – Open/Short Circuit→Go to 1a or 1b↓
1a. CAN Communication Failure. See CBB 4 Wheel CAN Communication→
1b. CAN Communication Failure. See DBB 4 Wheel CAN Communication→
2. Motor Controller(s) Failure?→Component Operational Check↓

WARNING
The CBB Truck requires the removal of the battery to access the Controllers and Motors
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-332 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller CAN Communication Failure (Cont)

Check 3

Power ON→ Fault Remains Service Required ? No Fault→ Resume Operation

FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-333
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller CAN Communication Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the Faulty Component/Connection

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-334 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller CAN Communication Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
1.5 – 2.0 CBB SCHEMATIC CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-335
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller CAN Communication Failure (Cont)

2.2 – 3.0 DBB SCHEMATIC CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-336 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller CAN Communication Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx 3, 4, and 5

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-337
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller CAN Communication Failure (Cont)

CAUSE A
See CBB 4 Wheel CAN Communication or DBB 4 Wheel CAN Communication
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D

WARNING
Do not do Component Operational Check until Component Operational Check is complete.

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-338 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller CAN Communication Failure (Cont)

STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming
STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-339
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller CAN Communication Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-340 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select Incorrect

Fault Codes
DTC 12802
Direction Select

Data Incorrect –

Direction Signals Incorrect

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-341
Diagnostic Trouble Codes Electrical System

Travel Direction Select Incorrect (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
TRAVEL DIRECTION SELECT INCORRECT CAUSES A B C D E > ?

CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C

Power OFF→ Disconnect sensor→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-342 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select Incorrect (Cont)

STEP C1 CHECK RESISTANCE - Ω - OHMS

0 ? = Short circuit↑ Find→ Short circuit. ˜ 9K? = OK Go to Component Operational

Check. ?
Repair OPEN Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369.→
Recheck ?↑ → Reconnect→ Test OK→ YES→ Resume Operation NO→ Component Operational Check ↓
Recheck ?↑ → Reconnect→ Use Display Diagnostics to validate→ Test OK→ YES→ Resume Operation NO→
Component Operational Check ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-343
Diagnostic Trouble Codes Electrical System

Travel Direction Select Incorrect (Cont)

CAUSE D

Power OFF→ Reconnect sensor→ Power ON→ Step D1 ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-344 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select Incorrect (Cont)

STEP D1

1. Measure Pedal Neutral Voltage DS2 and DS1

? DS2 (1.13V ± 2%) volts ˜ ½ DS1 (2.25V ± 2%) volts?→ YES→Go to 2 NO →Go to 3↓
2. Select FORWARD Position – Foot DCS or Man Hyd DCS and Measure voltage at points 1 & 2
? DS2 (1.8 ? ?2.1)volts ˜ ½ DS1(3.6 ? ?4.1)volts ?→ YES→Go to Step D2NO →Go to Step D3↓
Note: >4.9 Volts→ Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH)→
Note: <0.31 Volts→ Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL)→

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-345
Diagnostic Trouble Codes Electrical System

Travel Direction Select Incorrect (Cont)

STEP D2 CHECK VOLTAGE

1. Select REVERSE Position – Foot DCS or Man Hyd DCS and Measure voltage at points 1 & 2
2. ? DS2 (0.9 ? ?1.4)volts ˜ ½ DS1(0.4 ? ?0.7)volts ?→YES→Go to Component Operational CheckNO →Go to
Step D3↓
Note >4.9 Volts→ Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH)→
Note <0.31 Volts→ Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL)→

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-346 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select Incorrect (Cont)

STEP D3 CHECK VOLTAGE

Power OFF→ Reconnect sensor→ Power ON→ Go to next step.

? Fault DTC gone→ Old sensor faulty→ Resume operation

Fault DTC present→ Old sensor OK/Reinstall old Go to Component Operational

sensor→ Check.
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-347
Diagnostic Trouble Codes Electrical System

Travel Direction Select Incorrect (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

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9030-20-348 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select Data Incorrect – 2 Sources

Fault Codes
DTC 12806
Direction Select – Data Incorrect

2 + Direction Devices Installed

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-349
Diagnostic Trouble Codes Electrical System

Travel Direction Select Data Incorrect – 2 Sources (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
TRAVEL DIRECTION SELECT DATA INCORRECT CAUSES A B C D E > ?

WARNING
The Fault DTC will be displayed if more than one Direction Control Device is installed.
CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C
Not Applicable

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-350 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Travel Direction Select Data Incorrect – 2 Sources (Cont)

CAUSE D

Power OFF→ Locate and Disconnect Incorrect Direction Selection Device→ Step D1 ?
For MLM see Electrical System 2200SRM1337/Electrical System 2200SRM1369→
STEP D1

Retest - Power ON→ NO → Go to Compo- Is fault DTC gone? Fault corrected→ Continue operation.
nent Operational
Check NO ← YES →
CAUSE E

Power OFF→ Inspect VSM Connections→ Go to Not OK Correct/Repair→ Go to

Cause E1. Cause E1.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-351
Diagnostic Trouble Codes Electrical System

Travel Direction Select Data Incorrect – 2 Sources (Cont)

CAUSE E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO ← YES →
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-352 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Direction Select Data Incorrect - No DCS Source

DTC 12807
Direction Select Data Incorrect - No DCS Source

Fault Codes

Power OFF→ Wait 30 sec- Power Fault remains. No fault→ Resume operation
onds→ ON→ Service required.
Go to Component
Operational
Check.

QUICK CHECK X Open Circuit/Fail ) = Short Circuit

Check 1

1. Is there any other DCS devices installed except the armrest DCS?
2. YES→Check 2NO→Go to 3↓
3. Is DCS installed on the armrest?YES→Check 2NO→Obtain and Install DCS→Go to 4↓
4. See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
5. Test new DCS→Function OK/DTC gone→YES→Resume OperationNO→Check 2↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-353
Diagnostic Trouble Codes Electrical System

Direction Select Data Incorrect - No DCS Source (Cont)

Check 2

Push in Emergency Stop Disconnect Battery and Wait 30 seconds Release Emergency Stop
Sound Horn to Discharge
Capacitors. Depending on
your lift truck, go to Frame
0100SRM1329 or Frame
0100SRM1342.
FAULT LOG CODE Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ VSM/MLM Fault Logs→ View all VSM/MLM DTCs→ ?

3? All VSM/MLM DTCs Erase all VSM/MLM DTCs→ E Exit Fault Log Power OFF↓
NOTE: ?DTC 33034 ?→ A935 – K160 CAN Communication Failure
NOTE: ?DTC 12807 ?→Component Operational Check↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-354 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Direction Select Data Incorrect - No DCS Source (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
DIRECTION SELECT DATA INCORRECT - NO DCS SOURCE CAUSES A B C D E > ?

CAUSE A
DCS Wiring/Connections

1. Push In Emergency Stop

2. NOTE: Do not remove PCB Cassette to Remove DCS↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
4. Disconnect DCS from harness
5. Release Emergency Stop
STEP A1 CHECK VOLTAGE
MLM Open Circuit CAN Hi/CAN Lo

1. 0 Volts →Step A2↓ 1. ˜ 5 Volts →Step A3↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-355
Diagnostic Trouble Codes Electrical System

Direction Select Data Incorrect - No DCS Source (Cont)

STEP A2 CHECK VOLTAGE

1. Disconnect Cassette Connector as Indicated→Measure Volts↓

2. 0 Volts→Faulty MLM Cassette→Component Opera- ˜ 5 Volts → Step A3 ↓
tional Check↓
STEP A3

Disconnect Cassette Connector as Indicated→ Measure ?↓

1. 8 ?→OPEN Circuit→Go to 4↓ 1. 0 ?→Go to 2↓
2. 8 ?→OPEN Circuit→Go to 4↓ 2. 0 ?→Go to 3↓
3. 8 ?→OPEN Circuit→Go to 4↓ 3. 0 ?→Step A4↓
4. Find/Repair OPEN Circuit→Go to 5↓
5. See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
6. Recheck ?↑→ Reconnect→Test OK→No DTCs→YES→Resume OperationNo→Step A4↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-356 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Direction Select Data Incorrect - No DCS Source (Cont)

STEP A4 CHECK RESISTANCE - Ω - OHMS

1. 0?→Short Circuit→Go to 3↓ 1. 8 ?→Go to 2↓

2. 0?→Short Circuit→Go to 3↓ 2. 8 ?→Component Operational Check↓
3. Find/Repair Short Circuit→Go to 5↓
5. See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
6. Recheck ?↑→ Reconnect→Test OK→No DTCs→YES→Resume OperationNo→Component Operational
Check↓
CAUSE B
Not Applicable

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-357
Diagnostic Trouble Codes Electrical System

Direction Select Data Incorrect - No DCS Source (Cont)

CAUSE C

Reconnect Cassette Connector and DCS as Indicated→ Select FOWARD Position→ Measure Volts↓
1. Does FORWARD Voltage DS1 = 3.25V ± 0.25 V?↓
NO: Replace DSC→ See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
YES: Select REVERSE Position→ Measure Volts→ Does REVERSE Voltage DSC1 = 1.75V ± 0.25 V?↓
NO: Replace DSC→ See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
YES→ Replace PCB Cassette→ Component Operational Check ↓
Note: >4.9 Volts→ Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH)→
Note: <0.31 Volts→ Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL)→

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9030-20-358 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Direction Select Data Incorrect - No DCS Source (Cont)

CAUSE D

Power OFF→ Remove and Replace MLM PCB Cassette Assembly→ See Electrical System 2200SRM1337/
Electrical System 2200SRM1369↓
Check Replacement MLM < Version→ See Label Information→ Step D1 ↓
STEP D1

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Cassette Software Version the Latest Version
2. NO→Download the latest Application <→Install on truck→Step D2↓
3. YES→Test New Installation→Step D2↓
STEP D2

Power ON→ ? DTCs gone→ Original MLM Cassette faulty→ Resume operation

DTCs Still Present→ Original MLM Cassette OK/Reinstall Original Cas-

sette→ ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-359
Diagnostic Trouble Codes Electrical System

Direction Select Data Incorrect - No DCS Source (Cont)

CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

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9030-20-360 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Temperature Sensor Failure

DTC 16912 DTC 17168 DTC 25105

Motor Temperature Controller/Heatsink Temper- Temperature Sensor
High ature High Failure

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? Over Temperature Icon Displayed at Power ON?

POSSIBLE CAUSES
1. Sensor(s) – Motor/Motor Controller – Connections/Wiring?→ Component Operational
Check ↓
2. Sensor(s) Failure?→ Component Operational
Check ↓
3. Motor Controller(s) Hardware Failure?→ Component Operational
Check ↓
Note: Hydraulic Oil Over Temperature and Sensor Issues see Hydraulic Temperature Sensor Out of Range High
(OORL) Hydraulic Temperature Sensor Out of Range High (OORH)

? Over Temperature Icon Displayed during Operation/Reduced Performance/Function Failure?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-361
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

POSSIBLE CAUSES
1. Motor/Motor Controller/Hydraulic Fluid Overheating?→ Aggressive Operation?→
2. Sensor – Motor/Motor Controller/Hyd Tank – Connections/Wiring?→ Component Operational
Check ↓
3. Sensor(s) Failure?→ Component Operational
Check ↓
4. Motor Controller(s) Failure ?→ Component Operational
Check ↓

WARNING
The CBB Truck requires the removal of the battery to access the Controllers and Motors
Table 9030-20-14. Motor Controller Temperature and Silicon Temperature Sensor

Note: For further assistance on Motor Controller Temperature and Silicon Temperature Sensor readings, see
Table 9030-10-4.
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.
Check 3

Power ON→ Fault Remains Service Required ? No Fault→ Resume Operation

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9030-20-362 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

Check 4

Reduced Performance→ Check Display Icons?

Motor/Motor Controller Temperature Icon On
1. Check fan operation→Are fans operating?→NO → A935 – K160 D203 Motor Controller Fan FailureYES →2. ?
2. Temp Sensor/Controller to Motor connection→Open Circuit→Component Operational Check↓
3. Use the following steps for viewing Motor Temperature
Note: The Motor Temperature ICON will be displayed for any Over Temperature of Traction 1/Traction 2, Pump
Motor and their associated Controllers plus Hydraulic Fluid
Note: The Diagnostics Display Menu Flowchart will show which device is overheating See Check 5
Note: The Service Tech may need to operate the truck for an extended time on a 20% grade to have this Over
temperature icon(s) display again after it has been first reported
Check 5
Diagnostics Temperature Analysis – Go to Display Menu Flowchart

Enter Service Password→ Diagnostics→ Motor→ Traction1/Traction2/ Motor/Control-

Pump→ ler Data

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-363
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

Fan(s) Operation Temperature Threshold: Traction = 55°C (131°F) Pump = 65°C (149°F)
Reduced Performance: Traction = 80°C (176°F) Pump = 80°C (176°F)

Motor Motor Controller

Invalid Temperature Signal (Traction/Pump Motor(s) Only): Sensor Connections/Sensor Open Circuit

Return to Diagnostics Menu→ ?

Check 6
Fault Log DTC – Go to Display Menu Flowchart

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

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9030-20-364 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

3? all Motor Codes→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-365
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
CBB SCHEMATIC CAUSES A B C D E > ?

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9030-20-366 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

DBB SCHEMATIC CAUSES A B C D E > ?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-367
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx Fan Motor Connector Cxx 146, 154,
3, 4, and 5 and 155
CAUSE A

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ Go to Step A1
Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP A1
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections
A DMM Temperature probe can also be used to determine which device is overheating

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9030-20-368 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

STEP A2 CHECK RESISTANCE - Ω - OHMS
Motor Temperature Sensor

1. Disconnect Motor Connector→Measure ? as indicated→

Note: For temperature sensor readings, see Table 9030-10-4.
At xxx deg→ sensor ? ˜ match Temperature Chart 340? @ → -40°C (25°F) to 2791? @ 300°C (572°F) ↓
2. <300? to 0? = Motor Sensor Short Circuit→Go to 8↓
3. >2800? to 8? = Motor Sensor Open Circuit/High Resistance Connection→Go to 8↓
4. Reconnect Motor Connector↓
5. Disconnect Controller Connector→Measure ? as indicated→See Table 9030-10-4.↓
6. <300? to 0? = Short Circuit→Go to 9↓
7. >2800? to 8? = Open Circuit/High Resistance Connection→Go to 9↓
8. Replace Motor→Go to 10↓
9. Find/Repair Harness OPEN/SHORT Circuit→Go to 10↓
10. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 11↓
11. Recheck ?↑→ Reconnect→Resume Operation

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-369
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

STEP A3
Motor Temperature Sensor (Controller Check)

1. Disconnect Motor Temperature Sensor Connector from suspect Controller→

2. Connect a ¼ watt resistor (>3300? to <10,000?) as shown
3. Reconnect Battery and all other Connectors
4. Does Over Temperature ICON Appear?↓
5. YES: Go to 7↓
6. NO: Controller is Faulty→Component Operational Check↓
7. Repeat Resistor Test on other Controllers↓
8. Temperature ICON is Displayed?→YES: Controller tested OK, Go to 9→NO: Controller tested Faulty→Com-
ponent Operational Check↓
9. Reconnect other Motor Temperature Sensors
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.

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9030-20-370 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓
STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-371
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

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9030-20-372 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller Current Sensor Failure

DTC 21008
Current Sensor Offset Calibration Error

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? No Traction/Hydraulics Truck Operation ?

Possible Causes
Motor Controller(s) Failure ?→ → Component Operational
Check ↓

WARNING
The CBB Truck requires the removal of the battery to access the Controllers and Motors
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-373
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller Current Sensor Failure (Cont)

Check 3

Power ON→ Fault Remains Service Re- No Fault→ Resume Operation

quired ?
FAULT LOG Review - Go to Display Menu

Enter SERVICE Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

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9030-20-374 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller Current Sensor Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-375
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller Current Sensor Failure (Cont)

CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓

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9030-20-376 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller Current Sensor Failure (Cont)

STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming
STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-377
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller Current Sensor Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

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9030-20-378 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Calibration Required

DTC 4096
Hydraulic Calibration Required

Fault Codes
FAULT LOG CODE Review - Go To Display Review

Power ON→ Fault Remains Service Required ? No Fault→ Resume Operation

Calibration Process - Go to Display Menu

Enter Service Pass- D Diagnostics → F* E Hydraulic Input ?

word→ F*

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-379
Diagnostic Trouble Codes Electrical System

Hydraulic Calibration Required (Cont)

Hydraulic Lever Sensor Input Values

1. F*"Hydraulic Levers at Center position# < ± 2.5% = v" Proceed with Calibration ?

2. F*"Hydraulic Levers at Center position# > ± 2.5% = X = Faulty Lever Mechanism " Repair, Go to 3?
3. Manual Hydraulics Depending on your lift truck see, Main Control Valves 2000SRM1334 or Main Control
Valves 2000SRM1439.

Calibration Process - Go to Display Menu

Calibration Menu
This Hydraulic Calibration Display Menu is viewable to those logged in with a supervisor or service level pass-
word.
E-Hydraulics and Manual Hydraulics Threshold Calibration: For Display Menu graphics see following pages.
1. Access Calibration Menu→Press *→Scroll to Hydraulic Calibration→Press*↓
2. Move the lever for function 1 in the A direction until the forks begin to visibly move in the A [Link]*
The VSM will record the setting and the Display will automatically step to the next Calibration step.E.g.
1A→1B→2A→2B.
Note: Calibration reading outside of the allowable engineering tolerances = X across the graphic. Press any key
to return to the A direction graphic for the valve under calibration. Repeat calibration steps.
3. Last Calibration completed.→Display transitions back to the Calibration Maintenance Menu List.
Manual-Hydraulic: For Display Menu graphics see following pages.
1. Access Calibration Menu→Press *→Scroll to Manual Hydraulic Valve→Press*↓
2. Move the Lift Lever first to the end of mechanical travel in one direction and then to the other endPress*
Repeat for the other Levers.
When all levers have been calibrated Press the Scroll Left Button to return to the previous Menu.

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9030-20-380 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Hydraulic Calibration Required (Cont)

Note: If the calibration reading is outside of the allowable engineering tolerances the Display will display an X’
across the graphic.

Wait 3 seconds→Press*→Repeat the calibration for this Lever.

Calibration Process - Go to Display Menu

Calibration → F* ↓ Hydraulic Valve Threshold

Hydraulic Valve Threshold - Manual and E-Hydraulic

F* Operate Indicated Control until Hyd movement is observed Repeat for each Function
F* F*

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-381
Diagnostic Trouble Codes Electrical System

Hydraulic Calibration Required (Cont)

X = Calibration Failure F # to Reset↑ Repeat Calibration

WARNING: X = MLM Lever operated in the wrong direction. Repeat Calibration

Manual Hydraulic Valve

F* Lift/LowerG F * v Next Lever G X = Calibration Fail I_touchup FontFamname="Wingdings" 1 3 sec-

onds F* Repeat Calibration
FAULT DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Dis-
play Menu Flowchart - Clearing DTCs.

CAUSE A
End of Task
END FAULT

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Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller 15 – 5 Volt Internal Failure

DTC 20753 DTC 20755

15 Volt Supply Low Voltage 5 Volt Supply Low/High Voltage

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? No Traction/Hydraulics Truck Operation ?

Possible Causes
20753/20755→ Motor Controller(s) Failure ?→ Component Operational
Check ↓

WARNING
The CBB Truck requires the removal of the battery to access the Controllers and Motors
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-383
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller 15 – 5 Volt Internal Failure (Cont)

Check 3

Power ON→ Fault Remains Service Re- No Fault→ Resume Operation

quired ?
FAULT LOG Review - Go to Display Menu

Enter SERVICE Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

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9030-20-384 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller 15 – 5 Volt Internal Failure (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection
CAUSE A
Not Applicable
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-385
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller 15 – 5 Volt Internal Failure (Cont)

STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming
STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

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9030-20-386 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller 15 – 5 Volt Internal Failure (Cont)

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-387
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller DC Bus Low/High

DTC 12576 DTC 12817 DTC 12818 DTC 12833

DC Bus Charg- DC Bus Hi – Soft- DC Bus Hi – Hard- DC Bus Low –
ing Timeout ware Detected ware Detected Hardware/Soft-
ware

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? No Operation ?
POSSIBLE CAUSES
DTC 12576 DC Bus Charging Timeout Low Battery/High ® Connections→ Go to 1, 2, → Component Op-
and 3↓ erational Check ↓
DTC 12817 DC Bus Hi – Software De- Brake Torque Settings→ Go to 4↓ → Component Op-
tected erational Check ↓
DTC 12818 DC Bus Hi – Hardware De- High ® Connections→ Go to 3 and 4↓ → Component Op-
tected erational Check/
Component Opera-
tional Check↓
DTC 12833 DC Bus Low – Hardware/ High ® Connections→ Go to 3↓ Component Opera-
Software tional Check → ↓
1. Go to OORL. See Battery OORH/OORL
2. PTC Failure?→
3. Motor/Motor Controller Battery Connections/Wiring – High ®/Contactor Contacts?→
4. Commanded Braking Torque (Regen) is set too High for Battery Condition

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9030-20-388 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller DC Bus Low/High (Cont)

Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.
Check 3

Power ON→ Fault Remains Service Required ? No Fault→ Resume Operation

Check 4

Power ON→ Go to Diagnostics→ Battery/Supply→ View Bat Value→ Go to Display Menu Flowchart↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-389
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller DC Bus Low/High (Cont)

Check 5
Battery OORL/OORH as measured by the Motor Controllers
NOTE: OOR fault is set if OOR condition is present for longer than 1 second.
NOTE: Both Motor control and VSM OOR faults may appear due to the different thresholds levels
Battery Voltage
Nominal 36 48 72 80
Fully Charged 39.6 52.8 79.2 88
˜< OORL 23 30 41 48
˜ OORH 50 65 99 110
Is battery voltage ˜ < OORL value for correct battery?↓
YES → Battery OORH/OORL → Return to this Fault after Battery OORH/OORL/Retest is complete.?
NO→ Check 6?
FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostics→

Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

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9030-20-390 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller DC Bus Low/High (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Status→ Truck DiagnosticsF*↓

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-391
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller DC Bus Low/High (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
1.5 – 2.0 CBB SCHEMATIC CAUSES A B C D E > ?
®
= High Resistance Connections

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9030-20-392 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller DC Bus Low/High (Cont)

2.2 – 3.0 DBB SCHEMATIC CAUSES A B C D E > ?
®
= High Resistance Connections

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-393
Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller DC Bus Low/High (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx 3, 4, and 5

CAUSE A

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ ?

Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP A1
NOTE: ® Battery or Battery to Motor Controller Power Connections→ all DTC Faults are possible
NOTE: High Current drawn from the battery through ® = Voltage drops = OORL
NOTE: High Current sent to the battery through ® = Voltage increases = OORH

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9030-20-394 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller DC Bus Low/High (Cont)

STEP A2
For any Fault DTCs→ Locate Devices→ Inspect ALL Wiring/Connections

STEP A3

1. Inspect Contactor Top and Bottom Contacts for Pitting/Corrosion/Dirt Build-Up→Go to 2↓

2. Replace Contactor if Pitting/Corrosion is Observed/ Clean out any Dirt Build up↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 4↓
4. Check all Connections→Reconnect Battery→Step A4↓
STEP A4

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →

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Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller DC Bus Low/High (Cont)

STEP A5

Disconnect Battery and Sound Horn to Discharge Capacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→.?
Set DMM to Lowest ? scale→ Check Lead Resistance < 0.01?
Note: If the Resistance is > 0.01? then record this as the Zero ? Value→ Step A6 ↓
STEP A6 CHECK RESISTANCE - Ω - OHMS
PTC Failure

1. >10 ? @ 25 °C (77 °F) = Faulty PTC→Go to 2↓ 1. <10 ? >4 ? = OK→Go to 2↓

2. Replace PTC(s)→Go to 3↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 4↓
4. Recheck ?↑→ Reconnect→Step A7↓

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Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller DC Bus Low/High (Cont)

STEP A7

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE B

Enter SERVICE Password→ Diagnostics↓

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Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller DC Bus Low/High (Cont)

STEP B1

Scroll ↑ ↓ Indicated Motor with Fault DTC F*→ View Voltage→ 3? Voltage↓
STEP B2

Battery Voltage
Nominal 36 48 72 80
Fully Charged 39.6 52.8 79.2 88
˜ < OORL 23 30 41 48
˜ > OORH 50 65 99 110
1. Ensure that the Battery has been fully charged→Check Battery connections are clean and secure.
2 Operate Truck with Maximum Acceleration in Forward Direction→3? Maximum Voltage
3. Completely release acceleration pedal→Regen Braking Only→3? Maximum Voltage
4. Do Minimum and Maximum Voltages exceed the OORL or OORH thresholds?
5. YES →Step B3NO→Resume Operation

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Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller DC Bus Low/High (Cont)

STEP B3

1. Elevate Truck drive [Link] only approved support methodsSee Operating Manual
2. All Hydraulic Functions need to be free to be operated.
STEP B4 CHECK VOLTAGE

1. Connect DMM→Position 1→Measure Battery Volts at the Contactor terminals→3? Value↓

2. Operate Traction and Hoist Hydraulics against Relief Valve→3? DMM/Display Volts→Compare→Go to 2a↓
2a. Display Volts < DMM Volts < Controller Minimum?→® Connections→Go to 4↓
2b. Display Volts = DMM Volts > Controller Minimum?→Change DMM to Position 2→Repeat Step2?↑
3. Operate Traction and Hoist Hydraulics against Relief Valve→3? DMM/Display Volts→Compare→Go to 3a↓
3a. Display Volts < DMM Volts < Controller Minimum?→® Contactor Contacts→Go to 4↓
3b. Display Volts = DMM Volts > Controller Minimum?→Go to 4?↓
4. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 5?↓
5. Recheck Volts↑→Test Truck→
DTC Faults? YES→Step B3↓
NO → Resume Operation→

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Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller DC Bus Low/High (Cont)

STEP B5 CHECK VOLTAGE

1. Connect DMM→Measure Battery Volts at the Connector terminals→3? Value↓

2. Operate Traction and Hoist Hydraulics against Relief Valve→3? DMM/Display Volts→Compare→Go to 2a↓
2a. Display Volts < DMM Volts < Controller Minimum?→® Connections→Go to 3↓
2b. Display Volts = DMM Volts > Controller Minimum?→Go to 3↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 4↓
4. Recheck Volts↑→Test Truck→
DTC Faults? YES→Step B6↓
NO → Resume Operation→

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Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller DC Bus Low/High (Cont)

STEP B6 CHECK VOLTAGE

1. Connect DMM as shown→Measure Battery Volts at the Battery terminals→3? Value↓

2. Operate Truck Traction and Hoist Hydraulics against Relief Valve→3? Lowest Battery Voltage→Com-
pare→Go to 3↓
3. Battery Voltage < Controller Minimum?↓
4. YES Battery internal Resistance is too high→Battery Maintenance check/Replace Battery(s)→Go to 6↓
5. NO →Component Operational Check↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 7↓
4. Recheck Volts↑→Test Truck→
DTC Faults? YES→Component Operational Check↓
NO → Resume Operation→
CAUSE C
Battery OORL/OORH as measured by the Motor Controllers
NOTE: OOR DTC is set if OOR condition is present for longer than 1 second.

NOTE: Both Motor control and VSM OOR DTCs may appear due to the different thresholds levels
Battery Voltage
Nominal 36 48 72 80
Fully Charged 39.6 52.8 79.2 88
˜ < OORL 23 30 41 48
˜ > OORH 50 65 99 110
An OORH DTC can occur if the Regen braking setting is too high

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Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller DC Bus Low/High (Cont)

STEP C1
REGEN BRAKE SETTING – must be completed before making adjusted.

Enter Service Password→ Truck Setup→ F*→ Scroll to Braking Setup↑ ↓

Braking Setup

F*→ Scroll to Regen Function↑ ↓ F* To Select→ Enter Lower Value Using Number Buttons F*
STEP C2

Battery Voltage
Nominal 36 48 72 80
Fully Charged 39.6 52.8 79.2 88
˜ < OORL 23 30 41 48
˜ > OORH 50 65 99 110
1. Ensure that the Battery has been fully charged→Check Battery connections are clean and secure.
2 Operate Truck with Maximum Acceleration in Forward Direction→3? Maximum Voltage
3. Completely release acceleration pedal→Regen Braking Only→3? Maximum Voltage
4. Do Maximum Voltages exceed the OORH thresholds?
5. Yes→Repeat Step C1 until no fault exist.↑NO→Resume Operation

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Electrical System Diagnostic Trouble Codes

CBB/DBB Motor Controller DC Bus Low/High (Cont)

CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Capacitors.→ ?

Depending on your lift truck, go to Frame 0100SRM1329 or Frame
0100SRM1342→.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓
STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming

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Diagnostic Trouble Codes Electrical System

CBB/DBB Motor Controller DC Bus Low/High (Cont)

STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

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Electrical System Diagnostic Trouble Codes

CBB/DBB Traction Controller Driver Current High

DTC 21520 DTC 25106

Aux Driver Current High Park Brake Solenoid and Fan Driver Current High

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
It is recommended that the Display or PC Service Tool diagnostics be used as much as possible to determine
the potential Motor.

Motor Controller failure before starting as analysis using the CAUSE procedures,
CBB Motor Controller Access requires Battery removal
CBB Auto Brake Access requires Battery removal
DBB Motor Controller Connector Access is very difficult. Use a Break-Out Harness kit
DBB/CBB Motor Controller Component Access requires Battery removal
Check 1

POSSIBLE SYMPTOMS
No/ Reduced Traction - Auto Brake Does not Release/Fan(s) do not Operate at Key ON
POSSIBLE CAUSES
DTC 21520 Aux Driver Short to Bat (+) > 1 amp driver current → Component Operational
Check ↓
DTC 21520 Brake Coil (DBB)/Fan > 1 amp driver current → Component Operational
Short Circuit Check/Component Opera-
tional Check↓

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Diagnostic Trouble Codes Electrical System

CBB/DBB Traction Controller Driver Current High (Cont)

DTC 25106 Park Brake Coil > 1 amp driver current → Component Operational
Check ↓
DTC 25106 Cooling Fan > 1 amp driver current → Component Operational
Check ↓
Motor Controller(s) Failure ?→ Driver Failure → Component Operational
Check ↓
Also see, Observed Symptom - Auto Brake Does not Release/Fan(s) do Not Operate at Key ON
Check 2

Power ON→
YES→ Go to Check 3 → Component Operational Check ↓
NO→ Observed Symptoms - Fans do Not Operate→ Component Operational Check ↓
Check 3

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

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Electrical System Diagnostic Trouble Codes

CBB/DBB Traction Controller Driver Current High (Cont)

Check 4

Power ON→ Fault Remains No Fault→ Resume Operation

Service Required ?
Check 5
FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

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Diagnostic Trouble Codes Electrical System

CBB/DBB Traction Controller Driver Current High (Cont)

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection

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Electrical System Diagnostic Trouble Codes

CBB/DBB Traction Controller Driver Current High (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit ) = No DTC
1.5 – 2.0 CBB SCHEMATIC CAUSES A B C D E > ?

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Diagnostic Trouble Codes Electrical System

CBB/DBB Traction Controller Driver Current High (Cont)

2.2 – 3.0 DBB SCHEMATIC CAUSES A B C D E > ?

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Electrical System Diagnostic Trouble Codes

CBB/DBB Traction Controller Driver Current High (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx Fan Connector Cxx 94, 95, 156, and
3, 4, and 5 153

Auto Brake Motor Connector Cxx 15,

16, 17, 193, and 194
CAUSE A
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections→

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Diagnostic Trouble Codes Electrical System

CBB/DBB Traction Controller Driver Current High (Cont)

STEP A1

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.
STEP A2 CHECK RESISTANCE - Ω - OHMS
Auto Brake Short Circuit to Bat (+)

1. < 24 ? →Short to Bat (+)→CBB go to 1 > 24 ?→OK→Component Operational Check↓

2.↓DBB→Step A3→
2. Find/Repair Short/Open Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
3. Recheck ?↑→ Reconnect→Test OK→YES→Resume OperationNO→Component Operational Check↓

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Electrical System Diagnostic Trouble Codes

CBB/DBB Traction Controller Driver Current High (Cont)

STEP A3 CHECK RESISTANCE - Ω - OHMS
DBB Auto Brake Diode/Coil Short Circuit

Disconnect Coil, Measure ?

1. 0? = Short Diode→Go to 2↓ 1 8? = OK→Go to 2↓
2. < 26? > 30? = Faulty Coil→Go to 4↓ 2. > 26? < 30? = OK→Component Operational Check↓
3. Replace Diode Pack. →Go to 5↓
4. Replace Auto Brake Coil Assy. →Go to 5↓
5. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 6↓
5. Recheck ?↑→ Reconnect→Test OK→YES→Resume OperationNO→Component Operational Check↓
CAUSE B CHECK RESISTANCE - Ω - OHMS
Not Applicable

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Diagnostic Trouble Codes Electrical System

CBB/DBB Traction Controller Driver Current High (Cont)

CAUSE C CHECK RESISTANCE - Ω - OHMS
Fan Short Circuit

Disconnect Fans Measure ?

1. < 24 ? →Shorted Fan→Go to 2.↓ 1. > 24 ?→OK→Go to 2.↓
2. < 24 ? →Shorted Fan→Go to 2.↓ 1. > 24 ?→OK→Go to Step C1.↓
2. Replace Fan. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 3↓
3. Recheck ?↑→ Reconnect→Test OK→YES→Resume OperationNO→Component Operational Check↓
STEP C1 CHECK RESISTANCE - Ω - OHMS
Fan Harness Short Circuit

1. < 24 ? →Shorted Circuit→Go to 3.↓ 1. > 24 ?→OK→Go to Component Operational Check.↓

2. Find Short Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 3↓
3. Recheck ?↑→ Reconnect→Test OK→YES→Resume OperationNO→Component Operational Check↓

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Electrical System Diagnostic Trouble Codes

CBB/DBB Traction Controller Driver Current High (Cont)

CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓
STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming

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Diagnostic Trouble Codes Electrical System

CBB/DBB Traction Controller Driver Current High (Cont)

STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

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Electrical System Diagnostic Trouble Codes

DTC 8992
Synchronous Steering Coil Current
POSSIBLE CAUSE

A. STEERING COIL WIRING FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEERING COIL WIRING FAULT

PROCEDURE OR ACTION:
1. Inspect for short to B(+) between coil and VSM.
Is short to power detected?
YES: Repair short, clear code and retest system.
NO: Replace faulty coil.

END POSSIBLE CAUSES

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Diagnostic Trouble Codes Electrical System

DTC 8992 (Cont)

Synchronous Steering Coil Current
DIAGRAMS

Troubleshooting Scenes

END FAULT

DTC 13344
Synch Steering Coil Open Circuit
POSSIBLE CAUSE

A. ACC WIRING FAULT

B. COIL FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.

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Electrical System Diagnostic Trouble Codes

DTC 13344 (Cont)

Synch Steering Coil Open Circuit
NO: Proceed to Cause A.

CAUSE A - ACC WIRING FAULT

PROCEDURE OR ACTION:
1. Inspect for short to B(+) between coil and VSM.
Is short to power detected?
YES: Repair short, clear code and retest system.
NO: Disconnect battery and proceed to Cause B.

CAUSE B - COIL FAULT

PROCEDURE OR ACTION:
1. Disconnect suspected coil and measure resistance across coil terminals.
Is resistance between 20 +/- 5 ohms?
YES: Suspect faulty VSM.
NO: Replace faulty coil.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

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Diagnostic Trouble Codes Electrical System

CODES

DTC 9012 - ACC 2 Current OORH

DTC 65526 - Aux Driver Open
DTC 65534 - Aux Driver Short

POSSIBLE CAUSE

A. ACC WIRING FAULT

B. COIL FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - ACC WIRING FAULT

PROCEDURE OR ACTION:
1. Inspect for short to B(+) between coil and VSM.
Is short to power detected?
YES: Repair short, clear code and retest system.
NO: Disconnect battery and proceed to Cause B.

CAUSE B - COIL FAULT

PROCEDURE OR ACTION:
1. Disconnect suspected coil and measure resistance across coil terminals.
Is resistance between 20 +/- 5 ohms?
YES: Suspect faulty VSM.
NO: Replace faulty coil.

END POSSIBLE CAUSES

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Electrical System Diagnostic Trouble Codes

(Cont)
DIAGRAMS

Troubleshooting Scenes

END FAULT

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Diagnostic Trouble Codes Electrical System

DTC 65288
Loss of Communication Between the Primary and Secondary Controller
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Electrical System Diagnostic Trouble Codes

DTC 65293
EEPROM Checksum Failure
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Diagnostic Trouble Codes Electrical System

DTC 95520
Key Switch Voltage OORL
POSSIBLE CAUSE

A. KEY INPUT WIRING FAULT

B. KEY SWITCH RELAY FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - KEY INPUT WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position.

1. Disconnect the steer motor controller connector CPS6 and measure voltage between socket 15 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Cause C.
NO: Remove key switch relay 1 and proceed to Cause B.

CAUSE B - KEY SWITCH RELAY FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the key switch relay 1, socket 86 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect coil input circuit 513A for open or short. Inspect connector CPS135 for loose, damaged, or corro-
ded terminals. Verify key switch operation by measuring continuity between the display connector CPS20,
socket 5 and socket 1 while operating switch.
2. Measure voltage between the key switch relay 1, socket 86 and socket 85.
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect relay ground circuit 013K and 013A for open or short. Inspect VSM connector CPS2 for loose,
damaged, or corroded terminals.
3. Measure voltage between the key switch relay 1, socket 87 and B(-).

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Electrical System Diagnostic Trouble Codes

DTC 95520 (Cont)

Key Switch Voltage OORL
Is voltage 12 ± 1.5 Vdc?
YES: Inspect key voltage input circuit 010A for open, short, or source of excessive resistance.
NO: Inspect relay switch input circuit 200K and 200M for open or short. Inspect connectors CRPS52-55,
CRP52 for loose, damaged, or corroded terminals. Verify E-stop switch functionality by measuring continuity
while operating switch.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns, replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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Diagnostic Trouble Codes Electrical System

DTC 95520 (Cont)

Key Switch Voltage OORL
DIAGRAMS

Troubleshooting Scenes

END FAULT

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9030-20-426 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65296
Motor U-W Phase Voltage Measurement Fault
POSSIBLE CAUSE

A. PHASE CABLE FAULT

B. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - PHASE CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect individual phase cables from controller and motor. Measure resistance of individual cables.
Is resistance between .322 and .383 ohms?
YES: Proceed to Cause B.
NO: Replace faulty phase cable.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-427
Diagnostic Trouble Codes Electrical System

DTC 65296 (Cont)

Motor U-W Phase Voltage Measurement Fault
DIAGRAMS

Troubleshooting Scenes

END FAULT

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9030-20-428 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65297
Motor U-V Phase Voltage Measurement Fault
POSSIBLE CAUSE

A. PHASE CABLE FAULT

B. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - PHASE CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect individual phase cables from controller and motor. Measure resistance of individual cables.
Is resistance between .322 and .383 ohms?
YES: Proceed to Cause B.
NO: Replace faulty phase cable.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-429
Diagnostic Trouble Codes Electrical System

DTC 65297 (Cont)

Motor U-V Phase Voltage Measurement Fault
DIAGRAMS

Troubleshooting Scenes

END FAULT

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9030-20-430 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65352
Motor W-V Phase Voltage Measurement Fault
POSSIBLE CAUSE

A. PHASE CABLE FAULT

B. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - PHASE CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect individual phase cables from controller and motor. Measure resistance of individual cables.
Is resistance between .322 and .383 ohms?
YES: Proceed to Cause B.
NO: Replace faulty phase cable.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-431
Diagnostic Trouble Codes Electrical System

DTC 65352 (Cont)

Motor W-V Phase Voltage Measurement Fault
DIAGRAMS

Troubleshooting Scenes

END FAULT

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9030-20-432 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65312
Motor Phase Voltage Out of Range
POSSIBLE CAUSE

A. PHASE CABLE FAULT

B. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - PHASE CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect individual phase cables from controller and motor. Measure resistance of individual cables.
Is resistance between .322 and .383 ohms?
YES: Proceed to Cause B.
NO: Replace faulty phase cable.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-433
Diagnostic Trouble Codes Electrical System

DTC 65312 (Cont)

Motor Phase Voltage Out of Range
DIAGRAMS

Troubleshooting Scenes

END FAULT

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9030-20-434 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65333
Standby Current Too High
POSSIBLE CAUSE

A. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-435
Diagnostic Trouble Codes Electrical System

DTC 65340
DC Bus Capacitor Charge Timeout
DC Bus voltage does not rise above 14 volts in 3.2 seconds after key ON
POSSIBLE CAUSE

A. CONTROLLER WIRING FAULT

B. CONTACTOR PTC RESISTOR FAULT
C. FAULTY FUSE
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER WIRING FAULT

PROCEDURE OR ACTION:
1. Inspect power connection at appropriate controller.
Is connection loose or damaged?
YES: Repair connection, clear DTC, and retest system.
NO: If only E-Steer controller is reporting DTC, proceed to Cause D, if more than one controller is reporting
fault, proceed to Cause B.

CAUSE B - CONTACTOR PTC RESISTOR FAULT

PROCEDURE OR ACTION:
1. Disconnect PTC resistor and measure resistance.
Is resistance between 5 +/- 0.5 ohms?
YES: Proceed to Cause C.
NO: Replace PTC resistor, clear DTC, and retest system.

CAUSE C - FAULTY FUSE

PROCEDURE OR ACTION:
1. Inspect appropriate fuse:
• FU1-10A

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Electrical System Diagnostic Trouble Codes

DTC 65340 (Cont)

DC Bus Capacitor Charge Timeout
• FU2-10A
• FU3-10A
• FU4-5A
Is fuse blown?
YES: Inspect circuit for source of short and repair if necessary. Replace fuse, clear DTC, and retest system.
NO: Proceed to Cause D.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-437
Diagnostic Trouble Codes Electrical System

DTC 65340 (Cont)

DC Bus Capacitor Charge Timeout
DIAGRAMS

Troubleshooting Scenes

END FAULT

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9030-20-438 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65341
Controller Temperature Above Limit
POSSIBLE CAUSE

A. CONTROLLER OVER TEMP

B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER OVER TEMP

PROCEDURE OR ACTION:
1. Verify actual controller or ambient temperatures are above 8080°C (176°F).
Is controller temperature out of range?
YES: Allow controller to cool within acceptable temperatures, clear DTC and resume operation.
NO: Proceed to Cause B.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-439
Diagnostic Trouble Codes Electrical System

DTC 65345
Motor Temperature Above Limit
Motor temperatures above 120°C (248°F)
POSSIBLE CAUSE

A. MOTOR OVER TEMPERATURE

B. TEMP SENSOR WIRING FAULT
C. TEMP SENSOR FAULT
D. MOTOR FAULT
E. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - MOTOR OVER TEMPERATURE

PROCEDURE OR ACTION:
1. Using the PC Service Tool, verify steer motor serial data and then measure actual motor temperatures. Over
temp conditions are above 120°C (248°F).
Is motor temperature out of range?
YES: Allow motor to cool within acceptable temperatures, clear DTC and resume operation. If motor contin-
ues to overheat, proceed to Cause D.
NO: Disconnect battery and proceed to Cause B.

CAUSE B - TEMP SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect temperature sensor connectors from motor and controller and inspect pins and sockets.
Is connector damage evident?
YES: Repair connector, clear DTC and retest system.
NO: Proceed to .
2. Measure resistance between the following:
• Controller temp sensor connector, socket 6 and the motor temp sensor connector, socket 1.
• Controller temp sensor connector, socket 7 and motor temp sensor connector, socket 2.
Is resistance <1 ohm?

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Electrical System Diagnostic Trouble Codes

DTC 65345 (Cont)

Motor Temperature Above Limit
YES: Proceed to Cause C.
NO: Inspect appropriate temp sensor circuit for open or source of excessive resistance.

CAUSE C - TEMP SENSOR FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the temp sensor connector, pin 1 and pin 2. Refer to temp sensor specification
chart.
Is resistance within specifications?
YES: Proceed to Cause E.
NO: Replace faulty temp sensor.

CAUSE D - MOTOR FAULT

PROCEDURE OR ACTION:
1. Replace faulty motor.

CAUSE E - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-441
Diagnostic Trouble Codes Electrical System

DTC 65345 (Cont)

Motor Temperature Above Limit
DIAGRAMS

Troubleshooting Scenes

END FAULT

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Electrical System Diagnostic Trouble Codes

DTC 65350
Controller Internal Error
Hardware circuit limits maximum current.
POSSIBLE CAUSE

A. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-443
Diagnostic Trouble Codes Electrical System

DTC 65487
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Electrical System Diagnostic Trouble Codes

DTC 65488
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-445
Diagnostic Trouble Codes Electrical System

DTC 65490
Primary and Secondary Controller Version Mismatch
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Electrical System Diagnostic Trouble Codes

DTC 65492
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-447
Diagnostic Trouble Codes Electrical System

DTC 65493
Default Parameter Restore
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Electrical System Diagnostic Trouble Codes

DTC 65495
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-449
Diagnostic Trouble Codes Electrical System

DTC 65496
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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9030-20-450 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65501
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-451
Diagnostic Trouble Codes Electrical System

DTC 65505
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Electrical System Diagnostic Trouble Codes

DTC 65517
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-453
Diagnostic Trouble Codes Electrical System

DTC 65525
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-454 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65530
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-455
Diagnostic Trouble Codes Electrical System

DTC 65533
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-456 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65498
Controller Software Mismatch
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-457
Diagnostic Trouble Codes Electrical System

DTC 65489
Controller Internal Error
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-458 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65350
Motor Phase W Current OORL
POSSIBLE CAUSE

A. STEER MOTOR PHASE CABLE FAULT

B. STEER MOTOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEER MOTOR PHASE CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer motor cables from the steer controller and motor. Measure continuity of individual cables
to isolate fault.
Is continuity present?
YES: Proceed to Cause B.
NO: Repair or replace faulty phase cable.

CAUSE B - STEER MOTOR FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the traction motor terminals U and V.
Is resistance between .322 and .383?
YES: Proceed to Step 2.
NO: Repair or replace faulty phase cable.
2. Measure resistance between the traction motor terminals U and W.
Is resistance between .322 and .383?
YES: Proceed to Step 3.
NO: Repair or replace faulty phase cable.
3. Measure resistance between the traction motor terminals W and V.
Is resistance between .322 and .383?
YES: Proceed to Cause C.
NO: Repair or replace faulty phase cable.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-459
Diagnostic Trouble Codes Electrical System

DTC 65350 (Cont)

Motor Phase W Current OORL
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scene

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-460 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65351
Motor Phase V Current OORL
POSSIBLE CAUSE

A. STEER MOTOR PHASE CABLE FAULT

B. STEER MOTOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEER MOTOR PHASE CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer motor cables from the steer controller and motor. Measure continuity of individual cables
to isolate fault.
Is continuity present?
YES: Proceed to Cause B.
NO: Repair or replace faulty phase cable.

CAUSE B - STEER MOTOR FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the traction motor terminals U and V.
Is resistance between .322 and .383?
YES: Proceed to Step 2.
NO: Repair or replace faulty phase cable.
2. Measure resistance between the traction motor terminals U and W.
Is resistance between .322 and .383?
YES: Proceed to Step 3.
NO: Repair or replace faulty phase cable.
3. Measure resistance between the traction motor terminals W and V.
Is resistance between .322 and .383?
YES: Proceed to Cause C.
NO: Repair or replace faulty phase cable.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-461
Diagnostic Trouble Codes Electrical System

DTC 65351 (Cont)

Motor Phase V Current OORL
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-462 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65353
Motor Phase U Current OORL
POSSIBLE CAUSE

A. STEER MOTOR PHASE CABLE FAULT

B. STEER MOTOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEER MOTOR PHASE CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer motor cables from the steer controller and motor. Measure continuity of individual cables
to isolate fault.
Is continuity present?
YES: Proceed to Cause B.
NO: Repair or replace faulty phase cable.

CAUSE B - STEER MOTOR FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the traction motor terminals U and V.
Is resistance between .322 and .383?
YES: Proceed to Step 2.
NO: Repair or replace faulty phase cable.
2. Measure resistance between the traction motor terminals U and W.
Is resistance between .322 and .383?
YES: Proceed to Step 3.
NO: Repair or replace faulty phase cable.
3. Measure resistance between the traction motor terminals W and V.
Is resistance between .322 and .383?
YES: Proceed to Cause C.
NO: Repair or replace faulty phase cable.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-463
Diagnostic Trouble Codes Electrical System

DTC 65353 (Cont)

Motor Phase U Current OORL
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-464 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65531
Controller Initialization Test Failed
POSSIBLE CAUSE

A. BATTERY VOLTAGE MISMATCH

B. STEER MOTOR PHASE CABLE FAULT (E-STEER)
C. STEER MOTOR FAULT (E-STEER)
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - BATTERY VOLTAGE MISMATCH

PROCEDURE OR ACTION:
1. Verify battery installation.
Is correct battery installed?
YES: Proceed to Step 2.
NO: Install correct battery, verify settings in setup menu. Clear DTC and retest system.
2. Verify battery setting in menu matches battery installed.
Are settings properly configured?
YES: If truck is equipped with E-Steer, proceed to Cause B. If truck is not equipped with E-Steer, proceed to
Cause D.
NO: Configure settings.

CAUSE B - STEER MOTOR PHASE CABLE FAULT (E-STEER)

PROCEDURE OR ACTION:
1. Disconnect the steer motor cables from the steer controller and motor. Measure continuity of individual cables
to isolate fault.
Is continuity present?
YES: Proceed to Cause C.
NO: Repair or replace faulty phase cable.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-465
Diagnostic Trouble Codes Electrical System

DTC 65531 (Cont)

Controller Initialization Test Failed
CAUSE C - STEER MOTOR FAULT (E-STEER)

PROCEDURE OR ACTION:
1. Measure resistance between the traction motor terminals U and V.
Is resistance between .322 and .383?
YES: Proceed to Step 2.
NO: Repair or replace faulty phase cable.
2. Measure resistance between the traction motor terminals U and W.
Is resistance between .322 and .383?
YES: Proceed to Step 3.
NO: Repair or replace faulty phase cable.
3. Measure resistance between the traction motor terminals W and V.
Is resistance between .322 and .383?
YES: Proceed to Cause D.
NO: Repair or replace faulty phase cable.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-466 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65531 (Cont)

Controller Initialization Test Failed
DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-467
Diagnostic Trouble Codes Electrical System

DTC 65494
Rapid Change in Steering Wheel Position
POSSIBLE CAUSE

A. STEER SENSOR WIRING FAULT

B. STEER SENSOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEER SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect steer sensor connector CPS78 and steer motor controller CPS6. Measure resistance between the
following:
• CPS78, socket 2 and CPS6, socket 19
• CPS78, socket 3 and CPS6, socket 17
• CPS78, socket 4 and CPS6, socket 20
• CPS78, socket 1 and CPS6, socket 21
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect appropriate circuit for open or source of excessive resistance. Inspect connector CPS132 for
damage.

CAUSE B - STEER SENSOR FAULT

PROCEDURE OR ACTION:
1. Using the PC Service Tool, observe steer sensor output signals.
Does sensor output signal match Figure 1?
YES: Proceed to Cause C.
NO: Replace faulty steer sensor.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-468 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65494 (Cont)

Rapid Change in Steering Wheel Position
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-469
Diagnostic Trouble Codes Electrical System

DTC 65528
Steer Wheel Sensor Output Mismatch
POSSIBLE CAUSE

A. STEER SENSOR WIRING FAULT

B. STEER SENSOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEER SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect steer sensor connector CPS78 and steer motor controller CPS6. Measure resistance between the
following:
• CPS78, socket 2 and CPS6, socket 19
• CPS78, socket 3 and CPS6, socket 17
• CPS78, socket 4 and CPS6, socket 20
• CPS78, socket 1 and CPS6, socket 21
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect appropriate circuit for open or source of excessive resistance. Inspect connector CPS132 for
damage.

CAUSE B - STEER SENSOR FAULT

PROCEDURE OR ACTION:
1. Using the PC Service Tool, observe steer sensor output signals.
Does sensor output signal match Figure 1?
YES: Proceed to Cause C.
NO: Replace faulty steer sensor.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-470 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65528 (Cont)

Steer Wheel Sensor Output Mismatch
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-471
Diagnostic Trouble Codes Electrical System

DTC 65378
Steering Wheel Position Error
POSSIBLE CAUSE

A. STEER SENSOR WIRING FAULT

B. STEER SENSOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEER SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect steer sensor connector CPS78 and steer motor controller CPS6. Measure resistance between the
following:
• CPS78, socket 2 and CPS6, socket 19
• CPS78, socket 3 and CPS6, socket 17
• CPS78, socket 4 and CPS6, socket 20
• CPS78, socket 1 and CPS6, socket 21
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect appropriate circuit for open or source of excessive resistance. Inspect connector CPS132 for
damage.

CAUSE B - STEER SENSOR FAULT

PROCEDURE OR ACTION:
1. Using the PC Service Tool, observe steer sensor output signals.
Does sensor output signal match Figure 1?
YES: Proceed to Cause C.
NO: Replace faulty steer sensor.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-472 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65378 (Cont)

Steering Wheel Position Error
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-473
Diagnostic Trouble Codes Electrical System

DTC 65491
TFD Current within Range but Lower than Expected
POSSIBLE CAUSE

A. TFD WIRING FAULT

B. TFD COIL FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - TFD WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect TFD coil connector CPS78 and measure voltage between socket 5 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect input circuit for open or short.
2. Disconnect steer controller connector CPS6 and measure resistance between socket 10 and the TFD coil
connector CPS78, socket 6.
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground circuit for open or source of excessive resistance.

CAUSE B - TFD COIL FAULT

PROCEDURE OR ACTION:
1. Measure resistance across TFD coil terminals.
Is resistance 20 ± 2 ohms?
YES: Proceed to Cause C.
NO: Replace faulty TFD coil.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-474 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65491 (Cont)

TFD Current within Range but Lower than Expected
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-475
Diagnostic Trouble Codes Electrical System

DTC 65496
TFD Resistance Out of Range
POSSIBLE CAUSE

A. TFD WIRING FAULT

B. TFD COIL FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - TFD WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect TFD coil connector CPS78 and measure voltage between socket 5 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect input circuit for open or short.
2. Disconnect steer controller connector CPS6 and measure resistance between socket 10 and the TFD coil
connector CPS78, socket 6.
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground circuit for open or source of excessive resistance.

CAUSE B - TFD COIL FAULT

PROCEDURE OR ACTION:
1. Measure resistance across TFD coil terminals.
Is resistance 20 ± 2 ohms?
YES: Proceed to Cause C.
NO: Replace faulty TFD coil.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-476 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65496 (Cont)

TFD Resistance Out of Range
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-477
Diagnostic Trouble Codes Electrical System

DTC 65515
TFD Short to battery Negative
POSSIBLE CAUSE

A. TFD WIRING FAULT

B. TFD COIL FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - TFD WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect TFD coil connector CPS78 and measure voltage between socket 5 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect input circuit for open or short.
2. Disconnect steer controller connector CPS6 and measure resistance between socket 10 and the TFD coil
connector CPS78, socket 6.
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground circuit for open or source of excessive resistance.

CAUSE B - TFD COIL FAULT

PROCEDURE OR ACTION:
1. Measure resistance across TFD coil terminals.
Is resistance 20 ± 2 ohms?
YES: Proceed to Cause C.
NO: Replace faulty TFD coil.

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9030-20-478 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65515 (Cont)

TFD Short to battery Negative
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-479
Diagnostic Trouble Codes Electrical System

DTC 65516
TFD Stand-by Current OORH
POSSIBLE CAUSE

A. TFD WIRING FAULT

B. TFD COIL FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - TFD WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect TFD coil connector CPS78 and measure voltage between socket 5 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect input circuit for open or short.
2. Disconnect steer controller connector CPS6 and measure resistance between socket 10 and the TFD coil
connector CPS78, socket 6.
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground circuit for open or source of excessive resistance.

CAUSE B - TFD COIL FAULT

PROCEDURE OR ACTION:
1. Measure resistance across TFD coil terminals.
Is resistance 20 ± 2 ohms?
YES: Proceed to Cause C.
NO: Replace faulty TFD coil.

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9030-20-480 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65516 (Cont)

TFD Stand-by Current OORH
CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-481
Diagnostic Trouble Codes Electrical System

DTC 65500
Steering Motor Locked
POSSIBLE CAUSE

A. STEERING DAMAGE OR BINDING

B. STEER MOTOR PHASE CABLE FAULT
C. STEER MOTOR FAULT
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEERING DAMAGE OR BINDING

PROCEDURE OR ACTION:
1. Inspect steer wheel for obstruction or damage.
Is damage present?
YES: Remove obstruction or repair damage.
NO: Disconnect battery and proceed to Cause B.

CAUSE B - STEER MOTOR PHASE CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer motor cables from the steer controller and motor. Measure continuity of individual cables
to isolate fault.
Is continuity present?
YES: Proceed to Cause C.
NO: Repair or replace faulty phase cable.

CAUSE C - STEER MOTOR FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the traction motor terminals U and V.
Is resistance between .322 and .383 ohms?
YES: Proceed to Step 2.
NO: Repair or replace faulty motor.

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9030-20-482 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65500 (Cont)

Steering Motor Locked
2. Measure resistance between the traction motor terminals U and W.
Is resistance between .322 and .383 ohms?
YES: Proceed to Step 3.
NO: Repair or replace faulty motor.
3. Measure resistance between the traction motor terminals W and V.
Is resistance between .322 and .383 ohms?
YES: Proceed to Cause D.
NO: Repair or replace faulty motor.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-483
Diagnostic Trouble Codes Electrical System

DTC 65521
Steer Axle Slow Response
POSSIBLE CAUSE

A. STEERING DAMAGE OR BINDING

B. STEER MOTOR PHASE CABLE FAULT
C. STEER MOTOR FAULT
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEERING DAMAGE OR BINDING

PROCEDURE OR ACTION:
1. Inspect steer wheel for obstruction or damage.
Is damage present?
YES: Remove obstruction or repair damage.
NO: Disconnect battery and proceed to Cause B.

CAUSE B - STEER MOTOR PHASE CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer motor cables from the steer controller and motor. Measure continuity of individual cables
to isolate fault.
Is continuity present?
YES: Proceed to Cause C.
NO: Repair or replace faulty phase cable.

CAUSE C - STEER MOTOR FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the traction motor terminals U and V.
Is resistance between .322 and .383 ohms?
YES: Proceed to Step 2.
NO: Repair or replace faulty motor.

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9030-20-484 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65521 (Cont)

Steer Axle Slow Response
2. Measure resistance between the traction motor terminals U and W.
Is resistance between .322 and .383 ohms?
YES: Proceed to Step 3.
NO: Repair or replace faulty motor.
3. Measure resistance between the traction motor terminals W and V.
Is resistance between .322 and .383 ohms?
YES: Proceed to Cause D.
NO: Repair or replace faulty motor.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-485
Diagnostic Trouble Codes Electrical System

DTC 65508
Steer Axle Position Mismatch
POSSIBLE CAUSE

A. STEER AXLE SENSOR WIRING FAULT

B. STEER AXLE SENSOR FAULT
C. ENCODER FAULT
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEER AXLE SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer axle sensor connector CPS31 and measure voltage between socket A and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect supply circuit 089F for open or short. Inspect pigtail connector CRP31A for loose, damaged, or
corroded terminals.
2. Measure voltage between the steer axle sensor connector CPS31, socket A and socket C.
Is voltage 5 ± 0.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect ground circuit 117B for open or short. Inspect pigtail connector CRP31A for loose, damaged, or
corroded terminals.
3. Disconnect VSM connector CPS1 and measure resistance between socket 16 and the steer axle sensor con-
nector CPS31, socket B.
Is voltage 5 ± 0.5 Vdc?
YES: Connect steer axle sensor and proceed to Cause B.
NO: Inspect input signal circuit 068A for open or source of excessive resistance. Inspect pigtail connector
CRP31A, for loose, damaged, or corroded terminals.

CAUSE B - STEER AXLE SENSOR FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the VSM connector CPS1, socket 16 and B(-).

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9030-20-486 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65508 (Cont)

Steer Axle Position Mismatch
Does voltage respond to steer axle sensor movement?
YES: Proceed to Cause C.
NO: Replace faulty steer axle sensor.

CAUSE C - ENCODER FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer encoder connector and measure voltage between encoder 12 volt supply and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 284A for open or short.
2. Measure voltage between 12 volt supply circuit and ground circuit.
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect ground circuit 107A for open or short.
3. Disconnect steer controller connector and measure resistance between the following signal circuits:
• Steer motor controller, socket 1 and steer encoder, socket A.
• Steer motor controller, socket 3 and steer encoder, socket B.
Is resistance <1 ohm?
YES: Connect the encoder and steer controller connectors and proceed to Step 4.
NO: Inspect encoder signal circuits for open or source of excessive resistance.
4. Using the PC Service Tool, locate and observe the steer encoder count signal.
Does encoder provide accurate count signal during operation?
YES: Proceed to Cause D.
NO: Replace faulty steer encoder.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-487
Diagnostic Trouble Codes Electrical System

DTC 65508 (Cont)

Steer Axle Position Mismatch
DIAGRAMS

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9030-20-488 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65508 (Cont)

Steer Axle Position Mismatch

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-489
Diagnostic Trouble Codes Electrical System

DTC 65532
Steer Axle Sensor Output Mismatch
POSSIBLE CAUSE

A. STEER AXLE SENSOR WIRING FAULT

B. STEER AXLE SENSOR FAULT
C. ENCODER FAULT
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEER AXLE SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer axle sensor connector CPS31 and measure voltage between socket A and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect supply circuit 089F for open or short. Inspect pigtail connector CRP31A for loose, damaged, or
corroded terminals.
2. Measure voltage between the steer axle sensor connector CPS31, socket A and socket C.
Is voltage 5 ± 0.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect ground circuit 117B for open or short. Inspect pigtail connector CRP31A for loose, damaged, or
corroded terminals.
3. Disconnect VSM connector CPS1 and measure resistance between socket 16 and the steer axle sensor con-
nector CPS31, socket B.
Is voltage 5 ± 0.5 Vdc?
YES: Connect steer axle sensor and proceed to Cause B.
NO: Inspect input signal circuit 068A for open or source of excessive resistance. Inspect pigtail connector
CRP31A, for loose, damaged, or corroded terminals.

CAUSE B - STEER AXLE SENSOR FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the VSM connector CPS1, socket 16 and B(-).

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9030-20-490 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65532 (Cont)

Steer Axle Sensor Output Mismatch
Does voltage respond to steer axle sensor movement?
YES: Proceed to Cause C.
NO: Replace faulty steer axle sensor.

CAUSE C - ENCODER FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer encoder connector and measure voltage between encoder 12 volt supply and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 284A for open or short.
2. Measure voltage between 12 volt supply circuit and ground circuit.
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect ground circuit 107A for open or short.
3. Disconnect steer controller connector and measure resistance between the following signal circuits:
• Steer motor controller, socket 1 and steer encoder, socket A.
• Steer motor controller, socket 3 and steer encoder, socket B.
Is resistance <1 ohm?
YES: Connect the encoder and steer controller connectors and proceed to Step 4.
NO: Inspect encoder signal circuits for open or source of excessive resistance.
4. Using the PC Service Tool, locate and observe the steer encoder count signal.
Does encoder provide accurate count signal during operation?
YES: Proceed to Cause D.
NO: Replace faulty steer encoder.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-491
Diagnostic Trouble Codes Electrical System

DTC 65532 (Cont)

Steer Axle Sensor Output Mismatch
DIAGRAMS

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-492 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65532 (Cont)

Steer Axle Sensor Output Mismatch

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-493
Diagnostic Trouble Codes Electrical System

DTC 65503
Rapid Change in Steer Axle Position
POSSIBLE CAUSE

A. STEER AXLE SENSOR WIRING FAULT

B. STEER AXLE SENSOR FAULT
C. ENCODER FAULT
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEER AXLE SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer axle sensor connector CPS31 and measure voltage between socket A and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect supply circuit 089F for open or short. Inspect pigtail connector CRP31A for loose, damaged, or
corroded terminals.
2. Measure voltage between the steer axle sensor connector CPS31, socket A and socket C.
Is voltage 5 ± 0.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect ground circuit 117B for open or short. Inspect pigtail connector CRP31A for loose, damaged, or
corroded terminals.
3. Disconnect VSM connector CPS1 and measure resistance between socket 16 and the steer axle sensor con-
nector CPS31, socket B.
Is voltage 5 ± 0.5 Vdc?
YES: Connect steer axle sensor and proceed to Cause B.
NO: Inspect input signal circuit 068A for open or source of excessive resistance. Inspect pigtail connector
CRP31A, for loose, damaged, or corroded terminals.

CAUSE B - STEER AXLE SENSOR FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the VSM connector CPS1, socket 16 and B(-).

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9030-20-494 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65503 (Cont)

Rapid Change in Steer Axle Position
Does voltage respond to steer axle sensor movement?
YES: Proceed to Cause C.
NO: Replace faulty steer axle sensor.

CAUSE C - ENCODER FAULT

PROCEDURE OR ACTION:
1. Disconnect the steer encoder connector and measure voltage between encoder 12 volt supply and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 284A for open or short.
2. Measure voltage between 12 volt supply circuit and ground circuit.
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect ground circuit 107A for open or short.
3. Disconnect steer controller connector and measure resistance between the following signal circuits:
• Steer motor controller, socket 1 and steer encoder, socket A.
• Steer motor controller, socket 3 and steer encoder, socket B.
Is resistance <1 ohm?
YES: Connect the encoder and steer controller connectors and proceed to Step 4.
NO: Inspect encoder signal circuits for open or source of excessive resistance.
4. Using the PC Service Tool, locate and observe the steer encoder count signal.
Does encoder provide accurate count signal during operation?
YES: Proceed to Cause D.
NO: Replace faulty steer encoder.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-495
Diagnostic Trouble Codes Electrical System

DTC 65503 (Cont)

Rapid Change in Steer Axle Position
DIAGRAMS

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-496 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 65503 (Cont)

Rapid Change in Steer Axle Position

Troubleshooting Scenes

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-497
Diagnostic Trouble Codes Electrical System

DTC 65524
Primary and Secondary Parameter Mismatch
POSSIBLE CAUSE

A. STEERING WHEEL POSITION CALIBRATION

B. SOFTWARE UPDATE
C. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - STEERING WHEEL POSITION CALIBRATION

PROCEDURE OR ACTION:
1. Perform steer wheel position calibration procedure and retest system.
Does DTC return after steer wheel has been recalibrated?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause C.
NO: No further service is required.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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9030-20-498 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

CODES

DTC 65527 - Loss of CAN Communication

DTC 33050 - E-Steer CAN Communications Failure Right
DTC 33051 - E-Steer CAN Communications Failure Left

POSSIBLE CAUSE

A. CANBUS FAULT
B. VSM WIRING FAULT
C. CDF VERSION
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CANBUS FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the diagnostic connector CPS28, socket A and B(-).
Is voltage approximately 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect CAN HI circuit for open or short. if voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.
2. Measure voltage between the diagnostic connector CPS28, socket B and B(-).
Is voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the diagnostic connector CPS28, socket A and socket B.
Is resistance 60 ± 6 ohms?
YES: Connect battery and proceed to Cause B.
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damage termination resistor. If
resistance is 0 ohms, the CANbus circuit are shorted together.

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-499
Diagnostic Trouble Codes Electrical System

(Cont)
CAUSE B - VSM WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the VSM connector CPS2 and measure voltage between socket 35 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 200A and 200M for open or short. Inspect connector CRP52-55 for loose, damaged, or
corroded terminals.
2. Measure voltage between socket 35 and the VSM connector CPS2, socket 2.
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Cause C.
NO: Inspect 013-A for open or short.

CAUSE C - CDF VERSION

PROCEDURE OR ACTION:
1. Using the PC Service Tool, verify current CDF version.
Is CDF version current?
YES: Proceed to Cause D.
NO: Update CDF and retest system to verify repair.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-500 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

(Cont)
DIAGRAMS

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-501
Diagnostic Trouble Codes Electrical System

(Cont)

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-20-502 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 9045
Internal Error - Software
POSSIBLE CAUSE

A. SOFTWARE UPDATE
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause B.
NO: No further service is required.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. If DTC returns after reprogramming, replace faulty controller. Make sure to indicate the DTC code(s) on the
warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-503
Diagnostic Trouble Codes Electrical System

DTC 13058
5V Internal Supply Out of Range
5V supply is outside valid range.
POSSIBLE CAUSE

A. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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9030-20-504 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 13104
Sensor Ground Current OORH
POSSIBLE CAUSE

A. SENSOR WIRING FAULT

B. SPEED SENSOR FAULT (DOES NOT APPLY TO TEMP SENSOR)
C. TEMP SENSOR FAULT (DOES NOT APPLY TO SPEED SENSOR)
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the traction controller connector CPS3 and the temperature or speed sensor connector. Measure
resistance between the following:
• Temperature Sensor - CRS3, socket 17 and connector CRS155, socket 2
• Speed Sensor - CRS3, socket 4 and connector CRS153, socket 4
Is resistance <1 ohm?
YES: Connect traction controller connector CPS3 and proceed to Cause B for speed sensor troubleshooting,
or Cause C for temp sensor troubleshooting.
NO: Inspect the speed sensor ground circuit 103-A or 106-A for open or source of excessive resistance. In-
spect temperature sensor circuit 104-A or 107-A for open or source of excessive remittance.

CAUSE B - SPEED SENSOR FAULT (DOES NOT APPLY TO TEMP SENSOR)

PROCEDURE OR ACTION:
1. Measure voltage between the speed sensor connector CRP153, socket 1 and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Disconnect the controller connector CPS3 and proceed to Step 2.
NO: Inspect 5 volt supply circuit 282-A or 284-A for open or short.
2. Measure resistance between the traction controller connector CRS3, socket 6 and the speed sensor connec-
tor CRP153, socket 2.
Is resistance <1 ohm?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-505
Diagnostic Trouble Codes Electrical System

DTC 13104 (Cont)

Sensor Ground Current OORH
YES: Proceed to Step 3.
NO: Inspect circuit 574-A or 278-A for open or source of excessive resistance.
3. Measure resistance between the traction controller connector CRS3, socket 5 and the speed sensor connec-
tor CRP153, socket 3.
Is resistance <1 ohm?
YES: Replace faulty speed sensor.
NO: Proceed to Cause D.

CAUSE C - TEMP SENSOR FAULT (DOES NOT APPLY TO SPEED SENSOR)

PROCEDURE OR ACTION:
1. Measure resistance across temper sensor connector CRP155, socket 1 and socket 2.
Does resistance match temperatures (Refer to table 9030-10-4 for specification)?
YES: Proceed to Cause D.
NO: Replace faulty temperature sensor.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-506 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 13104 (Cont)

Sensor Ground Current OORH
DIAGRAMS

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Diagnostic Trouble Codes Electrical System

DTC 13104 (Cont)

Sensor Ground Current OORH

Troubleshooting Scenes

END FAULT

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9030-20-508 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 16913
Motor Temperature Sensor Open Circuit
POSSIBLE CAUSE

A. SENSOR WIRING FAULT

B. SPEED SENSOR FAULT (DOES NOT APPLY TO TEMP SENSOR)
C. TEMP SENSOR FAULT (DOES NOT APPLY TO SPEED SENSOR)
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the traction controller connector CPS3 and the temperature or speed sensor connector. Measure
resistance between the following:
• Temperature Sensor - CRS3, socket 17 and connector CRS155, socket 2
• Speed Sensor - CRS3, socket 4 and connector CRS153, socket 4
Is resistance <1 ohm?
YES: Connect traction controller connector CPS3 and proceed to Cause B for speed sensor troubleshooting,
or Cause C for temp sensor troubleshooting.
NO: Inspect the speed sensor ground circuit 103-A or 106-A for open or source of excessive resistance. In-
spect temperature sensor circuit 104-A or 107-A for open or source of excessive remittance.

CAUSE B - SPEED SENSOR FAULT (DOES NOT APPLY TO TEMP SENSOR)

PROCEDURE OR ACTION:
1. Measure voltage between the speed sensor connector CRP153, socket 1 and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Disconnect the controller connector CPS3 and proceed to Step 2.
NO: Inspect 5 volt supply circuit 282-A or 284-A for open or short.
2. Measure resistance between the traction controller connector CRS3, socket 6 and the speed sensor connec-
tor CRP153, socket 2.
Is resistance <1 ohm?

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-509
Diagnostic Trouble Codes Electrical System

DTC 16913 (Cont)

Motor Temperature Sensor Open Circuit
YES: Proceed to Step 3.
NO: Inspect circuit 574-A or 278-A for open or source of excessive resistance.
3. Measure resistance between the traction controller connector CRS3, socket 5 and the speed sensor connec-
tor CRP153, socket 3.
Is resistance <1 ohm?
YES: Replace faulty speed sensor.
NO: Proceed to Cause D.

CAUSE C - TEMP SENSOR FAULT (DOES NOT APPLY TO SPEED SENSOR)

PROCEDURE OR ACTION:
1. Measure resistance across temper sensor connector CRP155, socket 1 and socket 2.
Does resistance match temperatures (Refer to table 9030-10-4 for specification)?
YES: Proceed to Cause D.
NO: Replace faulty temperature sensor.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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Electrical System Diagnostic Trouble Codes

DTC 16913 (Cont)

Motor Temperature Sensor Open Circuit
DIAGRAMS

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-511
Diagnostic Trouble Codes Electrical System

DTC 16913 (Cont)

Motor Temperature Sensor Open Circuit

Troubleshooting Scenes

END FAULT

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9030-20-512 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 16914
Motor Temperature Sensor Short Circuit
POSSIBLE CAUSE

A. SENSOR WIRING FAULT

B. SPEED SENSOR FAULT (DOES NOT APPLY TO TEMP SENSOR)
C. TEMP SENSOR FAULT (DOES NOT APPLY TO SPEED SENSOR)
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the traction controller connector CPS3 and the temperature or speed sensor connector. Measure
resistance between the following:
• Temperature Sensor - CRS3, socket 17 and connector CRS155, socket 2
• Speed Sensor - CRS3, socket 4 and connector CRS153, socket 4
Is resistance <1 ohm?
YES: Connect traction controller connector CPS3 and proceed to Cause B for speed sensor troubleshooting,
or Cause C for temp sensor troubleshooting.
NO: Inspect the speed sensor ground circuit 103-A or 106-A for open or source of excessive resistance. In-
spect temperature sensor circuit 104-A or 107-A for open or source of excessive remittance.

CAUSE B - SPEED SENSOR FAULT (DOES NOT APPLY TO TEMP SENSOR)

PROCEDURE OR ACTION:
1. Measure voltage between the speed sensor connector CRP153, socket 1 and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Disconnect the controller connector CPS3 and proceed to Step 2.
NO: Inspect 5 volt supply circuit 282-A or 284-A for open or short.
2. Measure resistance between the traction controller connector CRS3, socket 6 and the speed sensor connec-
tor CRP153, socket 2.
Is resistance <1 ohm?

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Diagnostic Trouble Codes Electrical System

DTC 16914 (Cont)

Motor Temperature Sensor Short Circuit
YES: Proceed to Step 3.
NO: Inspect circuit 574-A or 278-A for open or source of excessive resistance.
3. Measure resistance between the traction controller connector CRS3, socket 5 and the speed sensor connec-
tor CRP153, socket 3.
Is resistance <1 ohm?
YES: Replace faulty speed sensor.
NO: Proceed to Cause D.

CAUSE C - TEMP SENSOR FAULT (DOES NOT APPLY TO SPEED SENSOR)

PROCEDURE OR ACTION:
1. Measure resistance across temper sensor connector CRP155, socket 1 and socket 2.
Does resistance match temperatures (Refer to table 9030-10-4 for specification)?
YES: Proceed to Cause D.
NO: Replace faulty temperature sensor.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-514 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 16914 (Cont)

Motor Temperature Sensor Short Circuit
DIAGRAMS

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-515
Diagnostic Trouble Codes Electrical System

DTC 16914 (Cont)

Motor Temperature Sensor Short Circuit

Troubleshooting Scenes

END FAULT

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9030-20-516 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 16912
Motor Temperature OORH
POSSIBLE CAUSE

A. MOTOR OVER TEMP

B. TEMP SENSOR WIRING FAULT
C. TEMPERATURE SENSOR FAULT
D. MOTOR FAULT
E. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - MOTOR OVER TEMP

PROCEDURE OR ACTION:
1. Using the PC Service Tool, verify steer motor temperature and then measure actual motor temperatures.
Over temp conditions are above 120°C (248°F).
Is motor temperature out of range?
YES: Allow motor to cool within acceptable temperatures, clear DTC and resume operation. If motor contin-
ues to overheat, proceed to Cause D.
NO: Disconnect battery and proceed Cause B

CAUSE B - TEMP SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect temperature sensor connectors from motor and controller and inspect pins/sockets.
Is connector damage present?
YES: Repair connector, clear DTC and retest system.
NO: Proceed to Step 2.
2. Measure resistance between the following:
• Controller temp sensor connector, socket 16 and motor temp sensor connector, socket 2.
• Controller temp sensor connector, socket 17 and motor temp sensor connector, socket 1.
Is resistance <1 ohm?
YES: Proceed to Cause E.

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Diagnostic Trouble Codes Electrical System

DTC 16912 (Cont)

Motor Temperature OORH
NO: Inspect appropriate temp sensor circuit for open or source of excessive resistance.

CAUSE C - TEMPERATURE SENSOR FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the temp sensor connector pin 1 and pin 2.
Does resistance match temperatures (Refer to table 9030-10-4 for specification)?
YES: Proceed to Cause E.
NO: Replace faulty temperature sensor.

CAUSE D - MOTOR FAULT

PROCEDURE OR ACTION:
1. Replace faulty motor.

CAUSE E - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-518 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 16912 (Cont)

Motor Temperature OORH
DIAGRAMS

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Diagnostic Trouble Codes Electrical System

DTC 16912 (Cont)

Motor Temperature OORH

Troubleshooting Scenes

END FAULT

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9030-20-520 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

Controller temperatures above 80°C (176°F)

CODES

DTC 65341 - Controller Internal Temperature OORH

DTC 65342 - Thermal Protection / Motor Temperature High

POSSIBLE CAUSE

A. CONTROLLER OVER TEMPERATURE

B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER OVER TEMPERATURE

PROCEDURE OR ACTION:
1. Using the PC Service Tool, verify controller temperature and measure actual controller temperature. Over
temp conditions are above 80°C (176°F).
Is controller temperature out of range?
YES: Allow controller to cool within acceptable temperatures, clear DTC and resume operation.
NO: Proceed to Cause B.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Diagnostic Trouble Codes Electrical System

DTC 65341
Controller Internal Temperature OORL
Controller temperatures below 45°C (113°F)
POSSIBLE CAUSE

A. CONTROLLER BELOW TEMPERATURE

B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER BELOW TEMPERATURE

PROCEDURE OR ACTION:
1. Using the PC Service Tool, verify controller temperature and measure actual controller temperature. Low
temp conditions are below 45°C (113°F).
Is controller temperature out of range?
YES: Bring controller temperatures above temperature threshold, clear DTC and resume operation.
NO: Proceed to Cause B.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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9030-20-522 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 21521
Fan Driver Current OORH
POSSIBLE CAUSE

A. FAN WIRING FAULT

B. FAN RELAY FAULT
C. FAN FAULT
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - FAN WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the appropriate cooling fan connector CRP156A/157A and measure voltage between socket 1
and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect appropriate voltage circuit 034-K, 034-H, and 034-J for open or short. If no wiring short is found,
proceed to Cause B.
2. Measure voltage between the cooling fan connector CRP126A/127A, socket 1 and socket 2.
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Cause B.
NO: Inspect fan ground circuit 013-X and 13-V for open or short.

CAUSE B - FAN RELAY FAULT

PROCEDURE OR ACTION:
1. Remove fan relay CRS214 and measure voltage between socket 86 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect coil power supply circuit 034-F for open or short.
2. Measure voltage between the fan relay CRS214, socket 30 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 3.

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Diagnostic Trouble Codes Electrical System

DTC 21521 (Cont)

Fan Driver Current OORH
NO: Inspect switch power supply circuit 034-G for open or short.
3. Measure voltage between the fan relay CRS214, socket 30 and socket 85.
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 4.
NO: Inspect ground circuit 898-E for open or short.
4. Using a jumper wire, bypass the fan relay by placing jumper wire between socket 30 and socket 87.
Does fan operate?
YES: Replace faulty fan relay.
NO: Install fan relay and proceed to Cause C.

CAUSE C - FAN FAULT

PROCEDURE OR ACTION:
1. Replace inoperative fan.
Is cooling fan operational?
YES: Clear DTC and verify correct operation.
NO: Proceed to Cause D.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-524 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 21521 (Cont)

Fan Driver Current OORH
DIAGRAMS

Troubleshooting Scenes

END FAULT

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Diagnostic Trouble Codes Electrical System

DTC 21776
Internal Error - Hardware
POSSIBLE CAUSE

A. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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9030-20-526 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 29232
Sensor Supply Reference voltage Out of Range
POSSIBLE CAUSE

A. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-527
Diagnostic Trouble Codes Electrical System

DTC 21522
Automatic Park Brake Driver Current OORH
POSSIBLE CAUSE

A. PARK BRAKE WIRING FAULT

B. PARK BRAKE SOLENOID FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - PARK BRAKE WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the park brake solenoid connector CPS195 and measure voltage between socket 1 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect supply circuit 010-J for open or short.
2. Measure voltage between the park brake solenoid connector CPS195, socket 1 and socket 2.
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Cause B.
NO: Inspect ground circuit 096-C for open or short.

CAUSE B - PARK BRAKE SOLENOID FAULT

PROCEDURE OR ACTION:
1. Measure resistance across the park brake solenoid connector CRP195, pin 1 and pin 2.
Is resistance XX ohms?
YES: Proceed to Cause C.
NO: Replace faulty park brake solenoid.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

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9030-20-528 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

DTC 21522 (Cont)

Automatic Park Brake Driver Current OORH
END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-529
Diagnostic Trouble Codes Electrical System

DTC 29216
Speed Sensor High Current
POSSIBLE CAUSE

A. SPEED SENSOR WIRING FAULT

B. SPEED SENSOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SPEED SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the speed sensor connector and measure voltage between encoder 5 volt supply and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 284A or 282-A for open or short.
2. Measure voltage between 5 volt supply circuit and ground circuit.
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect ground circuit 106-A or 103-A for open or short.
3. Disconnect traction controller connector and measure resistance between the following signal circuits:
• Traction controller connector, socket 6 and speed sensor connector, socket 2.
• Traction controller connector, socket 5 and speed sensor connector, socket 3.
Is resistance <1 ohm?
YES: Connect the speed sensor and traction controller connectors and proceed to Cause B.
NO: Inspect encoder signal circuits or open or source of excessive resistance.

CAUSE B - SPEED SENSOR FAULT

PROCEDURE OR ACTION:
1. Using the PC Service Tool, locate and observe the speed sensor count signal.
Does encoder provide accurate count signal during operation?
YES: Proceed to Cause C.

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Electrical System Diagnostic Trouble Codes

DTC 29216 (Cont)

Speed Sensor High Current
NO: Replace faulty speed sensor.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-531
Diagnostic Trouble Codes Electrical System

DTC 29217
Speed Sensor Not Connected
POSSIBLE CAUSE

A. SPEED SENSOR WIRING FAULT

B. SPEED SENSOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SPEED SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the speed sensor connector and measure voltage between encoder 5 volt supply and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 284A or 282-A for open or short.
2. Measure voltage between 5 volt supply circuit and ground circuit.
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect ground circuit 106-A or 103-A for open or short.
3. Disconnect traction controller connector and measure resistance between the following signal circuits:
• Traction controller connector, socket 6 and speed sensor connector, socket 2.
• Traction controller connector, socket 5 and speed sensor connector, socket 3.
Is resistance <1 ohm?
YES: Connect the speed sensor and traction controller connectors and proceed to Cause B.
NO: Inspect encoder signal circuits or open or source of excessive resistance.

CAUSE B - SPEED SENSOR FAULT

PROCEDURE OR ACTION:
1. Using the PC Service Tool, locate and observe the speed sensor count signal.
Does encoder provide accurate count signal during operation?
YES: Proceed to Cause C.

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Electrical System Diagnostic Trouble Codes

DTC 29217 (Cont)

Speed Sensor Not Connected
NO: Replace faulty speed sensor.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-533
Diagnostic Trouble Codes Electrical System

DTC 29233
Sensor Supply Circuit Out of Range
POSSIBLE CAUSE

A. SPEED SENSOR WIRING FAULT

B. SPEED SENSOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SPEED SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the speed sensor connector and measure voltage between encoder 5 volt supply and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 284A or 282-A for open or short.
2. Measure voltage between 5 volt supply circuit and ground circuit.
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect ground circuit 106-A or 103-A for open or short.
3. Disconnect traction controller connector and measure resistance between the following signal circuits:
• Traction controller connector, socket 6 and speed sensor connector, socket 2.
• Traction controller connector, socket 5 and speed sensor connector, socket 3.
Is resistance <1 ohm?
YES: Connect the speed sensor and traction controller connectors and proceed to Cause B.
NO: Inspect encoder signal circuits or open or source of excessive resistance.

CAUSE B - SPEED SENSOR FAULT

PROCEDURE OR ACTION:
1. Using the PC Service Tool, locate and observe the speed sensor count signal.
Does encoder provide accurate count signal during operation?
YES: Proceed to Cause C.

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Electrical System Diagnostic Trouble Codes

DTC 29233 (Cont)

Sensor Supply Circuit Out of Range
NO: Replace faulty speed sensor.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-535
Diagnostic Trouble Codes Electrical System

CODES

DTC 29536 - Loss of Speed Sensor Channel A

DTC 65362 - Encoder Error
DTC 65512 - Wrong Encoder Set

POSSIBLE CAUSE

A. SPEED SENSOR WIRING FAULT

B. SPEED SENSOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:

NOTE: If DTC 65512 is set, verify parameters are correct for type of encoder. If parameter matches encoder type,
continue with the following procedures.

1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SPEED SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the speed sensor connector and measure voltage between encoder 5 volt supply and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 284A or 282-A for open or short.
2. Measure voltage between 5 volt supply circuit and ground circuit.
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect ground circuit 106-A or 103-A for open or short.
3. Disconnect traction controller connector and measure resistance between the following signal circuits:
• Traction controller connector, socket 6 and speed sensor connector, socket 2.
• Traction controller connector, socket 5 and speed sensor connector, socket 3.
Is resistance <1 ohm?
YES: Connect the speed sensor and traction controller connectors and proceed to Cause B.
NO: Inspect encoder signal circuits or open or source of excessive resistance.

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Electrical System Diagnostic Trouble Codes

(Cont)
CAUSE B - SPEED SENSOR FAULT

PROCEDURE OR ACTION:
1. Using the PC Service Tool, locate and observe the speed sensor count signal.
Does encoder provide accurate count signal during operation?
YES: Proceed to Cause C.
NO: Replace faulty speed sensor.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-537
Diagnostic Trouble Codes Electrical System

CODES

DTC 29552 - Loss of Speed Sensor Channel B

DTC 65362 - Encoder Error
DTC 65512 - Wrong Encoder Set

POSSIBLE CAUSE

A. SPEED SENSOR WIRING FAULT

B. SPEED SENSOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:

NOTE: If DTC 65512 is set, verify parameters are correct for type of encoder. If parameter matches encoder type,
continue with the following procedures.

1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SPEED SENSOR WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the speed sensor connector and measure voltage between encoder 5 volt supply and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 284A or 282-A for open or short.
2. Measure voltage between 5 volt supply circuit and ground circuit.
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect ground circuit 106-A or 103-A for open or short.
3. Disconnect traction controller connector and measure resistance between the following signal circuits:
• Traction controller connector, socket 6 and speed sensor connector, socket 2.
• Traction controller connector, socket 5 and speed sensor connector, socket 3.
Is resistance <1 ohm?
YES: Connect the speed sensor and traction controller connectors and proceed to Cause B.
NO: Inspect encoder signal circuits or open or source of excessive resistance.

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9030-20-538 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System Diagnostic Trouble Codes

(Cont)
CAUSE B - SPEED SENSOR FAULT

PROCEDURE OR ACTION:
1. Using the PC Service Tool, locate and observe the speed sensor count signal.
Does encoder provide accurate count signal during operation?
YES: Proceed to Cause C.
NO: Replace faulty speed sensor.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-539
Diagnostic Trouble Codes Electrical System

DTC 65346
Battery Low
POSSIBLE CAUSE

A. KEY INPUT OR BATTERY WIRING FAULT

B. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - KEY INPUT OR BATTERY WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position.

1. Disconnect the appropriate traction controller connector CPS3/CPS4. Measure voltage between controller
connector CPS3/CPS4, cavity 1 and B(-).
Is voltage 36 ± 3.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuits 010LB, 010R, and 010A for open or short.

NOTE: Key in ON position.

2. Measure voltage between the appropriate traction controller B(+) terminal and B(-).
Is voltage 36 ± 3.5 Vdc?
YES: Proceed to Cause B.
NO: Suspect faulty battery. Charge and retest system.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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Electrical System Diagnostic Trouble Codes

DTC 65346 (Cont)

Battery Low
DIAGRAMS

Troubleshooting Scenes

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-541
Diagnostic Trouble Codes Electrical System

DTC 65529
Check Up Needed
POSSIBLE CAUSE

A. SERVICE NEEDED

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SERVICE NEEDED

PROCEDURE OR ACTION:
1. Truck has exceeded hours needed for service requirements. Service truck, clear DTC, and return to opera-
tion.

END POSSIBLE CAUSES

END FAULT

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Electrical System Diagnostic Trouble Codes

DTC 95360
Forw + Back
POSSIBLE CAUSE

A. FWD / REV SELECT SWITCH WIRING FAULT

B. FWD / REV SELECT SWITCH FAULT
C. TRACTION CONTROLLER CANBUS FAULT
D. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - FWD / REV SELECT SWITCH WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position.

1. Disconnect the FWD / REV select switch connector CRP64 and measure voltage between cavity 1 (Harness
side) and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect 5 volt supply circuit 089(250) or 250B for open or short.

NOTE: Key in ON position.

2. Measure voltage between FWD / REV select switch connector CRP64, cavity 1 and cavity 2 (Harness side).
Is voltage 5 ± 0.5 Vdc?
YES: Connect FWD / REV select switch connector CRP64 and proceed to Step 3.
NO: Inspect ground circuits 120(115) or 115C for open or short.
3. Measure voltage between the FWD / REV select switch connector, cavity 3 and B(-). Place select switch in
FWD position.
Is signal 1 circuit voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 4.
NO: Inspect signal 1 circuit 008C, 008B, and 006AB for open or short.
4. Measure voltage between the FWD / REV select switch connector, cavity 2 and B(-). Place select switch in
REV position.
Is signal 1 circuit voltage 5 ± 0.5 Vdc?

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Diagnostic Trouble Codes Electrical System

DTC 95360 (Cont)

Forw + Back
YES: Proceed to Cause B.
NO: Inspect signal 2 circuit 006A, 006B, and 006AB for open or short.

CAUSE B - FWD / REV SELECT SWITCH FAULT

PROCEDURE OR ACTION:
1. Disconnect FWD / REV select switch connector CRP64 and measure continuity between cavity 1 and cavity
3. Place select switch in FWD position.
Is continuity present?
YES: Proceed to Cause D.
NO: Replace faulty switch.
2. Measure continuity between switch connector CRP64, cavity 1 and cavity 2. Place select switch in REV posi-
tion.
Is continuity present?
YES: Proceed to Cause C.
NO: Replace faulty switch.

CAUSE C - TRACTION CONTROLLER CANBUS FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position.

1. Disconnect the appropriate traction controller connector CPS3/CPS4. Measure voltage between cavity 20 and
B(-).
Is CAN HI voltage approximately 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.
2. Measure voltage between the traction controller connector CPS3/CPS4, cavity 21/12 and B(-).
Is CAN HI voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the traction controller connector CPS11, socket A21 and socket A20.
Is resistance 60 ± 6 ohms?
YES: Cause D
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.
If resistance is 0 ohms, the CANbus circuits are shorted together.

CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

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Electrical System Diagnostic Trouble Codes

DTC 95360 (Cont)

Forw + Back
DIAGRAMS

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Diagnostic Trouble Codes Electrical System

DTC 95360 (Cont)

Forw + Back

Troubleshooting Scenes

END FAULT

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Electrical System Diagnostic Trouble Codes

CODES

DTC 65481 - Wrong Slave Version

DTC 65519 - Controller Mismatch
DTC 65522 - Parameter Transfer
DTC 65511 - No Slave Enabled

POSSIBLE CAUSE

A. SOFTWARE FAULT
B. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE FAULT

PROCEDURE OR ACTION:
1. Verify software version in both right and left traction controllers.
Is software version the same in both controllers?
YES: Proceed to Cause B.
NO: Proceed to Step 2.
2. Reprogram controller with correct software version.
Was reprogram successful?
YES: Clear DTC and verify repairs.
NO: Proceed to Cause B.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-547
Diagnostic Trouble Codes Electrical System

CODES

DTC 65486 - Initial VMN High

DTC 65333 - Standby Current High
DTC 65310 - VMN Low
DTC 65311 - VMN High

POSSIBLE CAUSE

A. PHASE CABLE FAULT

B. TRACTION MOTOR FAULT
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - PHASE CABLE FAULT

PROCEDURE OR ACTION:

NOTE: Disconnect battery.

1. Disconnect the traction motor cables from the appropriate traction controller and traction motor. Measure con-
tinuity of individual cables to isolate fault.
Is continuity present?
YES: Proceed to Cause B.
NO: Repair or replace faulty phase cable.

CAUSE B - TRACTION MOTOR FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the traction motor terminals U and V.
Is resistance between .322 and .383 ohms?
YES: Proceed to Step 2.
NO: Repair or replace faulty traction motor.
2. Measure resistance between the traction motor terminals U and W.
Is resistance between .322 and .383 ohms?
YES: Proceed to Step 3.
NO: Repair or replace faulty traction motor.

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Electrical System Diagnostic Trouble Codes

(Cont)
3. Measure resistance between the traction motor terminals W and V.
Is resistance between .322 and .383 ohms?
YES: Proceed to Cause C.
NO: Repair or replace faulty traction motor.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-549
Diagnostic Trouble Codes Electrical System

DTC 65504
Waiting for Node
POSSIBLE CAUSE

A. TRACTION CONTROLLER CANBUS FAULT

B. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - TRACTION CONTROLLER CANBUS FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position.

1. Disconnect the appropriate traction controller connector CPS3/CPS4. Measure voltage between cavity 20 and
B(-).
Is CAN HI voltage approximately 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.
2. Measure voltage between the traction controller connector CPS3/CPS4, cavity 21/12 and B(-).
Is CAN HI voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the traction controller connector CPS11, socket A21 and socket A20.
Is resistance 60 ± 6 ohms?
YES: Cause B
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.
If resistance is 0 ohms, the CANbus circuits are shorted together.

CAUSE B - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

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Electrical System Diagnostic Trouble Codes

DTC 65504 (Cont)

Waiting for Node
END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-551
Diagnostic Trouble Codes Electrical System

CODES

DTC 12836 - Brake Pedal Sensor A OORL

DTC 12837 - Brake Pedal Sensor A OORH
DTC 12876 - Brake Pedal Sensor B OORL
DTC 12877 - Brake Pedal Sensor B OORH
DTC 12813 - Foot Brake Position Rationality

POSSIBLE CAUSE

A. BRAKE PEDAL SENSOR WIRING FAULT

B. BRAKE PEDAL SENSOR SIGNAL FAULT
C. BRAKE PEDAL SENSOR FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - BRAKE PEDAL SENSOR WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position.

1. Disconnect brake pedal sensor connector CPS274, and measure voltage between cavity C/D and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect 5 volt supply circuits 250L and 250AB (Sensor A) / 089F and 089A (Sensor B) for open or short.

NOTE: Key in ON position.

2. Measure voltage between brake pedal sensor connector CPS274, cavity C/D and B/E.
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Cause B.
NO: Inspect ground circuit 120N (Sensor A) / 115N (Sensor B) for open or short.

CAUSE B - BRAKE PEDAL SENSOR SIGNAL FAULT

PROCEDURE OR ACTION:
1. Disconnect VSM connector CPS1. Measure resistance between the following:

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Electrical System Diagnostic Trouble Codes

(Cont)
• Brake pedal connector CPS274, cavity A and VSM connector CPS1, cavity 1.
• Brake pedal connector CPS274, cavity F and VSM connector CPS1, cavity 27.
Is resistance <1 ohm?
YES: Proceed to Cause C.
NO: Inspect appropriate brake pedal signal circuit for open, short, or source of excessive resistance.

CAUSE C - BRAKE PEDAL SENSOR FAULT

PROCEDURE OR ACTION:
1. Replace faulty brake pedal sensor.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-553
Diagnostic Trouble Codes Electrical System

DTC 4117
FOC Configuration Mismatch
POSSIBLE CAUSE

A. SOFTWARE CONFIGURATION FAULT

B. INCORRECT CDF SETUP
C. BAD SERVICE BRAKE POSITION SENSOR
D. CONTROLLER FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - SOFTWARE CONFIGURATION FAULT

PROCEDURE OR ACTION:
1. Locate and view traction controller version.
Does traction 1 controller version match AE2M?
YES: Proceed to Step 2.
NO: Proceed to Cause B.
2. Verify controller is configured with electric brake option CDF.
Is controller equipped with electric brake?
YES: Proceed to Cause C.
NO: Proceed to Cause D.

CAUSE B - INCORRECT CDF SETUP

PROCEDURE OR ACTION:
1. Bad CDF, disable electric brake option in CDF.

CAUSE C - BAD SERVICE BRAKE POSITION SENSOR

PROCEDURE OR ACTION:
1. Measure output voltage at brake pedal signal B.
Is fault 12876 also present with this fault?
YES: Proceed to Diagnostic Trouble Codes, Page 9030-20-552.
NO: Proceed to Cause D.

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Electrical System Diagnostic Trouble Codes

DTC 4117 (Cont)

FOC Configuration Mismatch
CAUSE D - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-555
Diagnostic Trouble Codes Electrical System

DTC 33040
Various CAN Errors
POSSIBLE CAUSE

A. CANBUS FAULT
B. SOFTWARE UPDATE
C. CONTROLLER FAULT

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
Does reported DTC reoccur?
YES: Proceed to Step 2.
NO: Problem not verified, resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical Sys-
tem manual.
NO: Proceed to Cause A.

CAUSE A - CANBUS FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the diagnostic connector CPS28, socket A and B(-).
Is voltage approximately 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect CAN HI circuit for open or short. if voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.
2. Measure voltage between the diagnostic connector CPS28, socket B and B(-).
Is voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the diagnostic connector CPS28, socket A and socket B.
Is resistance 60 ± 6 ohms?
YES: Connect battery and proceed to Cause B.
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damage termination resistor. If
resistance is 0 ohms, the CANbus circuit are shorted together.

CAUSE B - SOFTWARE UPDATE

PROCEDURE OR ACTION:
1. Reprogram controller and retest system.
Does DTC return after controller has been reprogrammed?
YES: Proceed to Cause C.

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Electrical System Diagnostic Trouble Codes

DTC 33040 (Cont)

Various CAN Errors
NO: No further service required.

CAUSE C - CONTROLLER FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

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Confidential/Proprietary - Do Not Copy or Duplicate 9030-20-557
 NOTES

9030-20-558
Electrical System Observed Symptoms

Group 30

Observed Symptoms

No Display/No Truck Operation

DTC None
No Display/No Truck Operation

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Symptom 1 No Display/No Truck Operation

Power ON→ No Display→ No truck Operation

Check 1
Battery Voltage
Nominal 36 48 72 80
Fully Charged 39.6 52.8 79.2 88
˜< OORL 18 24 36 40
˜ OORH 48.6 57.6 97.2 108
1. Check Emergency Disconnect Button is Released↓
2. Check Battery Connections/Wiring↓
3. Check Battery Voltage→See Table↑
4. Battery Voltage OK→YES Check 2↓NO→See Battery Service Manual for Battery Charging Instruction?

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Observed Symptoms Electrical System

No Display/No Truck Operation (Cont)

Check 2

1. Use PC Service Tool to Check for DTCs↓

2. ? DTCs→YES→VSM OK→Check Display Power Connections→Component Operational Check↓
3. ? DTCs→NO Check 3↓
A935/K160 Refer to Diagrams 8000SRM1528.

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Electrical System Observed Symptoms

No Display/No Truck Operation (Cont)

4 Wheel CBB

4 Wheel DBB

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Observed Symptoms Electrical System

No Display/No Truck Operation (Cont)

Connectors

VSM Cxx 1 and Cxx 2 Display Cxx 20 and 135

For further information showing VSM/Display/Fuse location see General Description
Check 3
CAUTION:A Open Circuit Fuse Indicates a Short Circuit in the Wiring
Locate the Short before replacing the fuse

1. Is Key Switch Turning without binding?→YES Go to 2↓NO Go to 3 for Replacement Instructions↓

2. Check VSM/Display Power/Fuses/Connections/Wiring→Component Operational Check↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
4. Repair/Replace→Reconnect→Test→Go to Check 4↓
Check 4

Retest - Power ON→ NO → ? Does Display Turn ON? Fault corrected→ Continue opera-
tion.
Is fault DTC gone? NO
YES ← →

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Electrical System Observed Symptoms

No Display/No Truck Operation (Cont)

CAUSE A

Disconnect Battery and Sound Horn to Discharge Capacitors.→ Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342→. Disconnect VSM→Reconnect Battery→
STEP A1 CHECK VOLTAGE
VSM Power Connections

Disconnect VSM connector CPS2 and check for Battery Volts

1. <18 Volts = Flat Battery↓ 1. Battery Volts = OK, Go to 2↓
2. 0 Volts = Open Circuit→Step A2↓ 2. Battery Volts = OK, Go to 3↓
3. 0 Volts = NFuse→Component Operational Check↓ 3. Battery Volts = OK, Go to 4↓

4. 0 Volts = NFuse→Component Operational Check↓ 4. Battery Volts = OK, Go to 5↓

5. 0 Volts = Open Circuit→Go to 7↓ 5. Battery Volts = OK, Go to 6↓
6. 0 Volts = Open Circuit→Go to 7↓ 6. Battery Volts = OK, Component Operational Check↓
7. Open Circuit→Find/Repair Open Circuit, Go to 8↓
8. Find/Repair Open Circuit See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
9. Recheck Volts at (+) 5 & 6 (-) 2↑→Battery Voltage Present?YES→Component Operational CheckResume Op-
erationNo→Step A2↓

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Observed Symptoms Electrical System

No Display/No Truck Operation (Cont)

STEP A2 CHECK RESISTANCE - Ω - OHMS
VSM Power Connections Open Circuit

Disconnect Battery→ Check for ?

1. 8? = Open Circuit, Go to 3↓ 1. 0 ? = OK, Go to 2↓
2. 8? = Open Circuit, Go to 3↓ 2. 0 ? = OK, Component Operational Check↓
3. Find/Repair Open Circuit, Go to 4↓
4. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
5. Recheck ? at 1 & 2↑→= 0 ??YES→Go to 6↓Resume OperationNo→Go back to 3↑
Reconnect Battery→ Test→ Battery Voltage Present? Yes→ Resume Operation→ No→ Component Opera-
tional Check ↓
CAUSE B CHECK RESISTANCE - Ω - OHMS
VSM Power Connections NFuse (Short Circuit)

1. 0? = Short Circuit→Go to 3↓ 1. 8? = OK→Go to 2↓

2. 0? = Short Circuit→Go to 3↓ 2. ˜ 8? = OK→Step B2↓
3. Find/Repair Short, Circuit Go to 4↓
4. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Step B2↓

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Electrical System Observed Symptoms

No Display/No Truck Operation (Cont)

STEP B1 CHECK RESISTANCE - Ω - OHMS
VSM Power Connections Open Circuit

Replace Fuse(s)→ Reconnect Battery→ Check Volts→ Go to 1↓

1. Battery Volts Present?Yes→Go to 2↓
2. Battery Volts Present?Yes→Go to 3↓
3. Disconnect Battery→4. Reconnect VSM→5. Reconnect Battery, Step B2↓
STEP B2

Retest - Power ON→ NO → Component Op- Does Display Turn Fault corrected→ Continue operation.
erational Check ON?
Is fault DTC gone?

NO YES ← →
CAUSE C
DISPLAY Connection Failure
See A935 – K160 CAN Communication Failure, CBB 4 Wheel CAN Communication, and DBB 4 Wheel CAN
Communication→
END FAULT

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Observed Symptoms Electrical System

A935 – K160 D203 Motor Controller Fan Failure

DTC None
A935 – K160 Motor Controller Fan Failure

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? Function Failure/Reduced Performance/Uncommanded Continuous Operation?

POSSIBLE CAUSES
1. Fan/Motor Controller Connections/Wiring ?→
2. Fan Motor Failure ?→
3. Motor Controller(s) Failure ?→

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Electrical System Observed Symptoms

A935 – K160 D203 Motor Controller Fan Failure (Cont)

Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.
Check 3

Power ON→ Fault Remains Service Re- No Fault→ Resume Operation

quired ?

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Observed Symptoms Electrical System

A935 – K160 D203 Motor Controller Fan Failure (Cont)

Check 4

Reduced Performance→ Check Display Icons?

Motor/Motor Controller Temperature Icon On
1. Check fan operation→Are fans operating?→NO →Component Operational CheckYES →Go to 2?
2. Temp Sensor/Sensor Connection→Open Circuit→Observed Symptoms, Page 9030-30-21
3. Use the following steps for viewing Motor Temperatures
Fan(s) Operation Temperature Threshold Traction = 55°C (131°F) Pump = 65°C (149°F)
Reduced Performance: Traction = 80°C (176°F) Pump = 80°C (176°F)
Temperature > Operation Threshold→ No Fan Operation = Faulty Fan/Fan Connections
Check 5
Diagnostics Temperature Analysis – Go to Display Menu Flowchart

Enter Service Password→ Diagnostics→ Motor→ Traction1/Traction2/Pump→ Motor/Controller Data

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Electrical System Observed Symptoms

A935 – K160 D203 Motor Controller Fan Failure (Cont)

FAULT LOG Review - Go to Display Menu

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

3? all Motor DTCs→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

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Observed Symptoms Electrical System

A935 – K160 D203 Motor Controller Fan Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
CAUSES A B C D E > ?

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Electrical System Observed Symptoms

A935 – K160 D203 Motor Controller Fan Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx Fan Motor Connector Cxx 156, 157,
3, 4, and 5 595A, 595B
CAUSE A

Power OFF→ ?
STEP A1
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections

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Observed Symptoms Electrical System

A935 – K160 D203 Motor Controller Fan Failure (Cont)

STEP A2 CHECK VOLTAGE
Fan Operation

Disconnect Fan(s) and connect DMM as indicated↓

1. 0 Volts = Open Circuit (Fuse)→Step A6↓ 1 ˜ Bat Volts = OK Go to 2↓
2. 0 Volts = Open Circuit→Go to 4↓ 2. ˜ Bat Volts = OK Go to 3↓
3. 0 Volts = Open Circuit→Go to 4↓ 3. ˜ Bat Volts = OK Go to Step A3↓
4. Find/Repair Open Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
5. Recheck ?↑→ Reconnect→Retest→Step A5↓
STEP A3 CHECK RESISTANCE - Ω - OHMS
Fan Operation

Disconnect Relevant Controller and connect DMM as indicated↓

1. 8? = Open Circuit→Go to 3↓ 1 ˜ 0? = OK Go to 2↓
2. 8? = Open Circuit→Go to 3↓ 2. ˜ 0? = OK Go to Step A4↓
3. Find/Repair Open Circuit. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→
4. Recheck ?↑→ Reconnect→Retest→Step A5↓

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Electrical System Observed Symptoms

A935 – K160 D203 Motor Controller Fan Failure (Cont)

STEP A4 CHECK RESISTANCE - Ω - OHMS
Fan Operation

1. 8? = Open Circuit→Go to 3↓< 150?→Component 1 ˜ 200 to 260? = OK Go to 2↓

Operational Check↓
2. 8? = Open Circuit→Go to 3↓< 150?→Component 2. ˜ 200 to 260? = OK Go to Step A5↓
Operational Check↓
3. Find/Repair Open Circuit/Replace Fan See Electrical System 2200SRM1337/Electrical System
2200SRM1369→
4. Recheck ?↑→ Reconnect→Retest→Step A5↓
STEP A5
Fan Operation Test

1. Connect Fan(s) Circuit to Bat (-) as shown→Go to 2↓

2. Fan(s) Do not operate→Go to 3↓ 2. Fan(s) operate→Go to 4↓
3. Replace Fan→Retest with Jumper wire→Go to 4↓
4. Reconnect Controller→Operate Truck (Traction/Hydraulics) for at least 10 minute↓
5. Fan(s) operate→Resume Operation
6. Fan(s) Do not operate→Component Operational Check↓

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Observed Symptoms Electrical System

A935 – K160 D203 Motor Controller Fan Failure (Cont)

STEP A6 CHECK RESISTANCE - Ω - OHMS
Fan Operation from Step A1

1. Remove Fuse→Measure ?→8? = Fuse Open Circuit→Go to 2↓

2. 0? = Short Circuit→Go to 3↓
3. Find/Repair Short Circuit→Go to 4↓
4. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 5↓
5. Replace Fuse→Reconnect Controller→Operate Truck (Traction/Hydraulics) for at least 10 minute↓
6. Fan(s) operate→Resume Operation
7. Fan(s) Do not operate→Component Operational Check↓
CAUSE B
Not Applicable

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Electrical System Observed Symptoms

A935 – K160 D203 Motor Controller Fan Failure (Cont)

CAUSE C
Fan Operation

1. Remove Fuse→Measure ?→0? = Short Circuit→Go to 2↓

2. Find/Repair Short Circuit→Go to 3↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 6↓
4. From Step A30 to 150? = Fan Short Circuit→Go to 5↓
5. Replace Fan →See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 6↓
6. Replace Fuse→Reconnect Controller→Operate Truck (Traction/Hydraulics) for at least 10 minute↓
7. Fan(s) operate→Resume Operation
8. Fan(s) Do not operate→Component Operational Check↓

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Observed Symptoms Electrical System

A935 – K160 D203 Motor Controller Fan Failure (Cont)

STEP C1 CHECK RESISTANCE - Ω - OHMS
Fan Operation (Continuous)

1. Remove Fuse→Measure ?→0? = Short Circuit→Go to 2↓

2. Find/Repair Short Circuit→Go to 3↓
3. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 4↓
4. Replace Fuse→Reconnect Controller→Operate Truck (Traction/Hydraulics) for at least 10 minute↓
5. Fans Operate Continuously at Power ON→Faulty Controller→Component Operational Check↓
6. Fans operate briefly and then don't operate until at least 1 minute of Operation→Resume Normal Operation↓

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Electrical System Observed Symptoms

A935 – K160 D203 Motor Controller Fan Failure (Cont)

CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.
STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓
STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming

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Observed Symptoms Electrical System

A935 – K160 D203 Motor Controller Fan Failure (Cont)

STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

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Electrical System Observed Symptoms

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure

DTC None
A935 – K160 Motor/Motor Controller Temperature Sensor Failure

Fault Codes
QUICK CHECK X Open Circuit/Fail ) = Short Circuit
Check 1

? Over Temperature Icon Displayed at Power ON?

POSSIBLE CAUSES
1. Sensor(s) – Motor/Motor Controller – Connections/Wiring?→ Component Operational
Check ↓
2. Sensor(s) Failure?→ Component Operational
Check ↓
3. Motor Controller(s) Hardware Failure?→ Component Operational
Check ↓
Note: Hydraulic Oil Over Temperature and Sensor Issues seeHydraulic Temperature Sensor Out of Range High
(OORL) /Hydraulic Temperature Sensor Out of Range High (OORH)

? Over Temperature Icon Displayed during Operation/Reduced Performance/Function Failure?

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Observed Symptoms Electrical System

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

POSSIBLE CAUSES
1. Motor/Motor Controller/Hydraulic Fluid Overheating?→ Aggressive Operation?→
2. Sensor – Motor/Motor Controller/Hyd Tank – Connections/Wiring?→ Component Operational
Check ↓
3. Sensor(s) Failure?→ Component Operational
Check ↓
4. Motor Controller(s) Failure ?→ Component Operational
Check ↓
Note: For further assistance on Silicon Temperature Sensor readings, see Motor Temperature Sensor.
Temperature Control Chart Table
Application Performance Cutback Start Performance Cutback Finish Fan ON
°C °F °C °F °C °F
Traction Motor 165 329 185 365
Traction Con- 80 176 115 239 65 149
troller
Pump Motor 145 293 160 320
Pump Control- 80 176 115 239 55 131
ler
Hyd Fluid 85 185 100 212
Check 2

Disconnect Battery and Sound Horn to Discharge Ca- Wait 30 seconds Reconnect Battery
pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

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Electrical System Observed Symptoms

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

Check 3

Power ON→ Fault Remains Service Required ? No Fault→ Resume Operation

Check 4

Reduced Performance→ Check Display Icons?

Motor/Motor Controller Temperature Icon On
1. Check fan operation→Are fans operating?→NO → A935 – K160 D203 Motor Controller Fan FailureYES →2. ?
2. Temp Sensor/Controller to Motor connection→Open Circuit→Component Operational Check↓
3. Use the following steps for viewing Motor Temperature
Note: The Motor Temperature ICON will be displayed for any Over Temperature of Traction 1/Traction 2, Pump
Motor and their associated Controllers plus Hydraulic Fluid
Note: The Diagnostics Display Menu Flowchart will show which device is overheating See Check 5
Note: The Service Tech may need to operate the truck for an extended time on a 20% grade to have this Over
temperature icon display again after it has been first reported

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Observed Symptoms Electrical System

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

Check 5
Diagnostics Temperature Analysis – Go to Display Menu Flowchart

Enter Service Password→ Diagnostics→ Motor→ Traction1/Traction2/ Motor/Control-

Pump→ ler Data
Fan(s) Operation Temperature Threshold: Traction = 55°C (131°F) Pump = 65°C (149°F)
Reduced Performance: Traction = 80°C (176°F) Pump = 80°C (176°F)

Motor Motor Controller

Invalid Temperature Signal (Traction/Pump Motor(s) Only): Sensor Connections/Sensor Open Circuit

Return to Diagnostics Menu→ ?

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Electrical System Observed Symptoms

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

Check 6
Fault Log DTC – Go to Display Menu Flowchart

Enter Service Password→ Diagnostic→ FAULT LOGs→ Motor Fault Log(s)→ View all Motor DTCs→ ?

3? all Motor Codes→ E Exit Fault Log→ Truck Status ?

Motor Versions→ 3?Hardware/Software Versions→ E Exit Versions→ Power OFF?

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Observed Symptoms Electrical System

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

POSSIBLE CAUSES X = Open Circuit/Fail ) = Short Circuit
CAUSES A B C D E > ?

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Electrical System Observed Symptoms

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

CONNECTORS

VSM Cxx 1 and Cxx 2 Traction/Pump Controller Cxx Fan Motor Connector Cxx 156, 157,
3, 4, and 5 595A, and 595B
CAUSE A

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342. ?
STEP A1
For any Fault DTC→ Locate Device→ Inspect ALL Wiring/Connections
A DMM Temperature probe can also be used to determine which device is overheating

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Observed Symptoms Electrical System

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

STEP A2 CHECK RESISTANCE - Ω - OHMS
Motor Temperature Sensor

1. Disconnect Motor Connector→Measure ? as indicated→

Note: For temperature sensor readings, see Motor Temperature Sensor.
At xxx deg→ sensor ? ˜ match Temperature Chart 340? @ -40°C (25°F) to 2791? @ 300°C (572°F)→ ↓
2. <300? to 0? = Motor Sensor Short Circuit→Go to 8↓
3. >2800? to 8? = Motor Sensor Open Circuit/High Resistance Connection→Go to 8↓
4. Reconnect Motor Connector↓
5. Disconnect Controller Connector→Measure ? as indicated→See Temperature Sensor Chart↑↓
6. <300? to 0? = Short Circuit→Go to 9↓
7. >2800? to 8? = Open Circuit/High Resistance Connection→Go to 9↓
8. Replace Motor→Go to 10↓
9. Find/Repair Harness OPEN/SHORT Circuit→Go to 10↓
10. See Electrical System 2200SRM1337/Electrical System 2200SRM1369→Go to 11↓
11. Recheck ?↑→ Reconnect→Resume Operation

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Electrical System Observed Symptoms

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

STEP A3
Motor Temperature Sensor (Controller Check)

1. Disconnect Motor Temperature Sensor Connector from suspect Controller→

2. Connect a ¼ watt resistor (>3300? to <10,000?) as shown
3. Reconnect Battery and all other Connectors
4. Does Over Temperature ICON Appear?↓
5. YES: Go to 7↓
6. NO: Controller is Faulty→Component Operational Check↓
7. Repeat Resistor Test on other Controllers↓
8. Temperature ICON is Displayed?→YES: Controller tested OK, Go to 9→NO: Controller tested Faulty→Com-
ponent Operational Check↓
9. Reconnect other Motor Temperature Sensors
CAUSE B
Not Applicable
CAUSE C
Not Applicable
CAUSE D

Power OFF→ Disconnect Battery and Sound Horn to Discharge Ca-

pacitors. Depending on your lift truck, go to Frame
0100SRM1329 or Frame 0100SRM1342.

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Observed Symptoms Electrical System

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

STEP D1

Remove and Replace Faulty Motor Controller↓

See Electrical System 2200SRM1337/Electrical System 2200SRM1369↓
Check Replacement Controller < Version→ See Label Information→ Step D2 ↓
STEP D2

1. Go to TRD/ Hypass Online /Software.?? Is Replacement Controller Application Software Version the Latest
Version??
2. NO→Download the latest Application <→Install on truck→Step D3↓
3. YES→Test New Installation→↓Step D3↓
4. Return Faulty Display→Dealer→Factory→Failure Analysis→?? Reprogramming

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Electrical System Observed Symptoms

A935 – K160 D203 Motor/Motor Controller Temperature Sensor Failure (Cont)

STEP D3

Retest - Power ON→ NO → ? Is fault DTC gone? Fault corrected→ Continue operation.

NO YES ← →
CAUSE E

Power OFF→ Inspect VSM Connections→ OK Step E1 Not OK Correct/Repair→ Step E1

STEP E1

Retest - Power ON→ NO → Go to VSM Con- Is fault DTC gone? Fault corrected→ Continue operation.
troller Check
NO YES ← →
DTC LOGS: DTC logs should only be cleared once the data is 3? by the Service Tech. See Display Menu
Flowchart - Clearing DTCs.
END FAULT

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Observed Symptoms Electrical System

Horn Failure
DIAGRAMS

WIRE # 005 (RED) = HORN SUPPLY

WIRE # 045 (WHITE) = SIGNAL GROUND
WIRE # 124 (BLACK) = HORN GROUND

Horn Schematic

CONNECTOR(S)

Connector CPS4 Connector CPS8

Connector CPS9 Connector CPS10

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Electrical System Observed Symptoms

Connector CPS15

POSSIBLE CAUSE
A. FUSE BLOWN
B. OPEN CIRCUIT IN WIRING HARNESS
C. HORN FAILURE
D. VSM FAILURE

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Open engine cover to gain access to batteries. See Operating Manual.
2. Examine connections between batteries.
Are connections correct and secure?
YES: Go to Cause B.
NO: Connect cables, as required. Depending on your lift truck, see Electrical System 2200SRM1369, or
Electrical System 2200SRM1337.

CAUSE A - FUSE BLOWN

PROCEDURE OR ACTION:
1. At the fuse access cover, open access cover.
2. Using DMM, measure voltage on both sides of fuse F6 (+) with respect to ground (-).
Is voltage on one side of fuse less than 0.5 Vdc?
YES: Check wiring harness for shorts between wires 005 and 124 or 005 and the vehicles frame. Repair or
Replace wiring harness. Depending on your lift truck, see Wire Harness Repair 2200SRM1128, or Fuse 6 is
blown, replace blown fuse.
NO: Fuse 6 is OK. Go to Cause C.

CAUSE B - OPEN CIRCUIT IN WIRING HARNESS

NOTE: If DTC 524213-4 appears, go to

PROCEDURE OR ACTION:
1. Disconnect horn at CPS 89.
2. Using DMM, measure voltage between Pin B and Pin C on CPS 89.
Is battery voltage present?
YES: Go to Step 3.
NO: Check wiring harness for shorts between wires 005 and 124 for open circuit. Repair or Replace wiring
harness. Depending on your lift truck, see Wire Harness Repair 2200SRM1128.
3. Change DMM to ohms scale. Verify DMM zero reading.
Is the reading approximately 28??

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Observed Symptoms Electrical System

YES: Go to Step 4.
NO: Wire 045 has a short to ground in the wiring harness. Repair/Replace wiring harness. Depending on your
lift truck, see Wire Harness Repair 2200SRM1128.

NOTE: Do not disconnect wiring harness at horn button.

4. Remove only horn button from top of steering wheel. Ensure that wire is still connected.
5. Set DMM to volts scale.
6. Measure voltage on both sides of horn button terminals with respect to ground (-).
Is battery voltage present?
YES: Go to Step 7.
NO: Go to Step 8.
7. Connect DMM to slip ring wires. During voltage measurement, rotate steering wheel from lock-to-lock position
to test the entire slip ring surface.
Is battery voltage present?
YES: Repair or Replace slip ring assembly. Refer to appropriate Frame manual, depending on lift truck
model, Steering Column Repair section.
NO: Wire 025 and 109 has open circuit in wiring harness. Repair/Replace wiring harness. Depending on your
lift truck, see Wire Harness Repair 2200SRM1128.
8. Push horn button.
Does DMM voltage go to zero?
YES: Go to Cause D.
NO: Replace horn button.

CAUSE C - HORN FAILURE

PROCEDURE OR ACTION:
1. Connect horn at CPS 89.
2. Using a jumper wire to short circuit, connect Pin A and Pin C at CPS 89.
Does DMM voltage go to zero?
YES: Go to Cause E.
NO: Replace horn.

CAUSE D - VSM FAILURE

PROCEDURE OR ACTION:
1. Replace VSM. Depending on your lift truck, see Electrical System 2200SRM1369, or Electrical System
2200SRM1337.

END SYMPTOM

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Electrical System Observed Symptoms

Lights Inoperative
DIAGRAMS

WIRE # 034A, (RED)= 12 V DC/DC SOURCE

WIRE # 013A, (BLACK)= DC/DC GROUND

3 Wheel Lift Trucks With or Without Turn Signal

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Observed Symptoms Electrical System

WIRE # 034A, (RED)= 12 V DC/DC SOURCE

WIRE # 125A, (BLACK)= DC/DC GROUND

4 Wheel Lift Trucks With Turn Signal

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Electrical System Observed Symptoms

WIRE # 034A, (RED)= 12 V DC/DC SOURCE

WIRE # 125A, (BLACK)= DC/DC GROUND

4 Wheel Lift Trucks Without Turn Signal

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Observed Symptoms Electrical System

CONNECTOR(S)

CPS2

POSSIBLE CAUSE
A. DEFECTIVE LAMP
B. LIGHT CIRCUIT OPEN SUPPLY OR GROUND WIRE
C. POWER SUPPLY CIRCUIT FAULT

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Turn switch for light to ON.
Does light operate correctly?
YES: Problem not verified. Resume operation.
NO: Go to Cause B.

CAUSE A - DEFECTIVE LAMP

PROCEDURE OR ACTION:
1. Replace lamp. Refer to the appropriate Electrical System manual, depending on lift truck model.
Does light turn on?
YES: Problem repaired. Resume operation.
NO: Go to Cause C.

CAUSE B - LIGHT CIRCUIT OPEN SUPPLY OR GROUND WIRE

PROCEDURE OR ACTION:
1. Turn cab accessory fan ON.
Does accessory fan operate?
YES: Go to Step 2.
NO: Go to Cause D
2. Remove light assembly to access wire connections.
3. Using DMM, measure the voltage across the terminals of the lamp socket.
Is voltage approximately system voltage?
YES: Circuit voltage and ground connections are OK. Replace cab light assembly. Refer to the appropriate
Electrical System manual, depending on lift truck model.
NO: Go to Step 4.
4. Change DMM to ohms scale. Verify zero reading.

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Electrical System Observed Symptoms

CAUTION
For this next measurement, make sure measurement is taken at the Black Wire. The red wire may have an
applied voltage that could damage meter.

5. Measure resistance between terminal on black wire and a clean frame ground.
Is the resistance less than 0.5 ohms?
YES: Wire # 034A (RED) has open circuit to supply voltage. Locate and repair/replace open wire/connection.
Refer to the appropriate Wiring Harness Repair manual, depending on lift truck model.
NO: For three wheel lift trucks, wire # 013A (BLACK) has open circuit to ground. For four wheel lift trucks with
or without turn signal, wire # 125A (BLACK) has open circuit to ground. Locate and repair/replace open wire/
connection. Refer to the appropriate Wiring Harness Repair manual, depending on lift truck model.

CAUSE C - POWER SUPPLY CIRCUIT FAULT

PROCEDURE OR ACTION:
1. Remove floor mat and floor plate to access lighting modules, fuses, and relays mounted to front bulkhead.
2. Using DMM, measure voltage across diode (+) and the negative terminal of battery (−).
Is the voltage on each side of diode approximately 12Vdc?
YES: Go to Step 3.
NO: Diode is blown. Replace defective lighting module with new lighting module.
3. Open dash cover near VSM and disconnect harness connector CPS 2.
4. Using DMM, measure voltage across pins 1(+) and 2(−) of CPS 2.
Is voltage approximately system voltage?
YES: Wire #034A/C (RED) has open circuit. Locate and repair/replace open wire/connection. Refer to the ap-
propriate Wiring Harness Repair manual, depending on lift truck model.
NO: Go to Step 5.
5. Move the negative (−) meter lead to a clean frame ground on the truck.
Is voltage approximately system voltage?
YES: For three wheel lift trucks, wire # 013A (BLACK) has open circuit. For four wheel lift trucks with or with-
out turn signal, wire # 125A (BLACK) has open circuit. Locate and repair/replace open wire/connection. Refer
to the appropriate Wiring Harness Repair manual, depending on lift truck model.
NO: Wire # 034A/C (RED) has open circuit to supply voltage. Locate and repair/replace open wire/connec-
tion. Refer to the appropriate Wiring Harness Repair manual, depending on lift truck model.

END SYMPTOM

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 NOTES

9030-30-40
Electrical System Icons and Graphics

Group 55

Icons and Graphics

Icon Glossary
INTRODUCTION TO ICONS small space. In addition, the use of icons reduces the
difficulty of communicating with operators who speak
An icon is a symbol that conveys a unique meaning different languages.
without words, such as an arrow. The Operating
Screen on this lift truck presents information to an op- The following table, are icons used during the Diag-
erator solely through the use of symbols which are nostic Troubleshooting Procedures. For further details
mostly icons, along with some numbers and a few text on displays and icons, see User Interface Supervi-
characters. Icons make it possible to simultaneously sor 2200SRM1335 or User Interface Service Tech-
display up to 12 kinds of information graphically in a nician 2200SRM1336 .

Symbols/Icons Definition
Display FAULT Panel

Password Screen

System Power OFF

System Power ON/Display RUN Screen

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Icons and Graphics Electrical System

Symbols/Icons Definition
PC Service Tool

Vehicle System Manager

Operator Password

Supervisor Password

Service Password

Service Required/Fault Code

Digital Multimeter

Operate the Indicated Button/Key/Device

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Electrical System Icons and Graphics

Symbols/Icons Definition
Look For/Find

Garbage/Junk/Rubbish Receptacle

Operator Presence

Park Brake

Wait 30-Seconds

Work Lights

Battery

Battery Disconnect

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Icons and Graphics Electrical System

Symbols/Icons Definition
Reconnect Battery

Locate Diagnostic Connector

Sound Horn to Discharge Capacitors

Fork Truck

Travel Direction

Mast Tilt Position

Push in Emergency Stop

Release Emergency Stop

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Electrical System Icons and Graphics

Symbols/Icons Definition
Accelerator Pedal

Buzzer/Audible Warning Device

Contactor

DCS – Directional Control Selector

E-Hydraulic

Hydraulic Temperature

Load Weigh Pressure

Manual-Hydraulic

MLM Lever

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Icons and Graphics Electrical System

Symbols/Icons Definition
MLM PCB Cassette

Pump Motor

Service Brake Pressure

Steering Wheel Position

Steering Axle Position

Traction Motor

Accelerator Sensor

Hydraulic Temperature Sensor

Load Weight Pressure Sensor

Manual Hydraulic Position Sensor

Motor Speed Sensor

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Electrical System Icons and Graphics

Symbols/Icons Definition
Operator Presence Sensor

Park Brake/Mast Tilt Sensor

Steering Axle/Wheel Sensor

Temperature Sensor

Travel Direction Foot Pedal Sensor

Travel Direction Manual Hydraulic Sensor

Failure/Cause/Occurence

Failure A/Cause A/Occurence A

Shorted Connection/Fault e.g.C

Resistor e.g. Value = 1.1KOhms

Fuse – xx Amps

Emergency Disconnect

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Icons and Graphics Electrical System

Symbols/Icons Definition
Coil – Relay/Contactor/Valve

Contactor/Relay//Valve Coil

Switch – Normally Open

Switch – Normally Closed

High Resistance

Okay/Correct

3? Record

< Software

@ Repair Faulty Component

Go to Next Step

Go to Next Step

Go to Next Cause

Display arrow Left

\
Display arrow Right
]
Go to next step
?
ô Display Scroll UP/DOWN Push Buttons

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Electrical System Icons and Graphics

Symbols/Icons Definition
Lift/Lower Hydraulic Lever(s)
G
? Not Equal

? Ohms

Approximately
˜
8 Infinite Value

Question/Questionable Operation
?
Equal/Compare to
=
Less Than
<
Greater Than
>
N Dead - Destroyed – Beyond Redemption

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 NOTES

9030-55-10
 SECTION 9035

DRIVE AXLE/UNIT

TABLE OF CONTENTS

Group 10 - Principles of Operation

Drive Axle ...............................................................................................................................................9035-10-1
Description..........................................................................................................................................9035-10-1
Principles of Operation....................................................................................................................... 9035-10-1
Drive Units......................................................................................................................................9035-10-1
Brakes............................................................................................................................................ 9035-10-1
Drive Axle And ....................................................................................................................................... 9035-10-2
Drive Axle and ................................................................................................................................... 9035-10-2
Transaxle ........................................................................................................................................... 9035-10-4
Drive Axle .......................................................................................................................................... 9035-10-4
Transaxle ........................................................................................................................................... 9035-10-7
Service Brake Systems.......................................................................................................................9035-10-9
Parking Brake Systems...................................................................................................................... 9035-10-9
..........................................................................................................................................................9035-10-12
DESCRIPTION............................................................................................................................... 9035-10-2
PRINCIPLES OF OPERATION...................................................................................................... 9035-10-3
DESCRIPTION............................................................................................................................... 9035-10-4
PRINCIPLES OF OPERATION...................................................................................................... 9035-10-4
DESCRIPTION............................................................................................................................... 9035-10-4
PRINCIPLES OF OPERATION...................................................................................................... 9035-10-5
DESCRIPTION............................................................................................................................... 9035-10-7
PRINCIPLES OF OPERATION...................................................................................................... 9035-10-7
Dry Brake Systems.........................................................................................................................9035-10-9
Wet Brake Systems........................................................................................................................ 9035-10-9
Master Cylinder.............................................................................................................................. 9035-10-9
Manual Parking Brake For Lift Truck Models and ......................................................................... 9035-10-9
Automatic Park Brake For Lift Truck Models , , , , and .................................................................. 9035-10-9
Description....................................................................................................................................9035-10-12
Principles of Operation................................................................................................................. 9035-10-12
Group 30 - Observed Symptoms
One Drive Wheel Will Not Move..............................................................................................................9035-30-1
Noise During Operation That Is Not Normal........................................................................................... 9035-30-2
Oil Leaks................................................................................................................................................. 9035-30-4
Park Brake Does Not Operate Properly.................................................................................................. 9035-30-5
Motion Inhibited.......................................................................................................................................9035-30-6
Park Brake Troubleshooting Guide.....................................................................................................9035-30-8

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9035-2
Drive Axle/Unit Principles of Operation

Group 10

Principles of Operation

Drive Axle J1.5-2.0XNT (J30-40XNT) (K160) J1.6-2.0XN (A935)

DESCRIPTION • The drive unit housings also support the mast
through machined and bushed trunnion
This series of lift trucks is equipped with a transaxle mounts. The hang-on mast mounting system,
which consists of a drive motor, an in-line gear set with its mounting hardware accessible from
drive unit, and a park brake on each drive wheel. This above, provides a convenient way to install/
series of lift trucks is also equipped with a wet brake remove the mast. An easily accessible grease
system which is located within the transaxle. fitting is provided to lubricate the mast mount-
ing and bushing.
PRINCIPLES OF OPERATION • Wet disk brakes are designed as an integral
part of the drive unit.
The lift truck uses two drive units. One drive unit is
mounted on each side of the lift truck frame beneath Brakes
the cowl. The drive unit is an in-line gear set that in-
corporates a wet disk service brake assembly within • Dual, hydraulically operated, wet disk service
the drive unit. The traction motor and park brake is brakes are designed into the drive unit.
mounted on one side of the drive unit, and the drive
wheel and tire assemblies are mounted to the other • These brakes are inside the drive unit, and
side of the drive unit. The drive unit is secured to the therefore are impervious to water and operate
lift truck frame using a series of five capscrews. The with no degradation of performance in these
drive unit housing provides the mounts needed to at- conditions.
tach the mast to the lift truck. Power from the traction • The master cylinder and integrated reservoir
motor is transmitted to the drive unit through an inter- have fluid level sensor connected to a warning
nal spline in the input gear. See Figure 9035-10-1. light on the display panel.
• Spring applied, electrically released park brake
Drive Units is mounted at the end of each motor. The park-
ing brake is automatically set by the control
• Dual, in-line drive units are individually moun- system so that the brake is always applied
ted in the frame with complete and separate whenever the truck is not moving, and no trac-
traction motor and braking systems. This sys- tion has been requested. A manual release
tem allows for independent traction control for mechanism has been designed into the park
each wheel. brake.
• The drive unit assemblies mount to the frame
with five capscrews per side.

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Principles of Operation Drive Axle/Unit

Legend for Figure 9035-10-1

1. DRIVE UNIT
2. MAST MOUNTING CAPS
3. TRACTION MOTORS

Figure 9035-10-1. Transaxle Mounting

Drive Axle E2.2-3.5XN (E40-70XN) (A268), E1.6-2.0XN E30-40XN

(A269), J2.2-3.5XN (J45-70XN) (A276), E4.0-5.5XN, 5.0XNS
(E80-120XN, E100XNS) (A099), And J4.0-5.0XN (A970)
DRIVE AXLE E2.2-3.5XN (E45-70XN)
(A268) AND E1.6-2.0XN (E30-40XN) (A269)
DESCRIPTION

This lift truck is equipped with a conventional drive

axle and uses dry service brakes. See the Dry Brake
Systems section of this manual. The drive axle is fas-
tened to the frame of the lift truck with four bolts,
washers, and nuts. See Figure 9035-10-2. These lift
truck models may have a manual or an automatic
park brake.
NOTE: DRIVE AXLE FOR E2.2-3.5XN (E45-70XN)
(A268) SHOWN. E2.2-3.5XN (E45-70XN) (A268)
E1.6-2.0XN (E30-40XN) (A269) IS SIMILAR.

1. DRIVE AXLE ASSEMBLY

2. AXLE MOUNTING BOLT
3. WASHER
4. NUT

Figure 9035-10-2. Drive Axle Mounting for Lift

Truck Models E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)

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Drive Axle/Unit Principles of Operation

PRINCIPLES OF OPERATION hub and brake drum. The back plate and brake as-
semblies are fastened to the axle assembly or assem-
The outer ends of the axle housings are the spindles blies. The center section contains the speed reducer
for the wheel bearings. The cups for the tapered roller and differential assembly. See Figure 9035-10-3. The
bearings are pressed into the wheel hubs. The nut on speed reducer has a gear that engages the splines on
the end holds and adjusts the preload on the wheel the shaft of the traction motor. A second speed re-
bearings. The axle shafts are fastened to the hubs by ducer gear is fastened to the pinion shaft for the dif-
capscrews. Studs and nuts fasten the wheel to the ferential.

NOTE: DRIVE AXLE FOR E2.2-3.5XN (E45-70XN) (A268) SHOWN. E2.2-3.5XN (E45-70XN) (A268) E1.6-2.0XN
(E30-40XN) (A269) IS SIMILAR.

1. CAPSCREW 10. INNER BEARING CUP

2. AXLE SHAFT 11. INNER BEARING CONE
3. BEARING LOCK NUT 12. INNER SEAL
4. BEARING LOCK WASHER 13. LOCK BOLT
5. WHEEL BEARING WASHER 14. BRAKE ASSEMBLY
6. OUTER BEARING CONE 15. WASHER
7. OUTER BEARING CUP 16. LH HANGER
8. HUB 17. CENTER SECTION ASSEMBLY
9. OUTER SEAL

Figure 9035-10-3. Drive Axle Assembly for Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269)

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Principles of Operation Drive Axle/Unit

TRANSAXLE J2.2-3.5XN (J45-70XN) DRIVE AXLE E4.0-5.5XN, 5.0XNS

(A276) (E80-120XN, E100XNS) (A099)
DESCRIPTION DESCRIPTION

This transaxle is a modular rigid axle for use in front- This lift truck is equipped with a conventional drive
wheel-drive electric balance-weight forklift trucks and axle and uses wet service brakes. See the Wet Brake
uses wet service brakes. See the Wet Brake Systems Systems section of this manual. The drive axle is fas-
section of this manual. tened to the frame of the lift truck with four bolts,
washers, and nuts. See Figure 9035-10-5.
PRINCIPLES OF OPERATION

The transaxle consists of a centrally located park and

service brake system, two asynchronous traction mo-
tors, and two transmissions. The drive unit is joined to
the vehicle chassis and to the lift mast by means of
fixtures mounted on the axle.

1. TRACTION MOTOR
2. AXLE MOUNTING BOLT
3. WASHER
4. NUT (NOT SHOWN)
5. DRIVE AXLE

Figure 9035-10-5. Drive Axle Mounting for Lift

Truck Models E4.0-5.5XN, 5.0XNS (E80-120XN,
E100XNS) (A099)
1. BRAKE PEDAL
2. PARK BRAKE MANUAL RELEASE
3. PARK BRAKE RELEASE CABLE
4. PARK BRAKE ACTUATOR
5. MASTER CYLINDER RESERVOIR

Figure 9035-10-4. Transaxle for Lift Truck Models

J2.2-3.5XN (J45-70XN) (A276)

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Drive Axle/Unit Principles of Operation

PRINCIPLES OF OPERATION the drive axle housing. Socket head capscrews fasten
the left drive axle housing to the piston chamber and
The outer ends of the axle housings are the reduction the piston chamber to the right drive axle housing.
gear assemblies for the wheel hubs. The cups for the The right drive axle housing contains the differential
tapered roller bearings are pressed into the wheel housing and differential. Fastened to the right drive
hubs. The retaining plate on the end holds and ad- axle housing is the pinion and motor carrier. A traction
justs the preload on the wheel bearings. Studs and motor fastened to the motor carrier supplies rotation
nuts fasten the wheel to the wheel hub. Socket head to the pinion via a splined coupler which in turn en-
capscrews fasten the reduction gear assemblies to gages the differential. See Figure 9035-10-6.

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Principles of Operation Drive Axle/Unit

1. TRACTION MOTOR 10. COUPLER

2. PINION AND MOTOR CARRIER 11. SNAP RING
3. REDUCTION GEAR ASSEMBLY 12. WET BRAKE DISC PACK
4. LEFT AXLE SHAFT 13. AXLE HOUSING
5. O-RING 14. RIGHT AXLE SHAFT
6. DIFFERENTIAL HOUSING AND DIFFERENTIAL 15. RETAINING PLATE
7. RIGHT DRIVE AXLE HOUSING 16. WHEEL HUB COUPLER
8. PISTON CHAMBER 17. BEARING CAP
9. DIFFERENTIAL BEARING ADJUSTMENT NUT

Figure 9035-10-6. Drive Axle Assembly for Lift Truck Models E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
(A099)

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Drive Axle/Unit Principles of Operation

TRANSAXLE J4.0-5.0XN (J80-100XN)

(A970)
DESCRIPTION

This series of lift trucks is equipped with a transaxle

which consists of two drive motors, two gear boxes,
two transmission output assemblies and an automatic
park brake . This series of lift trucks is also equipped
with a wet brake system which is located within the
gear box housing. See the Wet Brake Systems sec-
tion of this manual.

PRINCIPLES OF OPERATION

The lift truck uses two traction motors installed in a

central traction motor housing. The traction motor
housing has fins to allow the traction motors to cool. 1. NUT
The wet brakes are contained within the gear box 2. WASHER
housing. The transaxle is mounted to the frame with 3. CAPSCREW
four mounting bolts, washers and nuts. The transaxle 4. LEVER ARM
housing provides the mounts needed to attach the 5. PARK BRAKE ACTUATOR
6. TRACTION MOTOR HOUSING
mast to the lift truck. Power from the traction motors is
transmitted to the gear box through an internal spline Figure 9035-10-7. Drive Axle Mounting for Lift
and on to the transmission output assembly. See Fig- Truck Models J4.0-5.0XN (J80-100XN) (A970)
ure 9035-10-8.

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Confidential/Proprietary - Do Not Copy or Duplicate 9035-10-7
Principles of Operation Drive Axle/Unit

1. SUPPORT DISC 11. GASKET

2. STEEL DISC 12. V-RING
3. SPRING 13. PHONIC WHEEL
4. SEPARATOR PLATE 14. BREATHER
5. STUD 15. SERVICE BRAKE PIPING CONNECTOR
6. DISC PUSHER 16. RIGHT GEAR BOX
7. LOCKING PIN 17. LEFT GEAR BOX
8. ELASTIC DISC 18. TRACTION MOTOR
9. RETAINING RING 19. LIFTING EYELET
10. PISTON

Figure 9035-10-8. Drive Axle Assembly for Lift Truck Models J4.0-5.0XN (J80-100XN) (A970)

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Drive Axle/Unit Principles of Operation

SERVICE BRAKE SYSTEMS PARKING BRAKE SYSTEMS

Dry Brake Systems Manual Parking Brake For Lift Truck Models
E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
General (E30-40XN) (A269)

The dry brake system includes the following parts: The parking brake system uses the service brake
park brake, service brakes, master cylinder, and auto- shoes. Additional linkage activates the parking brake
matic park brake or manual. The manual park brake system. When the pedal is moved to apply the park-
assembly contains a release handle, pedal, position ing brake, the cables and linkage expand the brake
sensor and cable. The service brake assembly con- shoes against the drums. The design of the parking
tains the brake pedal, master cylinder, brake assem- brake linkage adjusts each cable so that the tension is
bly (attached to wheel), and park brake cables. The the same when the pedal is moved to apply the park-
automatic park brake assembly contains the brake ing brake. The park brake sensor is located on the left
(attached to the traction motor), cable, and manual side of the park brake pedal. See Figure 9035-10-9.
override handle.
Automatic Park Brake For Lift Truck Models
Wet Brake Systems E2.2-3.5XN (E45-70XN) (A268) , E1.6-2.0XN
(E30-40XN) (A269) , J2.2-3.5XN (J45-70XN) (A276) ,
General E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
(A099) , and J4.0-5.0XN (J80-100XN) (A970)
The brake systems for all wet brake axles operate on
a common principal very similar to the transmission On lift truck models E2.2-3.5XN (E45-70XN) (A268)
clutch packs. Rotating friction discs are interleaved and J2.2-3.5XN (J45-70XN) (A276) E1.6-2.0XN
with stationary separator discs within the axle hous- (E30-40XN) (A269) , the automatic park brake (APB)
ing. An annular piston forces the discs together when is attached to the traction motor. See Fig-
pressure is provided by the service brake system. An ure 9035-10-9 The automatic park brake activates at
oil bath provides a shear film between the discs, zero speed. If the driver leaves the seat; a switch noti-
greatly reducing wear of the friction material. For park fies the operating software and the lift truck will slow
brake function, an actuator and lever arm on the drive to a stop. When the lift truck is stopped for a brief pe-
axle moves the piston instead of service brake oil riod, the park brake will apply automatically. When the
pressure. accelerator is applied, the brake will release.

Master Cylinder On lift truck model A276 , the automatic parking brake
is driven by a spring applied/ hydraulic release accu-
The master cylinder is designed for a single-circuit mulator assisted actuator mounted on the drive axle.
system. The master cylinder has a piston that oper- The single pole actuator engages a wedge face on a
ates in the bore of the master cylinder. ball ramp actuator which locks the brake disc set,
parking the lift truck. The parking brake is automati-
The reservoir is equipped with an indicator for low cally set by the control system so that the brake is al-
fluid level. A float in the reservoir moves up and down ways applied whenever the truck is not moving, and
with the fluid level. When the fluid level is low, a mag- no traction has been requested. The manual override
net on the float activates a switch in the bottom of the is a handle attached to the cable and for use when
reservoir. This switch signals the Vehicle System the lift truck has no power. The brake is in the applied
Manager (VSM) which illuminates an icon on the Dis- position when the handle rests against the mechani-
play Panel (DP). cal stop. The brake is manually released by pulling
the handle upright.

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Confidential/Proprietary - Do Not Copy or Duplicate 9035-10-9
Principles of Operation Drive Axle/Unit

NOTE: BOTH MANUAL AND AUTOMATIC PARK 1. MANUAL OVERRIDE HANDLE

BRAKE COMPONENTS SHOWN. 2. COWL
3. MANUAL OVERRIDE CABLE
NOTE: DRIVE AXLE FOR E2.2-3.5XN (E45-70XN) 4. TRANSAXLE
(A268) SHOWN. E1.6-2.0XN (E30-40XN) (A269) IS Figure 9035-10-10. Automatic Park Brake Manual
SIMILAR. Release for Lift Truck Models J2.2-3.5XN
1. PARK BRAKE RELEASE HANDLE (MANUAL (J45-70XN) (A276)
PARK BRAKE)
2. PARK BRAKE PEDAL (MANUAL PARK BRAKE) On lift truck model A970 , the automatic parking brake
3. PARK BRAKE POSITION SENSOR (LEFT-HAND is driven by a spring applied/ hydraulic release actua-
SIDE) (MANUAL PARK BRAKE) tor mounted beneath the traction motor housing. The
4. BRAKE PEDAL actuator has two opposed rods that engage right and
5. MASTER CYLINDER left park brake lever arms. The lever arms mechani-
6. BRAKE ASSEMBLY
7. PARK BRAKE CABLES cally apply the wet brakes, parking the lift truck. The
8. AUTOMATIC PARK BRAKE ASSEMBLY parking brake is automatically set by the control sys-
9. AUTOMATIC PARK BRAKE CABLE tem so that the brake is always applied whenever the
10. AUTOMATIC PARK BRAKE MANUAL OVER- truck is not moving, and no traction has been reques-
RIDE HANDLE ted. A manual release mechanism has been designed
11. TRACTION MOTOR
into the park brake for truck repairs.
Figure 9035-10-9. Brake System for Lift Truck
Models E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)

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Drive Axle/Unit Principles of Operation

On lift truck model A099 , the automatic parking brake For lift truck models J4.0-5.0XN (J80-100XN) (A970)
is driven by a spring applied/ hydraulic release actua- and E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)
tor mounted above the traction motor. The single pole (A099) , the park brake manifold valve consists of
actuator engages park brake lever arm on the drive SV1, a 2-pos / 3-way solenoid valve, in the circuit.
axle. The lever arm mechanically applies the wet When this valve is not energized, i.e., “normal” state,
brakes, parking the lift truck. The parking brake is au- the brake actuator is connected to the tank. In this
tomatically set by the control system so that the brake condition there is no hydraulic pressure at the B Port.
is always applied whenever the truck is not moving, Park brake actuator spring applies the park brake and
and no traction has been requested. A manual re- the truck is not moving. See Figure 9035-10-12 for
lease mechanism has been designed into the park schematic.
brake for truck repairs.

On lift trucks A099 and A970 the manual override is

on a manifold valve under the floor plate. The needle
valve handle must be swung clockwise to engage the
bypass. Then the manual hand pump will need to be
pump approximately fifteen times to release the auto-
matic park brake. See Figure 9035-10-11.

Figure 9035-10-12. Automatic Park Brake Manifold

Valve for Lift Truck Model J4.0-5.0XN (J80-100XN)
(A970) and E4.0-5.5XN, 5.0XNS (E80-120XN,
E100XNS) (A099)

1. MANIFOLD VALVE
2. NEEDLE VALVE HANDLE
3. PEDAL
4. MANUAL HAND PUMP

Figure 9035-10-11. Automatic Park Brake Manual

Release for Lift Truck Models J4.0-5.0XN
(J80-100XN) (A970) and E4.0-5.5XN, 5.0XNS
(E80-120XN, E100XNS) (A099)

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Principles of Operation Drive Axle/Unit

For lift truck models J2.2-3.5XN (J45-70XN) (A276) , MONOTROL® PEDAL

the function of the accumulator (ACC1) is to store
pressure and this stored pressure is used to release Description
the Park Brake which is connected to the Port B. The
Pressure Reducing Valve (PR1) reduces system The MONOTROL® pedal controls the speed of the
pressure (from Port P) to 400 psi. Whenever a hy- traction motor and direction of the drive unit. There
draulic (steering, hoist, tilt or aux) function is activated are two foot-actuated momentary-push-on switches
the accumulator gets charged. Steering standby flow on the left and right sides of the pedal. Pressing the
is not sufficient to charge the accumulator. Once the left side of the pedal actuates the forward direction
accumulator is charged it can provide approximately pedal switch. Pressing on the right side of the pedal
8-10 park brake releases before it has to be re- actuates the reverse direction pedal switch. Releasing
charged. It is unlikely, but if the pressure in the accu- the pedal releases both pedal direction switches.
mulator drops below 200 psi it will not be able to re-
lease the park brake. In order to address this condi- Principles of Operation
tion a pressure switch (PS1) is there to monitor the
accumulator pressure. If the pressure drops below There is a small directional switch under each pad of
200 psi the VSM will kick on the pump motor for a
the MONOTROL® pedal. Each switch controls one di-
short burst to charge the accumulator.
rection. If both sides of the MONOTROL® pedal are
The VSM energizes the solenoid (SV1). The pressure pushed at the same time no movement occurs.
in the accumulator releases and holds the Park
Brake. See Figure 9035-10-13 for schematic.

Figure 9035-10-13. Automatic Park Brake Manifold

Valve for Lift Truck Model J2.2-3.5XN (J45-70XN)
(A276)

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Drive Axle/Unit Observed Symptoms

Group 30

Observed Symptoms

One Drive Wheel Will Not Move

POSSIBLE CAUSE
A. ELECTRICAL SYSTEM FAULT
B. DAMAGE TO TRACTION MOTOR.
C. DAMAGE TO GEAR REDUCTION SYSTEM IN DRIVE UNIT.

CAUSE A - ELECTRICAL SYSTEM FAULT

PROCEDURE OR ACTION:
1. Troubleshoot electrical system.
Are any faults found during troubleshooting electrical system?
YES: Correct faults. Depending on your lift truck, see Electrical System 2200SRM1369, or Electrical Sys-
tem 2200SRM1337.
NO: Go to Cause B.

CAUSE B - DAMAGE TO TRACTION MOTOR.

PROCEDURE OR ACTION:
1. Inspect for damaged traction motor.
Is traction motor apparently damaged?
YES: Repair or replace traction motor. Depending on your lift truck, see Transaxle 1300SRM1330, Trans-
axle 1300SRM1370, or Drive Axle, Speed Reducer, and Differential 1300SRM1366.
NO: Go to Cause C.

CAUSE C - DAMAGE TO GEAR REDUCTION SYSTEM IN DRIVE UNIT.

PROCEDURE OR ACTION:
1. Inspect for damaged drive unit.
Does drive unit pass test?
YES: Resume operation.
NO: Replace drive unit. Depending on your lift truck, see Transaxle 1300SRM1330, Transaxle
1300SRM1370, or Drive Axle, Speed Reducer, and Differential 1300SRM1366.

END SYMPTOM

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Observed Symptoms Drive Axle/Unit

Noise During Operation That Is Not Normal

POSSIBLE CAUSE
A. MISSING OR LOOSE LUG NUTS
B. LOOSE DRIVE AXLE MOUNTING CAPSCREWS
C. LOW OIL LEVEL
D. BEARING DAMAGE
E. NOISE CONTINUES AFTER CORRECT OIL LEVEL
F. RING AND PINION BACKLASH IS NOT PROPER
G. NOISE CONTINUES

CAUSE A - MISSING OR LOOSE LUG NUTS

PROCEDURE OR ACTION:
1. Check for missing or loose lug nuts.
Are any lug nuts missing or loose?
YES: Tighten loose or missing lug nuts. Depending on your lift truck, see Periodic Maintenance
8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic
Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.
NO: Go to Cause B.

CAUSE B - LOOSE DRIVE AXLE MOUNTING CAPSCREWS

PROCEDURE OR ACTION:
1. Check for loose drive axle mounting capscrews.
Are any drive axle mounting capscrews loose?
YES: Tighten drive axle mounting capscrew. Depending on your lift truck, see Transaxle 1300SRM1330,
Transaxle 1300SRM1370, or Drive Axle, Speed Reducer, and Differential 1300SRM1366.
NO: Go to Cause C

CAUSE C - LOW OIL LEVEL

PROCEDURE OR ACTION:
1. Check level of oil.
Is oil level low?
YES: Add oil to correct level. See Operating Manual.
NO: Go to Cause E.

CAUSE D - BEARING DAMAGE

PROCEDURE OR ACTION:
1. Check for damage on bearings.
Are bearings damaged?
YES: Repair or replace traction motor. Depending on your lift truck, see Transaxle 1300SRM1330, Trans-
axle 1300SRM1370, or Drive Axle, Speed Reducer, and Differential 1300SRM1366.
NO: Go to Cause F.

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Drive Axle/Unit Observed Symptoms

CAUSE E - NOISE CONTINUES AFTER CORRECT OIL LEVEL

PROCEDURE OR ACTION:
1. Check for wear and damage in the gear reduction system.
Does gear reduction have wear and damage?
YES: Repair the drive axle, speed reducer and differential assembly. See Drive Axle, Speed Reducer, and
Differential 1300SRM1366.
NO: Go to Cause D.

CAUSE F - RING AND PINION BACKLASH IS NOT PROPER

PROCEDURE OR ACTION:
1. Check the ring and pinion backlash.
Is ring and pinion backlash within specifications?
YES: Go to Cause G.
NO: Adjust ring and pinion backlash. See Drive Axle, Speed Reducer, and Differential 1300SRM1366.

CAUSE G - NOISE CONTINUES

PROCEDURE OR ACTION:
1. Check to make sure that the ring and pinion is a matched gear set.
Are the ring and pinion a matched?
YES: Resume operation.
NO: repair or replace ring and pinion. See Drive Axle, Speed Reducer, and Differential 1300SRM1366.

END SYMPTOM

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Observed Symptoms Drive Axle/Unit

Oil Leaks
POSSIBLE CAUSE
A. OIL LEAK BETWEEN DRIVE UNIT HOUSING AND COVER
B. DAMAGED O-RINGS OR OIL SEALS
C. DRAIN, LEVEL, OR FILL PLUG LOOSE
D. OIL BEING EJECTED THROUGH BREATHER DUE TO OVERFILLING

CAUSE A - OIL LEAK BETWEEN DRIVE UNIT HOUSING AND COVER

PROCEDURE OR ACTION:

NOTE: This procedure is to be performed during the initial two year warranty period for lift trucks J1.5-2.0XNT
(J30-J40XNT) (K160) J1.6-2.0XN (A935)

1. Tighten housing bolts as directed in Transaxle 1300SRM1330, or Transaxle 1300SRM1370.

Did the leak stop?
YES: Continue lift truck operation.
NO: Replace the drive unit. See Transaxle 1300SRM1330, or Transaxle 1300SRM1370. After the two year
warranty period has expired on the above lift trucks go to Cause B.

CAUSE B - DAMAGED O-RINGS OR OIL SEALS

PROCEDURE OR ACTION:

NOTE: For lift trucks J1.5-2.0XNT (J30-J40XNT) (K160) J1.6-2.0XN (A935) the following procedure is to be per-
formed only after the two year warranty period has expired.

1. Inspect O-rings and oil seals.

Are O-rings or oil seals damaged?
YES: Repair or replace damaged O-rings or oil seals. Depending on your lift truck, see Transaxle
1300SRM1330, Transaxle 1300SRM1370, or Drive Axle, Speed Reducer, and Differential 1300SRM1366.
NO: Go to Cause C

CAUSE C - DRAIN, LEVEL, OR FILL PLUG LOOSE

PROCEDURE OR ACTION:
1. Inspect for loose drain, level, or fill plug.
Is drain, level, or fill plug loose?
YES: Tighten plug if necessary. Tighten to 22 N•m (16. lbf ft) Depending on your lift truck, see Transaxle
1300SRM1330, Transaxle 1300SRM1370, or Drive Axle, Speed Reducer, and Differential 1300SRM1366.
NO: Go to Cause D.

CAUSE D - OIL BEING EJECTED THROUGH BREATHER DUE TO OVERFILLING

PROCEDURE OR ACTION:
1. Inspect breather for ejection of excess oil.
Is excess oil being ejected from breather?
YES: Remove oil drain plug and allow excess to drain until level is at bottom of oil fill plug.
NO: Resume operation.

END SYMPTOM

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Drive Axle/Unit Observed Symptoms

Park Brake Does Not Operate Properly

POSSIBLE CAUSE
A. PARK BRAKE ACCUMULATOR IS FAULTY.

CAUSE A - PARK BRAKE ACCUMULATOR IS FAULTY.

PROCEDURE OR ACTION:
1. Bring truck to a complete stop.
2. Run tilt over relief for 15 seconds (this will fully charge the accumulator).
3. Press the accelerator pedal to move the lift truck 0.3 m (1 ft) with no hydraulic functions actuated including
steering.
4. Come to a compete stop then repeat Step 3.
Does hydraulic pump run at a fast rate for a brief period?
YES: Replace accumulator. See Transaxle 1300SRM1370
NO: Problem not Verified. Resume Operation.

END SYMPTOM

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Observed Symptoms Drive Axle/Unit

Motion Inhibited
POSSIBLE CAUSE
A. TRACTION OR HYDRAULIC INTERLOCK
B. MOTOR CONTROLLER FAULTED OR NOT READY
C. KEY SWITCH
D. BRAKE LINKAGE
E. BRAKE APPLIED

CAUSE A - TRACTION OR HYDRAULIC INTERLOCK

PROCEDURE OR ACTION:
1. Check display for active interlocks.
Is an interlock active?
YES: Cycle the key. Check display for active interlocks.
NO: Go to Cause B.

CAUSE B - MOTOR CONTROLLER FAULTED OR NOT READY

PROCEDURE OR ACTION:
1. Check operator presence.
Is the Operator Presence system working properly?
YES: Go to Cause C.
NO: Repair or replace the Operator Presence sensor. Refer to the appropriate Wiring Harness Repair SRM
or Electrical System SRM .

CAUSE C - KEY SWITCH

PROCEDURE OR ACTION:
1. Check for key switch related faults.
Are there any key switch related faults?
YES: Repair or replace the key switch. Refer to the appropriate Wiring Harness Repair SRM or Electrical
System SRM .
NO: Go to Cause D.

CAUSE D - BRAKE LINKAGE

PROCEDURE OR ACTION:
1. Check the brake linkage when motion is inhibited and there are no fault codes.
Is the brake linkage in good condition and working properly?
YES: Go to Cause E.
NO: Repair or replace damaged or worn components. Refer to the appropriate Transaxle or Drive Axle,
Speed Reducer, and Differential SRM .

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Drive Axle/Unit Observed Symptoms

CAUSE E - BRAKE APPLIED

PROCEDURE OR ACTION:
1. Check brake pressure sensor voltage. Without brake applied voltage should be 0.5 volts.
Is the brake pressure sensor reading 0.5 volts without the brake applied?
YES: Resume operation.
NO: Replace brake pressure sensor with new sensor. Refer to the appropriate Wiring Harness Repair SRM
or Electrical System SRM .

END SYMPTOM

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Observed Symptoms Drive Axle/Unit

PARK BRAKE TROUBLESHOOTING

GUIDE
Symptoms Possible Solutions Action
Check hose restrictions Replace hoses that have been
crushed or kinked.
Check needle valve setting Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check solenoid valve Refer to the appropriate Electrical
System SRM .
Check standby pressure Refer to the appropriate Main Con-
trol Valves SRM .
Check accelerator pedal Refer to the appropriate Electrical
System SRM .
Slow Park Brake Release Check linkage for damage Replace sheared clevis pins, worn
or damaged cables and springs and
retaining clips.
Check actuator rod damage Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check actuator rod interference Secure hoses, lines, and wires out
of the way to eliminate interference.
Check fault codes If fault code appears, go to Electrical
System, General Maintenance and
Diagnostic Data, Diagnostic Trouble
Codes, Page 9030-03-6.
Check needle valve setting Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check solenoid valve voltage, coil, Refer to the appropriate Electrical
Slow Park Brake Apply
contamination System SRM .
Check Tank return hose for kinks, Remove any excessive elbow joints
pinches or back pressure or other restrictions in the tank re-
turn hose.

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Drive Axle/Unit Observed Symptoms

Symptoms Possible Solutions Action

Check park brake cable for damage Replace park brake cable if dam-
aged.
Check park brake cable adjustment Refer to the appropriate Periodic
Maintenance SRM .
Check actuator stroke Refer to the appropriate Periodic
Maintenance SRM .
Check brake pack wear Refer to the appropriate Periodic
Maintenance SRM .
Check needle valve setting Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
No Park Brake Apply
Check for sticking solenoid valve Refer to the appropriate Electrical
System SRM .
Check actuator rod for damage Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check fault codes If fault code appears, go to Electrical
System, General Maintenance and
Diagnostic Data, Diagnostic Trouble
Codes, Page 9030-03-6.
Check speed sensor Refer to the appropriate Electrical
System SRM .
Check brake pack wear Refer to the appropriate Periodic
Maintenance SRM .
Check park brake cable adjustment Refer to the appropriate Periodic
Maintenance SRM .
Check for actuator damage Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check wheel size See your lift trucks name plate for
Partial Park Brake Apply the appropriate tire type and size.
Check oil type Refer to the appropriate Periodic
Maintenance SRM .
Check hose leaks Replace leaking hoses with new ho-
ses. Make sure clamps and fittings
are tight.
Check linkage for damage Replace sheared clevis pins, worn
or damaged cables and springs and
retaining clips.

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Observed Symptoms Drive Axle/Unit

Symptoms Possible Solutions Action

Check actuator stroke (locked) Refer to the appropriate Periodic
Maintenance SRM .
Check for actuator damage Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check solenoid connection Refer to the appropriate Electrical
System SRM .
Check solenoid valve voltage, cur- Refer to the appropriate Electrical
rent and coil System SRM .
Confirm hose routing Make sure all hoses have gradual
slopes and do not interfere with
moving components.
Check needle valve setting Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check standby pressure Refer to the appropriate Main Con-
No Park Brake Release trol Valves SRM .
Check accelerator pedal Refer to the appropriate Electrical
System SRM .
Check fault codes If fault code appears, go to Electrical
System, General Maintenance and
Diagnostic Data, Diagnostic Trouble
Codes, Page 9030-03-6.
Check pressure reducing valve Replace the parking brake valve if a
pressure of less than
2068±138 kPa (300±20 psi) is
measured at the pressure port on
the parking brake valve.
Check hoses for leaks Replace leaking hoses with new ho-
ses. Make sure clamps and fittings
are tight.
Check actuator rod interference Secure hoses, lines, and wires out
of the way to eliminate interference.

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Drive Axle/Unit Observed Symptoms

Symptoms Possible Solutions Action

Check park brake rod interference Secure hoses, lines, and wires out
of the way to eliminate interference.
Check needle valve setting Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check pressure reducing valve Replace the parking brake valve if a
pressure of less than
2068±138 kPa (300±20 psi) is
measured at the pressure port on
the parking brake valve.
Partial Park Brake Release
Check hoses for leaks Replace leaking hoses with new ho-
ses. Make sure clamps and fittings
are tight.
Check hose for kinks and pinches Replace hoses that have been
crushed or kinked.
Check actuator stroke (locked) Refer to the appropriate Periodic
Maintenance SRM .
Check linkage for damage Replace sheared clevis pins, worn
or damaged cables and springs and
retaining clips.
Check speed sensor Refer to the appropriate Electrical
System SRM .
Check accelerator pedal Refer to the appropriate Electrical
System SRM .
Check solenoid connection Refer to the appropriate Electrical
System SRM .
Unintentional Park Brake Apply
Check solenoid hardness connec- Refer to the appropriate Electrical
tion System SRM .
Check fault codes If fault code appears, go to Electrical
System, General Maintenance and
Diagnostic Data, Diagnostic Trouble
Codes, Page 9030-03-6.

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Observed Symptoms Drive Axle/Unit

Symptoms Possible Solutions Action

Check actuator damage Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check park brake cable damage Replace park brake cable if dam-
Park Brake is noisy aged.
Check for actuator interference Secure hoses, lines, and wires out
of the way to eliminate interference.
Check solenoid valve Refer to the appropriate Electrical
System SRM .
Check needle valve setting Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check solenoid valve Refer to the appropriate Electrical
System SRM .

Park Brake judder/vibration

Check pressure reducing valve Replace the parking brake valve if a

pressure of less than
2068±138 kPa (300±20 psi) is
measured at the pressure port on
the parking brake valve.
Check hoses leaks Replace leaking hoses with new ho-
ses. Make sure clamps and fittings
are tight.
Check hose kinks or pinches Replace hoses that have been
crushed or kinked.
Check brake pack wear Refer to the appropriate Periodic
Maintenance SRM .

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Drive Axle/Unit Observed Symptoms

Symptoms Possible Solutions Action

Check needle valve setting Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check pump prime Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check for leaks in hoses Replace leaking hoses with new ho-
ses. Make sure clamps and fittings
No Manual Override are tight.
Check tank return hose for kinks or Replace return hose with new return
pinches hose if kinks or pinches are found.
Check for actuator damage Refer to the appropriate Transaxle
or Drive Axle, Speed Reducer,
and Differential SRM .
Check actuator stroke (locked) Refer to the appropriate Periodic
Maintenance SRM .
Confirm software setting Refer to the appropriate User Inter-
face SRM .
Check accelerator pedal Refer to the appropriate Electrical
System SRM .
Park Brake engagement frequency Check operator presence sensor Refer to the appropriate Electrical
too high System SRM .
Check fault codes If fault code appears, go to Electrical
System, General Maintenance and
Diagnostic Data, Diagnostic Trouble
Codes, Page 9030-03-6.
Check speed sensor Refer to the appropriate Electrical
System SRM .
Park Brake engagement frequency Check accelerator pedal Refer to the appropriate Electrical
too low System SRM .
Check partial brake apply Refer to Observed Symptoms, Mo-
tion Inhibited, Page 9035-30-6

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 NOTES

9035-30-14
 SECTION 9050

HYDRAULIC SYSTEMS

TABLE OF CONTENTS

Group 10 - Principles of Operation

Manual Hydraulic Main Control Valve..................................................................................................... 9050-10-1
Description..........................................................................................................................................9050-10-1
Manual Hydraulic Control System...................................................................................................... 9050-10-1
General Description (Open Center Valve).......................................................................................... 9050-10-3
Features and Operation......................................................................................................................9050-10-3
General Description (Closed Center Valve)......................................................................................9050-10-11
Features and Operation....................................................................................................................9050-10-12
CONSTRUCTION...........................................................................................................................9050-10-3
VALVE TYPE..................................................................................................................................9050-10-3
INLET ASSEMBLY.........................................................................................................................9050-10-3
LIFT SECTION............................................................................................................................... 9050-10-5
TILT SECTION............................................................................................................................... 9050-10-8
AUXILIARY AND DUAL AUXILIARY SECTION.............................................................................9050-10-9
HYDRAULIC OIL COOLER..........................................................................................................9050-10-10
OUTLET COVER SECTION.........................................................................................................9050-10-10
CONSTRUCTION.........................................................................................................................9050-10-11
VALVE TYPE................................................................................................................................9050-10-11
INLET ASSEMBLY.......................................................................................................................9050-10-12
LIFT SECTION............................................................................................................................. 9050-10-14
TILT SECTION............................................................................................................................. 9050-10-18
AUXILIARY AND DUAL AUXILIARY SECTIONS........................................................................ 9050-10-20
E-Hydraulic Main Control Valve............................................................................................................ 9050-10-22
Electro-Hydraulic Control System.....................................................................................................9050-10-22
General Valve Description................................................................................................................ 9050-10-23
Features and Operation....................................................................................................................9050-10-24
Construction................................................................................................................................. 9050-10-23
Valve Type....................................................................................................................................9050-10-23
Inlet Section..................................................................................................................................9050-10-24
Lift Section....................................................................................................................................9050-10-27
Tilt Section....................................................................................................................................9050-10-31
Spacer Sections........................................................................................................................... 9050-10-33
Auxiliary and Dual Auxiliary Sections........................................................................................... 9050-10-33
Steering System....................................................................................................................................9050-10-34
Description........................................................................................................................................9050-10-34
Steering Control Unit (SCU) Operation.............................................................................................9050-10-40
Accumulator, Piston......................................................................................................................9050-10-36
Priority Steer (E-Hydraulic Control Valve).................................................................................... 9050-10-37
Priority Steer (Manual Hydraulics Open Center Control Valve)....................................................9050-10-38
Priority Steer (Manual Hydraulics Closed Center Control Valve)................................................. 9050-10-39
Group 33 - Observed Symptoms-Gear Pump
Abnormal Hydraulic Noise and/or Vibration............................................................................................ 9050-33-1
Abnormal Smell/Discoloration/Foaming of Oil.........................................................................................9050-33-4
Cycle Times Too Fast - Fast Actuation (E-Valve)................................................................................... 9050-33-5
Jump/Delay In Lift or Lower Activation After Moving MLM (E-Valve)......................................................9050-33-7

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 Jump/Delay In Auxiliary Function Actuation After Moving MLM (E-Valve)..............................................9050-33-9
Jump/Delay In Tilt Forward or Back Actuation (E-Valve)...................................................................... 9050-33-11
Forks Drop Slightly Before Lifting (E-Valve)..........................................................................................9050-33-12
Forks Lower Without Command (E-Valve)............................................................................................9050-33-13
Forks Raise or Actuate Without Command (E-Valve)...........................................................................9050-33-15
Hydraulic Oil Cooler Not Functioning Correctly.....................................................................................9050-33-16
Intermittent Activation (E-Valve) While Commanding Function............................................................ 9050-33-18
Forks Tilt Forward Without Command (E-Valve).................................................................................. 9050-33-19
Lift/Lower Function Maximum Speed Too Slow (E-Valve)....................................................................9050-33-21
Lift Function Will Not Move With MLM Movement (E-Valve)................................................................ 9050-33-24
Lift/Lower Continues To Move For Awhile After MLM Is Released (E-Valve).......................................9050-33-27
Lift/Lower/Auxiliary Function Suddenly Jumps In Middle of Stroke (E-Valve).......................................9050-33-28
Lower Function Will Not Move With MLM Movement (E-Valve)........................................................... 9050-33-29
Poor Metering on Lift or Lower Functions (E-Valve)............................................................................. 9050-33-30
Auxiliary Function Continues to Move for Awhile After MLM Is Released (E-Valve)............................ 9050-33-32
Auxiliary Function Maximum Speed Too Slow (E-Valve)......................................................................9050-33-33
Auxiliary Function or Tilt Back Moves Without Command (E-Valve).................................................... 9050-33-36
Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move With MLM Movement (E-Valve).........9050-33-37
Tilt Forward or Tilt Back Function Continues to Move for Awhile When
MLM Is Released (E-Valve).................................................................................................................. 9050-33-41
Tilt Forward or Tilt Back Will Not Move With MLM Movement (E-Valve).............................................. 9050-33-42
Too Much MLM Movement (Deadband) to Start Function Moving (E-Valve)....................................... 9050-33-44
Wrong Actuation Operates or Actuation is Backward (E-Valve)........................................................... 9050-33-45
Actuation Exhibits Slight Movement in Opposite Direction Before Moving (Manual Valve).................. 9050-33-46
Auxiliary Function is Slow or Does Not Function (Manual Valve)......................................................... 9050-33-47
Cycle Times Too Fast - Fast Actuation (Manual Valve)........................................................................9050-33-50
Function Continues to Activate After Returning to Neutral....................................................................9050-33-51
Lift Function Is Slow or Does Not Function (Manual Valve)..................................................................9050-33-52
Tilt Back Function Will Not Operate (Manual Valve)............................................................................. 9050-33-55
Tilt Forward or Tilt Back Will Not Function When Activated (Manual Valve).........................................9050-33-56
No Steering (All Other Hydraulic Functions OK)................................................................................... 9050-33-57
Steering Is Slow or Difficult................................................................................................................... 9050-33-59
Steering Operation Is Not Smooth........................................................................................................ 9050-33-61
Steering Wheel End Lock Position Cannot Be Felt by Operator...........................................................9050-33-63
Steering Wheel Turns By Itself or Does Not Return To Neutral............................................................9050-33-64
Steering Wheel Turns the Tires in the Wrong Direction........................................................................9050-33-66
Actuations Do Not Act Simultaneously..................................................................................................9050-33-67
Oil Leaking/Component Life Too Short................................................................................................. 9050-33-68
Abnormal Steer Axle Noise................................................................................................................... 9050-33-71
Abnormal Steering Wheel Vibration...................................................................................................... 9050-33-73
Back Lash/Kick Back in Steering Wheel............................................................................................... 9050-33-74
Group 43 - Tests and Adjustments-Gear Pump
Hydraulic Warm-up Procedure................................................................................................................9050-43-1
Primary Relief Valve Test and Adjustment..............................................................................................9050-43-2
Secondary Relief Valve Test and Adjustment.........................................................................................9050-43-6
Hydraulic Pump Flow Test.................................................................................................................... 9050-43-11
Main Control Valve LS Leakage Test (E-Valve)....................................................................................9050-43-13
Main Control Valve Unloader Margin Test............................................................................................ 9050-43-13
E-Hydraulic Valve Leakage Test...........................................................................................................9050-43-14
Steering Relief Pressure Test and Adjustment..................................................................................... 9050-43-18
Steering Control Unit LS Pressure Test................................................................................................ 9050-43-22
Lift Cylinder Leakage Test.................................................................................................................... 9050-43-23
Tilt Cylinder Leakage Test.................................................................................................................... 9050-43-26
Steering Cylinder Leakage Test............................................................................................................9050-43-29

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Hydraulic Systems Principles of Operation

Group 10

Principles of Operation

Manual Hydraulic Main Control Valve

DESCRIPTION The system consists of the following components:
• Manual Hydraulic Control Valve
The manual main control valve controls the lift, tilt,
and auxiliary functions. The main control valve is in- • Vehicle Master Controller
stalled to the right of the operator, below the floor • Hydraulic Pump Motor Controller
plate. • Dash Display

The sections are held together with four through bolts • Pump Motor and Fixed Displacement Gear
and nuts. Each function of the main control valve is Pump
made as a separate section having a spool and valve • Operator's Seat and Armrest
body. Each valve body casting is the same. The con- • PC Based Service Software (ETACC)
trol spools are different for each function. Other sec-
tions are added to the main control valve to control See Figure 9050-10-1 for component location.
optional auxiliary functions.
The manual hydraulic main control valve incorporates
Each spool has a spring that returns the spool to the an emergency (manual) lowering valve. This valve al-
neutral position when the control lever is released. lows the operator or service technician to lower the lift
Each valve section has a check valve in the valve truck's mast assembly if the electrical power to the lift
body. The check valve and spring is held in the valve truck is disrupted.
body by the next section.
The vehicle master controller, manual control levers,
This section will cover the principles of operation for and hydraulic pump motor controller communicate
two different types of manual hydraulic control valves. with each other via the CANbus communication sys-
The open center type valve and the closed center tem. The master controller controls the hydraulic
type valve. For the control valve used on J1.5-2.0XNT pump motor and the control valve based upon the in-
(J30-40XNT) (K160), J1.6-2.0XN (J30-40XN) (A935), puts received from the manual control levers. The
and E1.6-2.0XN (E30-40XN) (A269) A1.3XNT, master controller converts the operator's input into
A1.5XNT (A25XNT, A30XNT) (D203) , see General controlled oil flow by simultaneously commanding the
Description (Open Center Valve). For the control hydraulic pump motor controller to deliver a specific
valve used on E2.2-3.5XN (E45-70XN) (A268) and motor speed, and by commanding the manual hy-
J2.2-3.5XN (J45-70XN) (A276) , see General Descrip- draulic valve to deliver specific valve metering. Pump
tion (Closed Center Valve). speed is variable up to the maximum speed preset in
the master controller for the required hydraulic func-
MANUAL HYDRAULIC CONTROL tion.
SYSTEM
The manual hydraulic control system controls all hy-
draulic functions, to include, lift/lower, tilt, and auxili-
ary functions.

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Principles of Operation Hydraulic Systems

1. HORN BUTTON 10. EMERGENCY DISCONNECT SWITCH

2. ACCELERATOR PEDAL 11. DIRECTION CONTROL SWITCH
3. DISPLAY PANEL 12. BRAKE PEDAL
4. KEY SWITCH AND KEYLESS SWITCH 13. AUTOMATIC PARKING BRAKE MANUAL
5. LIGHT SWITCHES OVERRIDE HANDLE (OPTIONAL)
6. LIFT/LOWER CONTROL LEVER 14. STEERING WHEEL
7. TILT CONTROL LEVER 15. STEERING COLUMN TILT MEMORY LEVER
8. CONTROL LEVER FOR AUXILIARY HY- 16. MONOTROL® FOOT PEDAL CONTROL PEDAL
DRAULIC FUNCTIONS (3RD LEVER)
9. CONTROL LEVER FOR AUXILIARY HY-
DRAULIC FUNCTIONS (4TH LEVER)

Figure 9050-10-1. Operator Station Components

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Hydraulic Systems Principles of Operation

GENERAL DESCRIPTION (OPEN CENTER FEATURES AND OPERATION

VALVE)
INLET ASSEMBLY
CONSTRUCTION
Construction and Purpose
The valve assemblies for this application contain an
inlet section, a lift section, a tilt section, an auxiliary Inlet assemblies provide the majority of the port con-
section, and an outlet section. Some valve assem- nections used to connect various lines of the hydraulic
blies may include a dual (2nd) auxiliary section. All circuit to the valve. All inlet assemblies include a prior-
valves are assembled using tie rods and hex nuts. O- ity spool for the steering circuit and a main relief valve
ring seals are placed between the various sections to to protect the pump from over pressurization. The
prevent external fluid leakage between the sections. housing is grey iron, and the major internal compo-
nents are made of various types of steel.
VALVE TYPE
Porting
The valve assemblies are open-center type valve
used in conjunction with a fixed displacement pump. The inlet housing provides ports for the pump in (P),
A fixed displacement pump will provide a fixed tank (T), steer supply (S), steer return (ST), steer load
amount of fluid with each revolution of the pump shaft. sense (SL), and pump pressure (PG).
For example, if a 1 cubic inch per revolution pump is
rotated at 1000 revolutions per minute, the pump out-
put will be 1000 cubic inches per minute (1 cubic
inch/rev x 1000 rev/min = 1000 cubic inches/min =
4.329 gal/min). In open center type valves, flow is
passed through an open center core from the inlet
port to the outlet port of the valve when all the spools
are in the neutral (non-shifted) position. When a spool
is shifted, flow is directed to the selected work port of
the section and/or sections shifted. In open center
systems fluid will follow the path of least resistance,
meaning flow will be directed to the lowest load re-
quirement when two or more valve spools are shifted.
If flow is required by two or more sections at the same
time, the operator generally must adjust the travel of
1. LIFT
each spool to get the desired flow rate from both work 2. TILT
sections. See Figure 9050-10-2. 3. AUXILIARY #1

Figure 9050-10-2. Basic Open Center Circuit

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Principles of Operation Hydraulic Systems

Priority Steer rected through the valve assembly via the open cen-
ter core, across the work section spools to the outlet
Pump flow is directed across the priority spool before (T) port. See Figure 9050-10-3.
supplying flow for any downstream demands. There-
fore, the steering circuit has priority over any down- Relief Cartridge
stream flow demands. Priority steering is accom-
plished by using a normally open spring biased spool. The primary function of a system relief valve is to pre-
Pump flow is directed across the priority spool to the vent excessive system pressure. This valve assembly
steer port (S). If the steering control unit is not in use, uses a direct acting relief cartridge and it is sized to
there is no load sense signal communicated to the SL pass total pump flow. The relief cartridge is in parallel
port from the steering control unit. The inlet pressure with the pump inlet port. This design limits pressure to
(PG) will increase just enough to overcome the prior- a predetermined level equal to the force generated by
ity spool’s spring force. Since the inlet pressure is the relief spring. Inlet pressure is communicated
communicated to the blind end of the priority spool, through the relief body to the nose area of the poppet.
via the drilled passages within the spool, the spool will When the force caused by pressure acting on the
shift towards the spring end and flow to the steering nose end of the poppet exceeds the force generated
unit will decrease and pump flow will be directed by the spring, the poppet will move towards the relief
across the priority spool into a downstream (open spring. Pump flow is then directed through the holes
center) core. If there is a flow demand from the steer- in the relief cartridge body and the poppet to the outlet
ing unit, the load sense signal coming from the steer- side of the relief cartridge body. The outlet side of the
ing control unit is communicated to the spring end of cartridge is tied to the tank port (T) of the inlet assem-
the spool via the SL port. This increase in pressure bly. If the pressure acting on the nose of the poppet
will cause the spool to shift towards the blind end and decreases, the spring force will cause the poppet to
flow to the steer (S) port will increase to meet the de- move towards the nose end closing the outlet path.
mands of the steering control unit. The downstream When actively relieving pressure, the inlet pressure
core coming from the priority spool is directed to the (PG) will be slightly greater than the force generated
open center core of the valve assembly. If none of the by the relief spring.
work section spools are shifted, total pump flow is di-

1. OPEN CENTER CORE

2. RELIEF CARTRIDGE
3. PRIORITY STEER SPOOL
4. SPRING
Figure 9050-10-3. Cross-Sectional View of Inlet Assembly

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Hydraulic Systems Principles of Operation

LIFT SECTION When the spool is in neutral, flow passes through the
open-center (OC) core and then to the next work sec-
Construction tion. If all the work section spools are in neutral, the
flow will be directed to the tank (T) port in the inlet
The lift section major components include: the hous- section. When the lift spool is shifted out of the hous-
ing, a main spool, an operator presence solenoid ing, the open-center passage (OC) closes off, and
(OPS), a spool position sensor, a load check valve flow is directed through power core at the inlet to the
assembly and a manual emergency lowering car- load check assembly into the high pressure bridge
tridge. core. From the high pressure bridge core the flow is
directed across metering notches of the spool, and
Purpose out work port A to the lift cylinder and raises the mast.
Shifting the spool into the housing from neutral con-
The purpose of the lift section is to allow for extending nects work-port A to the tank core of the housing, thus
and retracting of the vehicle’s lift cylinder. The lift sec- allowing lowering of the mass. When lowering the
tion uses a 3-way spool for raising and lowering the mast, the open center core is open and directs flow to
mast and incorporates an Operator Presence Sole- downstream functions. This allows other downstream
noid (OPS) to help improve operator safety. SeeFig- functions to be used when lowering the mast.
ure 9050-10-4.

1. MAST LOWER CARTRIDGE

2. LOAD CHECK
3. OPERATOR PRESENCE SOLENOID
4. SPOOL POSITIONER
5. POSITION SENSOR
6. TANK CORE
7. OPEN CENTER CORE
8. POWER CORE
9. MAIN SPOOL
10. TANK CORE

Figure 9050-10-4. Cross-Section of Lift Section

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Principles of Operation Hydraulic Systems

Load Check

The load-check assembly prevents back flow from the

work ports under heavy load conditions. If the load
check assembly was absent, under a heavy load con-
dition the load would lower or drift when the spool is
actuated, until the pressure builds to a sufficient level
to move the load. Some drifting may occasionally oc-
cur since the load check assembly is not a zero leak
device. See Figure 9050-10-5.

1. OPERATOR PRESENCE SOLENOID

2. SPOOL EXTENSION

Figure 9050-10-6. Cross-Section of Operator

1. POPPET
2. POWER CORE Presence Solenoid
3. BRIDGE CORE
Position Sensor Assembly
Figure 9050-10-5. Cross Section of Load Check
Assembly The position sensor monitors the travel of the valve
spool and produces a variable output signal relative to
Operator Presence Solenoid how far the spool is from its neutral position. The vehi-
cle’s electronics supplies the sensor with a 5 volt dc
The Operator Presence Solenoid (OPS) has a spring signal. When the spool is in its’ neutral position, the
loaded plunger which extends into an extension at- sensor output will be approximately 2.5 volts dc. As
tached to the spool when de-energized. The plunger the spool is shifted from neutral, the sensor’s output
keeps the spool from moving when no electrical voltage will increase or decrease depending upon the
power is supplied to the solenoid’s coil. When power direction of spool travel. The output signal from the
is supplied to the coil, a force is generated which pulls sensor is used by the vehicle’s electronic control sys-
the plunger upward and out of the spool extension. tem to vary the hydraulic pump flow. The intent is to
Once the plunger disengages, the spool can be meet predetermined function speed requirements.
moved out of its neutral position. See Fig- See Figure 9050-10-7.
ure 9050-10-6.

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Hydraulic Systems Principles of Operation

1. SPRING
2. POSITION SENSOR

Figure 9050-10-7. Cross-Section of Position Sensor

Mast Lowering Cartridge handle on the cartridge clockwise will shut the valve
and turning it counter clockwise will open the valve.
The lift section housing incorporates a manual oper- The cartridge is intended to be used only in emer-
ated needle valve cartridge which allows the “A” work gency situations to lower the mast. See Fig-
port to be directly connected to the tank core in the ure 9050-10-8.
housing. When viewed from the lever end, turning the

1. WORK PORT AREA

2. TANK CORE AREA

Figure 9050-10-8. Cross-Section of Manual Lower Valve Cartridge

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Principles of Operation Hydraulic Systems

TILT SECTION When the spool is in neutral, flow passes through the
open-center (OC) core and then down stream to the
Construction next work section. If all the work section spools are in
neutral, flow will be directed to the tank (T) port in the
The tilt section major components include: the hous- inlet section.
ing, a main spool, a tilt lock spool, an operator pres- • Tilt Backward When the tilt spool is shifted out
ence solenoid, a spool position sensor and a load of the housing, the open-center (OC) core is
check valve assembly. closed off and flow is directed via the power
core through the load check assembly, into the
Purpose high pressure bridge core. From the high pres-
sure bridge core the flow is directed out work
The purpose of the tilt section is to extend and retract port B to the rod end of the tilt cylinders. The
the tilt cylinders, with an integrated “tilt-lock” shuttle flow from the base end of the tilt cylinders re-
spool which controls output flow when tilting the mast turns to the opposite work port (A), across me-
forward. The main function of the “tilt-lock” is that if tering notches in the main spool, and to the
the pump is not providing flow, the tilt cylinders will tank passage, thus tilting the mast backward.
not extend. The tilt section uses a 4-way spool for tilt-
ing the mast forward and backward and incorporates
an Operator Presence Solenoid (OPS) to help im-
prove operator safety. See Figure 9050-10-9.

1. LOAD CHECK
2. POWER CORE
3. OPERATOR PRESENCE SYSTEM
4. SPOOL POSITIONER
5. POSITION SENSOR
6. TILT LOCK SHUTTLE SPOOL
7. OPEN CENTER CORE
8. MAIN SPOOL

Figure 9050-10-9. Cross-Section of Tilt Section

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Hydraulic Systems Principles of Operation

• Tilt Forward During tilt forward operation, the Some auxiliary sections may include a spool lock sol-
internal “tilt-lock” shuttle spool helps to control enoid device which is the same as an operator pres-
unintended increases in forward tilt speed. ence solenoid assembly.
When the tilt spool is shifted into the housing,
the open-center (OC) core is closed off and Purpose
flow is directed via the power core through the
load check valve to the high pressure bridge The auxiliary section is used to control various attach-
core. The pressure is sensed at the base of the ments that can be installed on the vehicle. See Fig-
tilt-lock shuttle spool, sliding the shuttle spool ure 9050-10-10.
open against the spring. From the high pres-
sure bridge core the flow is directed out work When the spool is in neutral, flow passes through the
port A to the base end of the tilt cylinders. Flow open-center (OC) passage and downstream to the
from the rod end of the tilt cylinders returns to tank port of the valve.
the opposite work port (B), directed inside the
main spool, and metered out through holes in When the spool is actuated in or out, the open-center
the main spool to the tank core. If the pump is (OC) flow path is blocked off and forces the flow
not providing flow, there is no pressure at the through power core across the load check valve into
base end of the tilt-lock shuttle spool, and the the high pressure bridge core. From the high pressure
shuttle spool will not move. Under this condi- bridge core, the oil is directed out the selected work
tion, if the main spool is shifted, the tilt-lock port (3A or 3B for three-function valve, 3A, 3B, 4A, or
shuttle spool blocks off the internal passage of 4B for four-function valve) to the auxiliary attachment.
the spool, preventing flow from work port B to Oil returns from the auxiliary attachment to the oppo-
the tank core, therefore the mast will not tilt for- site work port in that section and is directed to the
ward. Since these are not zero-leak devices, tank passage.
some cylinder drift may occur.

AUXILIARY AND DUAL AUXILIARY SECTION

Construction

Auxiliary and/or a dual auxiliary section major compo-

nents include: the housing, a main spool, a spool po-
sition sensor, and a load check valve assembly.

1. LOAD CHECK 5. POSITION SENSOR

2. BRIDGE CORE 6. OPEN CENTER CORE
3. WORK PORT OPTION PLUG 7. POWER CORE
4. SPOOL POSITIONER 8. MAIN SPOOL
Figure 9050-10-10. Cross-Section Dual Auxiliary Section

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Principles of Operation Hydraulic Systems

HYDRAULIC OIL COOLER OUTLET COVER SECTION

Construction and Purpose Construction and Purpose

The hydraulic oil cooler option consist of an oil cooler, The outlet cover connects the open-center to the ex-
hydraulic oil temperature switch, two 12 volts fans and haust core, and has an optional Tank port, which is
shroud, and support bracketry. The purpose of the hy- plugged. The dual exhaust cores routed through the
draulic oil cooler is to keep hydraulic oil temperature previous work-sections are joined together in the out-
to the hydraulic tank no greater than 60°C (140°F). let. See Figure 9050-10-12.

Operation

The hydraulic oil cooler is in series with hydraulic sup-

ply circuit, between the filter assembly and main con-
trol valve. See Figure 9050-10-11. The cooling fans
are triggered when the hydraulic oil temperature
switch senses a hydraulic oil temperature of a
60°C (140°F).

1. TANK CORE
2. OPTIONAL TANK PORT

Figure 9050-10-12. Cross Section of Outlet Cover

A. DIRECTION OF AIR FLOW

1. HYDRAULIC OIL TEMPERATURE SWITCH
2. SHROUD
3. HYDRAULIC OIL COOLER
4. RETURN HOSE- FROM MAIN CONTROL
VALVE
5. FANS
6. RETURN HOSE - TO HYDRAULIC TANK

Figure 9050-10-11. Hydraulic Oil Cooler

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Hydraulic Systems Principles of Operation

GENERAL DESCRIPTION (CLOSED the pump output will be 1000 cubic inches per minute
CENTER VALVE) (1 cubic inch/rev x 1000 rev/min = 1000 cubic
inches/min = 4.329 gal/min). These load sense type
CONSTRUCTION valves (VAL) direct flow to a closed center passage-
way called a power core. Flow is blocked from going
Valve assemblies for this application are manually out the work ports when the main spools, located
shifted. All valve assemblies include an inlet section, within the sections are in the neutral position. Shifting
a lift section, a tilt section, and an auxiliary section. a spool directs flow to the selected work port. In these
Some valve assemblies may include a second dual valves, internal passageways in conjunction with shut-
auxiliary section. All valves are assembled using tie tle valves, direct the highest loads pressure signal
rods and hex nuts. O-ring seals are placed between (load sense pressure) back to an unloading spool lo-
sections to prevent external fluid leakage. cated in the inlet. Using an unloading spool allows the
use of a fixed displacement pump, but incorporates
VALVE TYPE the advantages of a load sensing circuit (system pres-
sure slightly above the load requirement and flow to
Valves supplied are closed center load sense type. match the loads’ demand). If flow is simultaneously
The valves are used with a fixed displacement pump. required by two or more work sections, the operator
A fixed displacement pump will provide a fixed must adjust the travel of each spool to get the desired
(known) amount of fluid with each revolution of the flow rate from each work section. See Fig-
pump shaft. For example, if a 1 cubic inch per revolu- ure 9050-10-13.
tion pump is rotated at 1000 revolutions per minute,

1. INLET 3. TILT
2. LIFT 4. AUXILIARY #1

Figure 9050-10-13. Load Sense Control Valve With Unloader and Priority Steering

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Principles of Operation Hydraulic Systems

FEATURES AND OPERATION Priority Steer

INLET ASSEMBLY Pump flow is directed across a priority spool before

supplying flow to any downstream functions. The
Construction and Purpose steering circuit flow demand has priority over any
downstream flow requirements. Priority steering is ac-
Inlet assemblies provide the majority of the porting complished by using a normally open spring biased
connections to connect various lines of the hydraulic spool. Pump flow is directed across the priority spool
circuit. All inlet assemblies for this type of valve in- to the steer port (S). If the steering control unit is not
clude a priority steering spool to control flow to the in use, there is no load sense signal communicated to
steer unit, a main relief valve to protect the pump from the SL port from the steering control unit. The inlet
over pressurization, and an unloading spool to unload pressure (P) will increase to overcome the priority
(dump to tank) any excess pump flow. spring force. The inlet pressure is communicated to
the blind end of the priority spool via the drilled pas-
Porting sages within the spool, the spool will shift towards the
spring end and flow will be directed across the spool
Port sizes vary based upon flow requirements and to a downstream core leading to the unloading spool.
features within each inlet assembly. All inlets provide If there is a flow demand at the steer (S) port, the load
connections for: pump (P), tank (T), steer supply (S), sense signal coming from the steering control unit is
steer return (ST), load sense signal coming from the communicated to the spring end of the spool via the
steering control unit (SL), pump pressure (PG), load SL port. This increase in pressure will cause the spool
sense gage port (LSG) coming from the work sec- to shift towards the blind end and flow to the steer (S)
tion’s shuttle circuit, and reduced pressure gage port port will increase to meet the demands of the steering
(BG). If a hydraulic brake option is required, ports are control unit. See Figure 9050-10-14.
provide for the brake supply (PB) and the brake return
(PBT). Be aware that the PB port is exposed to full
system pressure.

1. STEER UNIT OUTLET

2. PUMP INLET
3. UNLOADER SPOOL OUTLET
4. PRIORITY SPOOL
5. STEER LS PORT

Figure 9050-10-14. Cross-Section of Priority Steering Layout

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Hydraulic Systems Principles of Operation

If no work section spools are shifted, total pump flow side of the unloading spool is communicated to the
is directed across an unloading spool to the outlet (T) blind end of the unloading spool via the internal path-
port. way drilled within the spool. Pressure (PG) will rise
until it overcomes the force generated by the unload-
Unloading Spool and Relief Cartridge ing spring and the unloading spool will shift towards
the spring end. Flow will then be directed across the
The primary function of a relief cartridge is to prevent unloading spool and into a core that connects to the
excessive system pressure. The relief cartridge works tank (T) port of the inlet.
in conjunction with an unloading spool. The unloading
spool directs excess flow (not required by any selec- If a steering load demand is present in the priority
ted functions) back to tank (T). The advantage of this spring chamber (LS area), the inlet pressure will rise.
system is that a fixed (positive displacement) pump The priority spool will shift towards its blind end to
can be utilized. When there is no load from the steer- meet the demand. If required, flow to the steer (S)
ing control unit or the work sections, the pump will un- port will increase and flow available to the core feed-
load at a pressure which is only slightly higher than ing the unloading spool will decrease. If no work sec-
that required to overcome the forces generated by the tion spools are shifted, the unloading spool will con-
priority spring and the unloading spring plus any pres- tinue to unload any flow not required by the steering
sure losses. See Figure 9050-10-15. control unit to the tank (T) port.

The flow from the downstream side of the priority

spool is directed to the unloading spool and to the
downstream work sections. Pressure at the P port

1. STEER UNIT OUTLET

2. PUMP INLET
3. TANK CORE AREA
4. UNLOADING SPOOL
5. LOAD SENSE RELIEF CARTRIDGE
6. LOAD SENSE ORIFICE
7. PRIORITY SPOOL
8. LS FROM STEER UNIT

Figure 9050-10-15. Cross-Section of Unloading Spool Layout

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Principles of Operation Hydraulic Systems

When a downstream work function spool is shifted, in- ways within the lift section communicate the loads’
ternal passages (load sense shuttle circuit) of the pressure back to the spring chamber of the unloading
valve assembly will communicate the pressure gener- spool and the unloading spool shifts to meet the flow
ated by the load at the work section port to the spring demand of the work section, any excess pump flow is
end of the unloading spool. Pump pressure will rise to unloaded to the tank (T) port. If more than one work
meet the demand coming from the work section and section spool is shifted (downstream of lift function), a
the unloading spool will shift towards its blind end and load sense shuttle circuit allows only the highest load
restrict the amount of flow to the tank (T) port. If the pressure to be communicated to the unloading spool.
pressure in the spring chamber of the unloading spool This allows the pump pressure to raise enough to
is high enough to overcome the force generated by meet the highest load demand. The shuttle valve as-
the relief spring on the relief poppet, the poppet will sembly is physically located within each work section
open and limit the system pressure. The relief’s spring on the mating face between the sections. See Fig-
chamber is vented to the tank (T) port via internal ure 9050-10-17.
passages within the inlet housing. It should be noted
that the load sense/unloading spool design does not Load Check
limit the pressure in the steer control unit. The steer
control unit incorporates its own relief to control maxi- When there is a flow demand at the work section
mum pressure. (main spool is shifted), flow traveling through the
power core will communicate the pressure within the
LIFT SECTION power core to the blind end of the load check spool
via holes drilled into the spool. Once the pressure is
Purpose high enough to overcome the force caused by the
spring at the other end of the spool, the spool will shift
The purpose of the lift section housing is to allow for towards the spring end and flow will pass across the
extending and retracting of vehicle’s lift cylinder load check spool. Pressure within the downstream
(mast). core (feeding the main spool) is communicated to the
spring end of the spool via drilled holes within the load
Operation - Main Spool check spool. If the pressure on the downstream side
of the load check spool increases too much, the load
The lift section uses a 3-way spool for raising and check spool will shift towards the blind end and flow
lowering the mast. When all the spools of the valve across the check will be restricted. If pressure within
assembly are in neutral (no flow requirement), pump the power core decreases, pressure at the blind end
flow comes into the inlet, travels across the priority of the spool will decrease and the spring will try to
spool and into the power core which directs flow to close the check spool, thus flow across the spool will
the various work sections. Since the power core is be restricted. It should be noted that the load check
blocked (no spools shifted) at the last work section of spool is not a zero leak device. It will not completely
the valve stack (thus called closed center type), flow stop flow if a line were to break or if a leak develops
is directed across the unloading spool, located in the between the work port and the cylinder. It will de-
inlet section to the tank (T) port. See Fig- crease the flow output to the work port, but it will not
ure 9050-10-16. do anything to restrict the flow coming from the cylin-
der. The main purpose of the load check is to reduce
When the lift spool is shifted to raise the mast (spool the amount of cylinder drift when shifting the main
moved outward of the housing), flow travels from the spool from the raise to lower position. See Fig-
inlet via the power core, across the load check spool, ure 9050-10-18.
across the lift spool, and out work port A. Passage-

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Hydraulic Systems Principles of Operation

1. POSITION SENSOR
2. OPERATOR PRESENCE SOLENOID
3. BRIDGE CORE
4. WORK PORT
5. MANUAL LOWERING VALVE
6. LIFT SPOOL
7. TO LS SHUTTLE
8. POWER CORE
9. LOAD CHECK SPOOL

Figure 9050-10-16. Cross-Section of Manual Lift Section

Legend for Figure 9050-10-17

1. LS SIGNAL FROM DOWNSTREAM WORK SEC-

TION
2. O-RING
3. SHUTTLE BALL
4. SEAT
5. FROM WORK CURRENT SECTION LS PICKUP
6. TO INLET UNLOADING SPOOL

Figure 9050-10-17. Cross-Section of Shuttle Valve

Assembly

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Principles of Operation Hydraulic Systems

1. POWER CORE
2. LOAD CHECK SPOOL
3. DOWNSTREAM CORE
4. LOAD CHECK SPRING

Figure 9050-10-18. Cross-Section of Load Check Assembly

Operator Presence Solenoid

The Operator Presence Solenoid (OPS) has a spring

loaded plunger which extends into an extension at-
tached to the main spool. The plunger keeps the
spool from moving when no electrical power is sup-
plied to the solenoid’s coil. When power is supplied to
the coil, a force is generated which pulls the plunger
upward and out of the spool extension. Once the
plunger disengages, the spool can be moved out of its
neutral position. See Figure 9050-10-19

1. OPERATOR PRESENCE SOLENOID

2. SPOOL EXTENSION

Figure 9050-10-19. Cross-Section of Operator

Presence Solenoid

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Hydraulic Systems Principles of Operation

Position Sensor tral position, the sensor output will be approximately

2.5 volts DC. As the spool is shifted from neutral, the
The position sensor monitors the position of the valve sensor’s output voltage will increase or decrease de-
spool and produces a variable output signal relative to pending upon the direction of spool travel. The output
how far the spool has traveled from its neutral posi- signal from the sensor is used by the vehicle’s elec-
tion. The vehicle’s electronics supplies the sensor tronic control system to vary the hydraulic pump flow.
with a 5 volt DC signal. When the spool is in its neu- The intent is to meet predetermined function speed
requirements. See Figure 9050-10-20.

1. POSITION SENSOR
2. SPRING
Figure 9050-10-20. Cross-Section of Position Sensor Assembly

Mast Lowering Cartridge

The lift section housing incorporates a manual oper-

ated needle valve cartridge which allows the “A” work
port to be directly connected to the tank core. When
viewed from the hex end, turning the handle on the
cartridge clockwise will shut the valve and turning it
counter clockwise will open the valve. The cartridge is
intended to be use only in an emergency situation to
lower the mast. See Figure 9050-10-21.

Figure 9050-10-21. Cross-Section of Manual

Lowering Cartridge

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Principles of Operation Hydraulic Systems

TILT SECTION Since the flow in the power core is available to any
sections downstream of the tilt section, pressure to
Construction and Purpose sections downstream of the lift function will be limited
to the setting of the relief cartridge located in the pres-
The tilt section includes a pressure reducing valve as- sure reducing/load check assembly of the lift section.
sembly, a relief cartridge, a main spool assembly, an See Figure 9050-10-22.
operator presence solenoid (OPS), a position sensor
assembly, and a load sense shuttle assembly. The Main Spool with Tilt-Lock
operator presence solenoid, the position sensor and
the load sense shuttle assembly are the same as in The section’s main spool is shifted with manual input
the lift section and operate the same. The tilt section’s from the operator. The main spool is a 4 way type,
purpose is to allow for extending and retracting of ve- meaning that flow is available to both the A and B
hicle’s tilt cylinders. The major difference in this sec- work ports versus only the A port (3-way spool) in a
tion versus a lift section is that the load check assem- lift section. Shifting the main spool out of the housing
bly has an additional feature of a pressure reducing will pressurize work port B (tilt back) and shifting the
spool assembly and the addition of an internal “tilt- main spool into the housing will pressurize work port
lock” shuttle spool located inside a 4-way main spool. A (forward tilt). The main spool assembly contains an
The purpose of the pressure reducing assembly is to internal “tilt-lock” spool which is active only in the tilt
restrict the maximum pressure available to the tilt sec- forward direction.
tion and any downstream sections. The purpose of • Tilt Back
the load check feature is to prevent the forks from tilt- Actuating the main spool to the tilt back posi-
ing forward before they are commanded to tilt back. tion (B port pressurized) sends a load-sense
The main spool’s purpose is to direct flow to the sec- signal to the unloading spool located in the in-
tion’s work ports when the spool is shifted out of neu- let cover. The unloading spool in the inlet
tral. The purpose of the “tilt-lock” shuttle spool is to closes and flow is directed to the power core.
limit unanticipated forward tilting (runaway condition) Flow from the power core is directed across
of the mast when trying to tilt back. The tilt-lock shut- the pressure reducing/load check spool assem-
tle spool also prevents forward tilt of the mast when bly and travels to the main spool via a feed
the hydraulic pump is not running. core. Flow travels across the main spool into
the bridge core and is directed out of work port
Operation B. This “meter-in” flow is out the B workport to
the rod end of the cylinder and “meter-out” flow
The pressure reducing/load check assembly consists is from the base end of the cylinder to the A
of a spool and two springs. Flow enters the tilt section port. Return flow from the tilt cylinder(s) is
via the power core and is directed across the pres- routed through work port A across the main
sure reducing/load check spool. The pressure reduc- spool into the tank core of the housing. Flow in
ing/load check spool is held in the normally open posi- the tank core is directed through the valve sec-
tion by the springs. Pressure downstream of the spool tions back to the tank (T) port located in the in-
is communicated to both ends of the spool via the let section.
holes drilled into the pressure reducing/load check
spool. Once the pressure on the blind end of the • Tilt Forward
spool is high enough, it will override the force gener- During tilt forward operation, the internal “tilt-
ated by the springs and the spool will shift towards the lock” shuttle spool helps to control any uninten-
spring end, thus limiting the pressure on the down- ded increase in forward tilt speed. When the tilt
stream side of the spool to balance the force of the spool is shifted into the housing (A work port
springs plus the pressure on the downstream side of pressurized), the unloading spool in the inlet
the pressure reducing/load check spool feeding the closes and flow becomes available to the work
main spool. The lighter spring is used to limit the load sections. Flow travels from the power core
check pressure setting and the heavier spring is used across the pressure reducing/load check spool
to limit the reduced pressure setting. A relief cartridge into the main spool feed core. Flow travels
(same as the load sense relief in the inlet assembly) across the main spool into the bridge core.
is utilized to limit the maximum pressure on the down-
stream side of the pressure reducing spool.

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Hydraulic Systems Principles of Operation

Flow passes across the main spool and out the allows the tilt-lock spool to act like a counter-
A work port. This flows into the base end of the balance valve to keep the forks from running
cylinder is known as “meter-in” flow. Return away from the meter-in supply. If the load cau-
flow from the tilt cylinder(s) is directed into the ses the tilt to move forward too fast, the tilt-lock
B work port. Return flow is known as “meter- spool will lose the pilot signal from the meter-in
out” flow. Pressure in the bridge core and the A supply on the opposing work port, therefore
work port is communicated through cross holes preventing movement or ultimately slowing the
in the main spool to the blind end of the “tilt- flow rate so the meter-in flow can maintain the
lock” spool. The tilt spool shifts toward the proper pilot signal to the tilt-lock spool. If the
spring end and flow in work port B is throttled pump is not providing flow, there is no pressure
across the tilt-lock spool into the tank core. If at the blind end of the tilt-lock spool, and the
pressure seen at the blind end of the tilt-lock spool will not open to allow flow to the tank
spool decreases enough, the spring will force core. Therefore the tilt cylinder(s) should not
the tilt-lock spool to shift towards the blind end move. Since the tilt-lock spool and the main
and flow from work port B crossing the tilt-lock spool are not zero-leak devices, some cylin-
spool into the tank core will be restricted. This der(s) drift may occur.

1. POSITION SENSOR
2. OPERATOR PRESENCE SENSOR
3. TILT SPOOL
4. BRIDGE CORE
5. FEED CORE
6. TANK CORE
7. MAIN SPOOL
8. PRESSURE REDUCING LOAD CHECK SPOOL
9. POWER CORE
10. SPRING
11. RELIEF CARTRIDGE

Figure 9050-10-22. Cross-Section of Manual Tilt Section

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Principles of Operation Hydraulic Systems

AUXILIARY AND DUAL AUXILIARY SECTIONS section. Auxiliary sections do not contain a load check
assembly. Main spools are 4-way type, shifting the
Construction and Purpose spool out of the housing will pressurize work port B
and shifting the spool into the housing will pressurize
Auxiliary and dual auxiliary sections housings are work port A. To regulate the output flow of a work
constructed of grey iron and contain internal compo- port, the operator must position the spool until the de-
nents made from various steels. The purpose of auxil- sired flow rate is obtained. Shifting the spool out of
iary sections is to provide flow to any auxiliary func- neutral communicates a load sense signal via the in-
tions (attachments). When more than one auxiliary ternal shuttle circuit to the unloading spool in the inlet.
section is used, the upstream section is labeled as a The unloading spool will shift and direct flow to down-
dual auxiliary section. All valve assemblies contain an stream functions when a load demand is present.
end (single) auxiliary section. Both types of auxiliary
sections contain a 4-way main spool, a position sen- The optional clamp lock feature uses a solenoid and a
sor and a load sense shuttle valve. These compo- plunger assembly to prevent spool movement. This
nents are the same as used on the lift and tilt sections feature is controlled by the vehicle’s electronic con-
and operate the same. Some auxiliary sections in- trols. If there is no electric signal supplied to the coil,
clude an optional clamp lock feature. See Fig- the plunger is forced, via an internal spring within the
ure 9050-10-23. solenoid assembly, into a groove on the spool exten-
sion to prevent movement of the spool. The clamp
Operation lock solenoid assembly is the same part number as
the operator presence solenoid used on other sec-
Both the dual and end auxiliary sections operate the tions. The position sensor assembly is the same as
same. Input flow to all auxiliary sections are down- used on other sections. End auxiliary sections contain
stream of the feed core of the tilt section, therefore an SAE plug (BG port) on the outside surface which
the maximum load pressure is limited to the setting of connects to the power core. Pressure at this port
the relief cartridge used in conjunction with the pres- would represent the pressure setting of the pressure
sure reducing/load check assembly located in the tilt reducing valve assembly located in the tilt section.

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Hydraulic Systems Principles of Operation

1. POSITION SENSOR 4. TANK CORE

2. TANK CORE 5. FEED CORE
3. BRIDGE CORE 6. MAIN SPOOL

Figure 9050-10-23. Cross-Section of Auxiliary Section

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Principles of Operation Hydraulic Systems

E-Hydraulic Main Control Valve

ELECTRO-HYDRAULIC CONTROL • Hydraulic Pump Motor Controller
SYSTEM • Dash Display

The electro-hydraulic control system controls all hy- • Pump Motor and Fixed Displacement Gear
draulic functions, to include, lift/lower, tilt, and auxili- Pump
ary functions. The system consists of the following • Operator's Seat and Armrest
components: • PC Based Service Software
• Electro-Hydraulic Control Valve See Figure 9050-10-24 for component location.
• Mini-Levers
• Vehicle Master Controller

1. HORN BUTTON 10. EMERGENCY DISCONNECT SWITCH

2. ACCELERATOR PEDAL 11. DIRECTION CONTROL SWITCH
3. DISPLAY PANEL 12. BRAKE PEDAL
4. KEY SWITCH AND KEYLESS SWITCH 13. AUTOMATIC PARKING BRAKE MANUAL
5. LIGHT SWITCHES OVERRIDE HANDLE (OPTIONAL)
6. LIFT/LOWER CONTROL LEVER 14. STEERING WHEEL
7. TILT CONTROL LEVER 15. STEERING COLUMN TILT MEMORY LEVER
8. CONTROL LEVER FOR AUXILIARY HY- 16. HYSTER MONOTROL® PEDAL PEDAL
DRAULIC FUNCTIONS (3RD LEVER)
9. CONTROL LEVER FOR AUXILIARY HY-
DRAULIC FUNCTIONS (4TH LEVER)

Figure 9050-10-24. Operator Station Components

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Hydraulic Systems Principles of Operation

The electro-hydraulic main control valve controls the valve assemblies may include a second dual auxiliary
lift, tilt, and auxiliary functions. The electro-hydraulic section and/or a spacer section. All valves are assem-
control valve is installed to the right of the operator, bled using tie rods and hex nuts. O-ring seals are
below the floor plate. The electro-hydraulic main con- placed between sections to prevent external fluid
trol valve incorporates an emergency (manual) lower- leakage.
ing valve. This valve allows the operator or service
technician to lower the lift truck's mast assembly if the Valve Type
electrical signal to the electro-hydraulic main control
valve is disrupted. Valves supplied are closed center load sense type.
The valves can be used with a fixed displacement
The vehicle master controller, mini-levers, and hy- pump. A fixed displacement pump will provide a fixed
draulic pump motor controller communicate with each (known) amount of fluid with each revolution of the
other via the CANbus communication system. The pump shaft. For example, if a 1 cubic inch per revolu-
master controller controls the hydraulic pump motor tion pump is rotated at 1000 revolutions per minute,
and the electro-hydraulic control valve based upon the pump output will be 1000 cubic inches per minute
the inputs received from the mini levers. The master (1 cubic inch/rev x 1000 rev/min = 1000 cubic
controller converts the operator's input into controlled inches/min = 4.329 gal/min). These load sense type
oil flow by simultaneously commanding the hydraulic valves (VAL) direct flow to a closed center passage-
pump motor controller to deliver a specific motor way called a power core. Flow is blocked from going
speed, and by commanding the electro-hydraulic con- out the work ports when the main spools, located
trol valve to deliver specific valve metering. Pump within the sections, are in the neutral position. Shifting
speed is variable up to the maximum speed preset in a function’s spool is accomplished by applying an
the master controller for the required hydraulic func- electrical signal to a solenoid located on either end of
tion. the section. Pilot pressure is supplied by the main
pump, but at a reduced pressure. The pilot supply
This section will cover the principles of operation for pressure is reduced through the use of a pressure re-
two different types of manual hydraulic control valves. ducing pilot cartridge located in the inlet. Shifting a
The open center type valve and the closed center spool directs flow to the selected work port. In these
type valve. For the control valve used on J1.5-2.0XNT valves, internal passageways in conjunction with shut-
(J30-40XNT) (K160), J1.6-2.0XN (J30-40XN) (A935), tle valves, direct the highest load’s pressure signal
and E1.6-2.0XN (E30-40XN) (A269) A1.3XNT, (load sense pressure) back to an unloading spool lo-
A1.5XNT (A25XNT, A30XNT) (D203) , see General cated in the inlet. Using an unloading spool allows the
Description (Open Center Valve). For the control use of a fixed displacement pump, but incorporates
valve used on E2.2-3.5XN (E45-70XN) (A268) and the advantages of a load sensing circuit (system pres-
J2.2-3.5XN (J45-70XN) (A276) , see General Descrip- sure slightly above the load requirement and flow to
tion (Closed Center Valve). match the load's demand). If flow is simultaneously
required by two or more work sections, the operator
GENERAL VALVE DESCRIPTION must adjust the travel of each spool to get the desired
flow rate from each work section. See Fig-
Construction ure 9050-10-25.

Valve assemblies are electro-hydraulically shifted. All

valve assemblies include an inlet section, a lift sec-
tion, a tilt section, and an auxiliary section. Some

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Principles of Operation Hydraulic Systems

1. LIFT 3. SPACER
2. TILT 4. AUXILIARY 1

Figure 9050-10-25. Load Sense Control Valve With Unloader and Priority Steering

FEATURES AND OPERATION Porting

Inlet Section Port sizes vary based upon flow requirements and
features within each inlet section. All inlets provide
Construction and Purpose connections for: pump (P), tank (T), steer supply (S),
steer return (ST), load sense signal coming from the
Inlet section provides the majority of the porting con- steering control unit (SL), pump pressure (PG), load
nections to connect various lines of the hydraulic cir- sense gage port (LSG) coming from the work sec-
cuit. All inlet sections for this type of valve include a tion’s shuttle circuit, reduced pressure gage port (BG)
priority steering spool to control flow to the steer unit, and pilot pressure (PP). If a hydraulic brake option is
a main relief valve to protect the pump from over required, ports are provide for the brake supply (PB)
pressurization, an unloading spool to unload (dump to and the brake return (PBT). Be aware that the PB port
tank) any excess pump flow and a pressure reducing is exposed to full system pressure.
pilot cartridge.

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Hydraulic Systems Principles of Operation

Priority Steer sages within the spool, the spool will shift towards the
spring end and flow will be directed across the spool
Pump flow is directed across a priority spool before to a downstream core leading to the unloading spool.
supplying flow to any downstream functions. The If there is a flow demand at the steer (S) port, the load
steering circuit flow demand has priority over any sense signal coming from the steering control unit is
downstream flow requirements. Priority steering is ac- communicated to the spring end of the spool via the
complished by using a normally open spring biased SL port. This increase in pressure will cause the spool
spool. Pump flow is directed across the priority spool to shift towards the blind end and flow to the steer (S)
to the steer port (S). If the steering control unit is not port will increase to meet the demands of the steering
in use, there is no load sense signal communicated to control unit. See Figure 9050-10-26.
the SL port from the steering control unit. The inlet
pressure (P) will increase to overcome the priority If no work section spools are shifted, total pump flow
spring force. The inlet pressure is communicated to is directed across an unloading spool to the outlet (T)
the blind end of the priority spool via the drilled pas- port.

1. TO STEER UNIT 4. PRIORITY SPOOL

2. FROM PUMP 5. STEER LS PORT
3. TO UNLOADER SPOOL

Figure 9050-10-26. Cross Section of Priority Steering Layout

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Principles of Operation Hydraulic Systems

Unloading Spool and Relief Cartridge The priority spool will shift towards its blind end to
meet the demand. If required, flow to the steer (S)
The primary function of a relief cartridge is to prevent port will increase and flow available to the core feed-
excessive system pressure. The relief cartridge works ing the unloading spool will decrease. If no work sec-
in conjunction with an unloading spool. The unloading tion spools are shifted, the unloading spool will con-
spool directs excess flow (not required by any selec- tinue to unload any flow not required by the steering
ted functions) back to tank (T). The advantage of this control unit to the tank (T) port.
system is that a fixed (positive displacement) pump
can be utilized. When there is no load from the steer- When a downstream work function spool is shifted, in-
ing control unit or the work sections, the pump will un- ternal passages (load sense shuttle circuit) of the
load at a pressure which is only slightly higher than valve assembly will communicate the pressure gener-
that required to overcome the forces generated by the ated by the load at the work section port to the spring
priority spring and the unloading spring plus any pres- end of the unloading spool. Pump pressure will rise to
sure losses. See Figure 9050-10-27. meet the demand coming from the work section and
the unloading spool will shift towards its blind end and
The flow from the downstream side of the priority restrict the amount of flow to the tank (T) port. If the
spool is directed to the unloading spool and to the pressure in the spring chamber of the unloading spool
downstream work sections. Pressure at the (P) port is high enough to overcome the force generated by
side of the unloading spool is communicated to the the relief spring on the relief poppet, the poppet will
blind end of the unloading spool via the internal path- open and limit the system pressure. The relief’s spring
way drilled within the spool. Pressure (PG) will rise chamber is vented to the tank (T) port via internal
until it overcomes the force generated by the unload- passages within the inlet housing. It should be noted
ing spring and the unloading spool will shift towards that the load sense/unloading spool design does not
the spring end. Flow will then be directed across the limit the pressure in the steer control unit. The steer
unloading spool and into a core that connects to the control unit incorporates its own relief to control maxi-
tank (T) port of the inlet. mum pressure.

If a steering load demand is present in the priority

spring chamber (LS area), the inlet pressure will rise.

1. TO STEER UNIT 5. LOAD SENSE RELIEF CARTRIDGE

2. FROM PUMP 6. LOAD SENSE ORIFICE
3. TANK CORE AREA 7. PRIORITY SPOOL
4. UNLOADING SPOOL 8. FROM STEER UNIT
Figure 9050-10-27. Cross Section of Unloading Spool Layout

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Hydraulic Systems Principles of Operation

Pilot Cartridge erated by the spring. The reducing spool is constantly

modulating, and maintains the pilot pressure at the
The pilot cartridge receives flow from the pump and OUT passage based upon the spring force. Any leak-
maintains a constant reduced output pressure to feed age from the OUT side into the spring chamber is
the electro-hydraulic (EH) solenoids of the work sec- vented back to the tank side of the valve assembly.
tions. The supply pressure for the electro-hydraulic See Figure 9050-10-28.
solenoids must be reduced because the solenoids will
not withstand full system pressure. Flow enters the pi- Lift Section
lot cartridge at the IN passage and the OUT pressure
is sensed at the blind end of the reducing spool Construction and Purpose
through holes drilled into the spool. The pressure at
the blind end of the spool will build to match the force The lift section’s purpose is to allow for extending and
generated by the spring. The spool will shift to the left retracting of vehicle’s lift cylinder (mast).
or right to maintain a pressure equal to the force gen-

1. OUT 3. IN
2. TANK

Figure 9050-10-28. Cross Section of Pilot Cartridge

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Principles of Operation Hydraulic Systems

Operation - Main Spool the various work sections. Since the power core is
blocked (no spools shifted) at the last work section of
The lift section uses a 3-way spool for raising and the valve stack (thus called closed center type), flow
lowering the mast. When all the spools of the valve is directed across the unloading spool, located in the
assembly are in neutral (no flow requirement), pump inlet section to the tank (T) port. See Fig-
flow comes into the inlet, travels across the priority ure 9050-10-29.
spool and into the power core which directs flow to

1. EH SOLENOID 6. POWER CORE

2. BRIDGE CORE 7. FEED CORE
3. MAST LOWERING CARTRIDGE 8. LOAD CHECK
4. EH SOLENOID 9. TANK CORE
5. MAIN SPOOL

Figure 9050-10-29. Cross-Section of EH Lift Section

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Hydraulic Systems Principles of Operation

When the lift spool is shifted to raise the mast (sole-

noid on the A port side energized), flow travels from
the inlet via the power core, across the load check
spool, across the lift spool, and out workport A. Pas-
sageways within the lift section communicate the
loads’ pressure back to the spring chamber of the un-
loading spool and the unloading spool shifts to meet
the flow demand of the work section, any excess
pump flow is unloaded to the tank (T) port. If more
than one work section spool is shifted (downstream of
lift function), a load sense shuttle circuit allows only
the highest load pressure to be communicated to the
unloading spool. This allows the pump pressure to
raise enough to meet the highest load demand. The
shuttle valve assembly is physically located within
each work section on the mating face between the
sections. See Figure 9050-10-30.
1. LS SIGNAL FROM WORK SECTION
2. O-RING
3. SHUTTLE BALL
4. SEAT
5. FROM WORK CURRENT SECTION LS PICKUP
6. TO INLET UNLOADING SPOOL

Figure 9050-10-30. Cross-Section View of Shuttle

Valve Assembly

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Principles of Operation Hydraulic Systems

Load Check check spool will shift towards the blind end and flow
across the check will be restricted. If pressure within
When there is a flow demand at the work section the power core decreases, pressure at the blind end
(main spool shifted), flow traveling through the power of the spool will decrease and the spring will try to
core will communicate the pressure within the power close the check spool, thus flow across the spool will
core to the blind end of the load check spool via holes be restricted. It should be noted that the load check
drilled into the spool. Once the pressure is high spool is not a zero leak device. It will not completely
enough to overcome the force caused by the spring at stop flow if a line were to break or if a leak develops
the other end of the spool, the spool will shift towards between the workport and the cylinder. It will de-
the spring end and flow will pass across the load crease the flow output to the workport, but it will not
check spool. Pressure within the downstream core do anything to restrict the flow coming from the cylin-
(feeding the main spool) is communicated to the der. The main purpose of the load check is to reduce
spring end of the spool via drilled holes within the load the amount of cylinder drift when shifting the main
check spool. If the pressure on the downstream side spool from the raise to lower position. See Fig-
of the load check spool increases too much, the load ure 9050-10-31.

1. LOAD CHECK SPRING 3. LOAD CHECK SPOOL

2. POWER CORE 4. DOWNSTREAM CORE

Figure 9050-10-31. Cross-Section View Load Check Assembly

Mast Lowering Cartridge

The lift section housing incorporates a manually oper-

ated needle valve cartridge which allows the “A” work-
port to be directly connected to the tank core. When
viewed from the hex end, turning the handle on the
cartridge clockwise will shut the valve and turning it
counter clockwise will open the valve. The cartridge is
intended to be used only in an emergency situation to
lower the mast. See Figure 9050-10-32.

Figure 9050-10-32. Cross-Section View of Manual

Lowering Cartridge

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Hydraulic Systems Principles of Operation

Electro-Hydraulic (EH) Solenoid solenoids and an anti-cavitation check. The tilt sec-
tion’s purpose is to allow for extending and retracting
Reduced pressure flow coming from the pilot cartridge of vehicle’s tilt cylinders. The major difference in this
located in the inlet, is delivered to the inlet side of section versus a lift section is that the load check as-
each electro-hydraulic (EH) solenoid via internal holes sembly has an additional feature of a pressure reduc-
drilled into the work sections. When an electrical cur- ing spool assembly. The purpose of the pressure re-
rent is applied to the coil, a force is generated by the ducing assembly is to restrict the maximum pressure
coil which moves the pin within the solenoid and in available to the tilt section and any downstream sec-
turn moves the spool in the solenoid assembly. As the tions. The purpose of the load check feature is to pre-
spool moves away from the spring end of the assem- vent the forks from tilting forward before they are
bly, flow is passed from the inlet side to the output commanded to tilt back. The main spool’s purpose is
side of the spool. When the force generated by the to direct flow to the section’s workports when the
pressure acting on the spool area becomes equal to spool is shifted out of neutral.
the force generated by the current acting on the pin of
the solenoid, the spool will close and flow across the Operation
inlet to the outlet will stop. If the current applied to the
solenoid coil is varied, the regulated output pressure NOTE: 1-2 Ton valves do not include the relief car-
will vary to maintain a force balance between the out- tridge, but they do contain the pressure reducing/load
put pressure and the input current. In short, the output check spool. However the valve can be retrofitted with
pressure is a function of input current. a relief cartridge kit when one may be required be-
cause of pressure limitations of auxiliary equipment.
The output pressure from the solenoid assembly is
applied to the end of the main spool of the section be-
ing operated. Once the output pressure from the sole-
noid becomes great enough to overcome the force
generated by the return spring and spool drag, the
main spool will begin to shift. An increase in current at
the solenoid will increase the regulated output pres-
sure acting on the main spool and the spool will shift
further. Due to metering notches located on the main
spool, the flow across the main spool will increase
with an increase in current applied to the solenoid.
Therefore, the output flow of a work section is a func-
tion of input current to the solenoid. Thus the label of 1. INLET
"proportional" is given to the section, since output var- 2. TANK
3. REGULATED OUTPUT PRESSURE
ies as a function of input. See Figure 9050-10-33.
Figure 9050-10-33. Cross-Sectional View of
Tilt Section Electro-Hydraulic (EH) Solenoid

Construction and Purpose

The tilt section includes a pressure reducing valve as-

sembly, a relief cartridge, a main spool assembly, a
load sense shuttle assembly, two electro-hydraulic

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Principles of Operation Hydraulic Systems

The pressure reducing/load check assembly consists load check pressure and the heavier spring is used to
of a spool and two springs. Flow enters the tilt section regulate the reduced pressure setting. A relief car-
via the power core and is directed across the pres- tridge (same as the load sense relief in the inlet as-
sure reducing/load check spool. The pressure reduc- sembly) is utilized to limit the maximum pressure on
ing/load check spool is held in the normally open posi- the downstream side of the pressure reducing spool.
tion by the springs. Pressure downstream of the spool Since the flow into the offset power core is available
is communicated to both ends of the spool via the to any sections downstream of the tilt section, pres-
holes drilled into the pressure reducing/load check sure to sections downstream of the lift function will be
spool. Once the pressure on the blind end of the limited to the setting of the relief cartridge located in
spool is high enough, it will override the force gener- the pressure reducing/load check assembly of the lift
ated by the springs and the spool will shift towards the section. The anti-cavitation check, located next to the
spring end, thus limiting the pressure on the down- A work port become active when the pressure within
stream side of the spool to balance the force of the the work port is lower than the pressure in the tank
springs plus the pressure on the downstream side of core. This allows oil to pass from the tank core into
the pressure reducing/load check spool feeding the the work port to keep air out of the lines and the tilt
main spool. The lighter spring is used to produce the cylinder. See Figure 9050-10-34.

1. BRIDGE CORE 6. FEED CORE

2. ANTI CAVITY CHECK 7. PRESSURE REDUCING LOAD CHECK
3. EH SOLENOID 8. TANK CORE
4. MAIN SPOOL 9. EH SOLENOID
5. POWER CORE

Figure 9050-10-34. Cross-Section of EH Tilt Section

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Hydraulic Systems Principles of Operation

Main Spool to pass to the next work section. The only compo-
nents they contain are common plugs and section
The main spool is a 4-way type, meaning that flow is seals.
available to both the A and B work ports versus only
the A port (3-way spool) in a lift section. Energizing Auxiliary and Dual Auxiliary Sections
the solenoid on the A work port side of the section
shifts the spool to power workport A. Energizing the Construction and Purpose
solenoid on the B work port side of the section shifts
the spool to power work port B. Auxiliary and dual auxiliary sections housings are
• Tilt Back constructed of grey iron and contain internal compo-
Actuating the main spool to the tilt back posi- nents made from various steels. The purpose of auxil-
tion (B port pressurized) sends a load-sense iary sections is to provide flow to any auxiliary func-
signal to the unloading spool located in the in- tions (attachments). When more than one auxiliary
let cover. The unloading spool in the inlet section is used, the upstream section is labeled as a
closes and flow is directed to the power core. dual auxiliary section. All valve assemblies contain an
Flow from the power core is directed across end (single) auxiliary section. Both types of auxiliary
the pressure reducing/load check spool assem- sections contain a 4-way main spool, two electro-hy-
bly and travels to the main spool via a feed draulic solenoids to shift the main spool, and a load
core. Flow travels across the main spool into sense shuttle valve. These components are the same
the bridge core and is directed out of work port as used on the lift and tilt sections and operate the
B. Return flow from the tilt cylinder(s) is routed same. See Figure 9050-10-35.
through work port A across the main spool into
the tank core of the housing. Flow in the tank Operation
core is directed through the valve sections
back to the tank (T) port located in the inlet Both the dual and end auxiliary sections operate the
section. same. Input flow to all auxiliary sections are down-
stream of the feed core of the tilt section, therefore
• Tilt Forward the maximum load pressure is limited to the setting of
When the tilt spool is shifted to pressurize work the relief cartridge used in conjunction with the pres-
port A, the unloading spool in the inlet closes sure reducing/load check assembly located in the tilt
and flow becomes available to the work sec- section. Auxiliary sections do not contain a load check
tions. Flow travels from the power core across assembly. Main spools are 4-way type, energizing
the pressure reducing/load check spool into the solenoid A will power the A work port. Energizing sol-
main spool feed core. Flow travels across the enoid B will provide power the B work port. To regu-
main spool into the bridge core. Flow passes late the output flow of a work port, the operator must
across the main spool and out the A work port. position the spool until the desired flow rate is ob-
Return flow from the tilt cylinder(s) is directed tained. Shifting the spool out of neutral communicates
into the B work port. a load sense signal via the internal shuttle circuit to
the unloading spool in the inlet. The unloading spool
Spacer Sections will shift and direct flow to downstream functions
when a load demand is present. End auxiliary sec-
Construction and Purpose tions contain an SAE plug (BG port) on the outside
surface which connects to the power core. Pressure
Spacer sections are used in certain valve stacks to in- at this port would represent the pressure setting of the
crease the length of the valve stack to overcome me- pressure reducing valve assembly located in the tilt
chanical structure interference on certain vehicle section.
models. They contain drilled passageways to allow oil

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Principles of Operation Hydraulic Systems

1. BRIDGE CORE 4. FEED CORE

2. EH SOLENOID 5. MAIN SPOOL
3. TANK CORE 6. EH SOLENOID

Figure 9050-10-35. Cross-Section of EH Auxiliary Section

Steering System
DESCRIPTION The control of the steering is through a hydraulic cir-
cuit. See Priority Steer (E-Hydraulic Control Valve),
The steering column assembly uses a steering control Priority Steer (Manual Hydraulics Open Center Con-
unit with hose connections on the bottom of the unit to trol Valve), or Priority Steer (Manual Hydraulics
connect hydraulic hoses to the main control valve and Closed Center Control Valve) as applicable for your
the steering cylinder. The steering housing has lift truck.
mounts for the steering column and the steering con-
trol unit. The steering wheel is installed on the steer- If the hydraulic pump for the steering system does not
ing column. See Figure 9050-10-36. The housing is operate, steering is still possible. A check valve per-
adjustable and is held in position by a latch. The posi- mits the steering control unit to control the steering
tion of the housing can be tilted up or down for opera- cylinder. The lift truck is difficult to steer when the
tor comfort. If the lift truck is equipped with the tele- steering pump is not operating, but the steering con-
scopic option; the steering wheel may also be moved trol unit can operate the steering cylinder and make
toward or away from the operator. steering possible.

The steering system is a hydraulic system that does

not have a mechanical connection between the steer-
ing wheel and the steering axle.

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Hydraulic Systems Principles of Operation

Legend for Figure 9050-10-36

1. STEERING WHEEL
2. STEERING COLUMN
3. STEERING CONTROL UNIT
4. TILT MEMORY LEVER
5. STEERING DIRECTION SENSOR
6. TILT BASE
7. STEERING COLUMN TILT CYLINDER
8. MOUNTING BASE
9. HYDRAULIC HOSES
10. TELESCOPIC COLUMN ADJUSTING LEVER
11. TELESCOPIC COLUMN LOCKING HANDLE

Figure 9050-10-36. Steering Housing Assembly

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Principles of Operation Hydraulic Systems

Accumulator, Piston

The steering accumulator consists of a cylinder as-

sembly, piston assembly, and two end-caps assem-
blies. The cylinder assembly houses a piston assem-
bly, and incorporates provisions for securing the end-
caps. An accumulator contains a free-floating piston
with liquid on one side of the piston and pre-charged
nitrogen on the other side. An increase of liquid vol-
ume decreases the gas volume and increases gas
pressure, which provides a work potential when the
liquid is allowed to discharge.

When the steering wheel is held at relief and a hy-

draulic function is “suddenly” actuated to a pressure
higher than steering relief (eg., system relief) the fol-
lowing happens:
• There is a pressure spike in the LS line which
causes the priority spool to shift momentarily.
• When the priority spool shifts it momentarily
opens path for working hydraulic pressure to
steering P line.
• The accumulator absorbs the pressure that
comes from the momentary shift of the priority
spool.

The steering supply incorporates a back flow check

valve. This valve is the straight adapter in the main
control valve.

The accumulator in the steering control unit supply

circuit is designed to cushion any impulses that are
generated within the hydraulic steering system.

Figure 9050-10-37. Steering Accumulator

Schematic

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Priority Steer (E-Hydraulic Control Valve) sages within the spool, the spool will shift towards the
spring end and flow will be directed across the spool
Pump flow is directed across a priority spool before to a downstream core leading to the unloading spool.
supplying flow to any downstream functions. The If there is a flow demand at the steer (S) port, the load
steering circuit flow demand has priority over any sense signal coming from the steering control unit is
downstream flow requirements. Priority steering is ac- communicated to the spring end of the spool via the
complished by using a normally open spring biased SL port. This increase in pressure will cause the spool
spool. Pump flow is directed across the priority spool to shift towards the blind end and flow to the steer (S)
to the steer port (S). If the steering control unit is not port will increase to meet the demands of the steering
in use, there is no load sense signal communicated to control unit. See Figure 9050-10-38.
the SL port from the steering control unit. The inlet
pressure (P) will increase to overcome the priority If no work section spools are shifted, total pump flow
spring force. The inlet pressure is communicated to is directed across an unloading spool to the outlet (T)
the blind end of the priority spool via the drilled pas- port.

1. TO STEER UNIT 4. PRIORITY SPOOL

2. FROM PUMP 5. STEER LS PORT
3. TO UNLOADER SPOOL

Figure 9050-10-38. Cross Section of Priority Steering Layout

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Principles of Operation Hydraulic Systems

Priority Steer (Manual Hydraulics Open Center shift towards the spring end and flow to the steering
Control Valve) unit will decrease and pump flow will be directed
across the priority spool into a downstream (open
Pump flow is directed across the priority spool before center) core. If there is a flow demand from the steer-
supplying flow for any downstream demands. There- ing unit, the load sense signal coming from the steer-
fore, the steering circuit has priority over any down- ing control unit is communicated to the spring end of
stream flow demands. Priority steering is accom- the spool via the SL port. This increase in pressure
plished by using a normally open spring biased spool. will cause the spool to shift towards the blind end and
Pump flow is directed across the priority spool to the flow to the steer (S) port will increase to meet the de-
steer port (S). If the steering control unit is not in use, mands of the steering control unit. The downstream
there is no load sense signal communicated to the SL core coming from the priority spool is directed to the
port from the steering control unit. The inlet pressure open center core of the valve assembly. If none of the
(PG) will increase just enough to overcome the prior- work section spools are shifted, total pump flow is di-
ity spool’s spring force. Since the inlet pressure is rected through the valve assembly via the open cen-
communicated to the blind end of the priority spool, ter core, across the work section spools to the outlet
via the drilled passages within the spool, the spool will (T) port. See Figure 9050-10-39.

1. OPEN CENTER CORE 3. PRIORITY STEER SPOOL

2. RELIEF CARTRIDGE 4. SPRING

Figure 9050-10-39. Cross-Sectional View of Inlet Assembly

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Priority Steer (Manual Hydraulics Closed Center sages within the spool, the spool will shift towards the
Control Valve) spring end and flow will be directed across the spool
to a downstream core leading to the unloading spool.
Pump flow is directed across a priority spool before If there is a flow demand at the steer (S) port, the load
supplying flow to any downstream functions. The sense signal coming from the steering control unit is
steering circuit flow demand has priority over any communicated to the spring end of the spool via the
downstream flow requirements. Priority steering is ac- SL port. This increase in pressure will cause the spool
complished by using a normally open spring biased to shift towards the blind end and flow to the steer (S)
spool. Pump flow is directed across the priority spool port will increase to meet the demands of the steering
to the steer port (S). If the steering control unit is not control unit. See Figure 9050-10-40.
in use, there is no load sense signal communicated to
the SL port from the steering control unit. The inlet If no work section spools are shifted, total pump flow
pressure (P) will increase to overcome the priority is directed across an unloading spool to the outlet (T)
spring force. The inlet pressure is communicated to port.
the blind end of the priority spool via the drilled pas-

1. STEER UNIT OUTLET 4. PRIORITY SPOOL

2. PUMP INLET 5. STEER LS PORT
3. UNLOADER SPOOL OUTLET

Figure 9050-10-40. Cross-Section of Priority Steering Layout

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Principles of Operation Hydraulic Systems

STEERING CONTROL UNIT (SCU) This action causes the rotation of the sleeve and the
OPERATION rotor in the metering section. The oil then flows to one
side of the steering cylinder. Oil from the other side of
The steering control unit is a rotary valve operated by the cylinder returns through the control section of the
the steering wheel. See Figure 9050-10-41. During steering control unit.
the steering operation, the steering control unit con-
trols the direction and amount of oil flow to the steer- When the steering wheel stops moving, the metering
ing cylinder. The steering cylinder in the axle actuates action in the metering section also stops. The NEU-
the steering linkage to move the steer tires. Hydraulic TRAL position springs return the sleeve to the NEU-
oil returns from the steering cylinder to the steering TRAL position, stopping oil flow to or from the cylin-
control unit and then to the hydraulic tank. der. The pressure stays in the steering cylinder to
keep the steer tires in position. Oil from the pump
Turning the steering wheel actuates three main parts flows through the steering control unit to the tank or
of the steering control unit: the spool for the control other parts of the system. To return the steer wheels
section, the sleeve for the control section, and the ro- to the straight position, the steering wheel must be ro-
tor in the metering section. When the steering wheel tated in the opposite direction. The steering control
is not moving, the spool and sleeve are held in the unit will operate as described, but all parts will rotate
NEUTRAL (center) position by springs. During this in the opposite direction.
time, oil flows freely through the steering control unit
but none flows to the steering cylinder. The makeup valve (see Figure 9050-10-41) controls
steering synchronization between the steering wheel
As the steering wheel is turned, the spool begins to and the steered wheels to ensure that the steering
rotate. The springs try to move the sleeve to keep the wheel is always in the same position relative to the
NEUTRAL position between the spool and sleeve. steered wheels when the steered wheels are in the
However, the necessary force to turn the rotor is straight ahead direction.
greater than the pressure of the springs. The springs
begin to bend, letting the spool move a small amount Calibration procedures allow the operator to establish
within the sleeve. The spool stops moving when it a spinner knob comfort position when the steered
touches the center pin. In this position, the holes in wheels are in the straight ahead position. The system
the sleeve and the spool are aligned. Oil coming into will maintain this relationship between the steering
the control unit flows to the metering section. wheel and steered wheels through the use of the
makeup valve. The steering control unit and the
More rotation of the steering wheel causes the spool steered wheels have sensors mounted on them to de-
to rotate the pin. termine relative angles.

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9050-10-40 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Principles of Operation

1. STEERING CONTROL UNIT 5. SUPPLY PRESSURE

2. LOAD SENSE 6. LEFT
3. RETURN TO CONTROL VALVE 7. RIGHT
4. MAKE-UP VALVE

Figure 9050-10-41. Steering Control Unit

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-10-41
 NOTES

9050-10-42
Hydraulic Systems Observed Symptoms-Gear Pump

Group 33

Observed Symptoms-Gear Pump

Abnormal Hydraulic Noise and/or Vibration

POSSIBLE CAUSE
A. LOW OIL LEVEL IN TANK.
B. AIR TRAPPED IN CIRCUIT.
C. SUCTION SIDE OF HYDRAULIC PUMP IS RESTRICTED.
D. HYDRAULIC PUMP LEAK AT THE INLET SUCTION HOSES.
E. HYDRAULIC PUMP IS WORN.
F. VIBRATION WITH TILT FUNCTION ONLY.
G. UNSTABLE MAIN RELIEF VALVE.
H. UNSTABLE SECONDARY RELIEF VALVE.
I. HYDRAULIC SYSTEM OVERHEATING.
J. UNSTABLE UNLOADER SPOOL.
K. UNSTABLE PRIORITY VALVE IN CONTROL VALVE INLET.

CAUSE A - LOW OIL LEVEL IN TANK.

PROCEDURE OR ACTION:

NOTE: Cavitation of a hydraulic pump will cause noise and it is caused by air in the hydraulic oil. The hydraulic
pump suction oil must be free of air and unrestricted to pump.

1. Check hydraulic oil level in tank.

Is oil at correct level?
YES: Go to Cause B.
NO: Add oil to correct level. See Operating Manual.

CAUSE B - AIR TRAPPED IN CIRCUIT.

PROCEDURE OR ACTION:
1. Remove air from circuit by cycling functions at one-second intervals, for E-Valve hoist and lower only. All
other functions, cycle fully for 5 - 10 times. If symptom is still present, go to Cause C.

CAUSE C - SUCTION SIDE OF HYDRAULIC PUMP IS RESTRICTED.

PROCEDURE OR ACTION:
1. Check for restricted inlet screen.
Is inlet screen restricted?
YES: Clean or replace inlet screen.
NO: Go to Step 2.
2. Check for collapsed suction hose.
Is suction hose collapsed?
YES: Replace suction hose.
NO: Go to Cause D.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-1
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE D - HYDRAULIC PUMP LEAK AT THE INLET SUCTION HOSES.

PROCEDURE OR ACTION:
1. Look at Steering System component location drawing to identify suction hose. Depending on your lift truck,
see Steering System 1600SRM1331 or Steering System 1600SRM1363.
• Inspect suction hoses between tank and pump. Check for loose hose clamps and oil seepage.
Is oil leaking from suction side of hydraulic pump?
YES: Check and tighten suction hose clamps.
NO: Go to Cause E.
2. Inspect hydraulic oil. Check for foaming or aeration of oil.
Is oil foaming or aerated?
YES: Repair suction side air leak and test oil for contamination. See Maintenance, Oil Sampling Procedure.
Depending on your lift truck, see Periodic Maintenance 8000SRM1364, Periodic Maintenance
8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic Maintenance 8000SRM1373, or Periodic
Maintenance 8000SRM1442.
NO: Go to Cause E.

CAUSE E - HYDRAULIC PUMP IS WORN.

PROCEDURE OR ACTION:
1. Check hydraulic pump flow. See Hydraulic Pump Flow Test in this section.
Is hydraulic pump flow out of specifications?
YES: Replace hydraulic pump. Depending on your lift truck, see Hydraulic System 1900SRM1367 or Hy-
draulic System 1900SRM1333.
NO: Go to Cause F.

CAUSE F - VIBRATION WITH TILT FUNCTION ONLY.

PROCEDURE OR ACTION:
1. Inspect tilt spool and orifices for contamination or damage. Depending on your left truck see, Main Control
Valves 2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is tilt spool or orifices contaminated or plugged?
YES: Clean or replace valve section.
NO: Go to Cause G.

CAUSE G - UNSTABLE MAIN RELIEF VALVE.

PROCEDURE OR ACTION:
1. Install pressure gauge in hydraulic control valve. See Primary Relief Valve Test and Adjustment.
2. Operate the hoist function while observing pressure gauge.
Does pressure fluctuate during hoist function.
YES: Go to Cause H.
NO: Go to Step 3.
3. Hold hoist function over relief.
Does relief pressure meet test specifications?
YES: Go to Cause H.
NO: Replace relief valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.

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Hydraulic Systems Observed Symptoms-Gear Pump

CAUSE H - UNSTABLE SECONDARY RELIEF VALVE.

PROCEDURE OR ACTION:
1. Install pressure gauge in hydraulic control valve. See Secondary Relief Valve Test and Adjustment.
2. Operate a auxiliary function while observing pressure gauge.
Does pressure fluctuate during auxiliary function.
YES: Go to Cause I.
NO: Go to Step 3.
3. Hold auxiliary function over relief.
Does relief pressure meet test specifications?
YES: Go to Cause I.
NO: Replace relief valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE I - HYDRAULIC SYSTEM OVERHEATING.

PROCEDURE OR ACTION:

NOTE: If lift truck is equipped with Hydraulic Oil Cooler, see Observed Symptoms-Gear Pump, Page 9050-33-
16.

1. Check temperature sensor for operation.

Is temperature sensor working properly?
YES: Go to Cause J.
NO: Replace temperature sensor. Depending on your lift truck, see Hydraulic System 1900SRM1367 or Hy-
draulic System 1900SRM1333.

CAUSE J - UNSTABLE UNLOADER SPOOL.

PROCEDURE OR ACTION:
1. Inspect unloader valve for damage or contamination. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is unloader valve free of contamination and in good condition?
YES: Go to Cause K.
NO: Clean or replace unloader valve. Depending on your left truck see, Main Control Valves 2000SRM1334,
Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE K - UNSTABLE PRIORITY VALVE IN CONTROL VALVE INLET.

PROCEDURE OR ACTION:
1. Perform Operational Diagnostic Procedures, Operational Checkout, Page 9010-05-8.
Does priority flow divider valve pass the check?
YES: Priority flow divider valve is OK.
NO:
• Cannot turn steering wheel, wheel locks up. See Observed Symptoms-Gear Pump, No Steering (All
Other Hydraulic Functions OK), Page 9050-33-57.
• Steering wheel turns but fails Priority Valve Flow Divider Valve Check. Remove and clean flow divider
spool. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control Valves
2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

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Observed Symptoms-Gear Pump Hydraulic Systems

Abnormal Smell/Discoloration/Foaming of Oil

POSSIBLE CAUSE
A. HYDRAULIC SYSTEM HAS BEEN OVERHEATED.
B. HYDRAULIC FLUID CONTAMINATED OR WRONG TYPE.
C. AIR LEAK ON SUCTION SIDE OF HYDRAULIC PUMP.

CAUSE A - HYDRAULIC SYSTEM HAS BEEN OVERHEATED.

PROCEDURE OR ACTION:

NOTE: If lift truck is equipped with Hydraulic Oil Cooler, see Observed Symptoms-Gear Pump, Page 9050-33-
16.

1. Inspect for the following:

• Level and condition of hydraulic oil in tank
• Valve stuck causing system to run at relief
Are any of the above symptoms present?
YES: Drain and refill hydraulic tank. Periodic Maintenance 8000SRM1364, Periodic Maintenance
8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic Maintenance 8000SRM1373, or Periodic
Maintenance 8000SRM1442. Repair or replace stuck valve.
NO: Go to Cause B.

CAUSE B - HYDRAULIC FLUID CONTAMINATED OR WRONG TYPE.

PROCEDURE OR ACTION:
1. Check hydraulic oil for contamination and correct type.
Is hydraulic oil contaminated or incorrect type used?
YES: Drain and refill hydraulic tank. Depending on your lift truck see, Periodic Maintenance 8000SRM1364,
Periodic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic Maintenance
8000SRM1373, or Periodic Maintenance 8000SRM1442.
NO: Go to Cause C.

CAUSE C - AIR LEAK ON SUCTION SIDE OF HYDRAULIC PUMP.

PROCEDURE OR ACTION:
1. Inspect condition of hydraulic oil.
Is the hydraulic oil foaming or aerated?
YES: Repair leak on suction side of hydraulic pump. For [A268], E2.2-3.5XN (E45-70XN); [A276], J2.2- 3.5XN
(J40-70XN); see Hydraulic System 1900SRM1367, For [K160], J1.5-2.0XNT (J30-40XNT); [A955]
ERP16-20VF; see Hydraulic System 1900SRM1333.
NO: Check service record of lift truck to see if it requires periodic maintenance.

END SYMPTOM

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Hydraulic Systems Observed Symptoms-Gear Pump

Cycle Times Too Fast - Fast Actuation (E-Valve)

POSSIBLE CAUSE
A. MAX FUNCTION SPEED SETTING TOO HIGH.
B. RAMP SETTING TOO HIGH FOR FUNCTION.
C. ORIFICES MISSING OR INSTALLED WRONG IN CYLINDER PORTS (ON AFTERMARKET CYLINDERS).
D. FAULTY MLCV FOR LOWERING FUNCTION ONLY.
E. UNLOADER VALVE PRODUCING TOO MUCH MARGIN PRESSURE.

CAUSE A - MAX FUNCTION SPEED SETTING TOO HIGH.

PROCEDURE OR ACTION:
1. Adjust function speed setting on Display Panel. If problem is still present, go to Cause B.

CAUSE B - RAMP SETTING TOO HIGH FOR FUNCTION.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Adjust function ramp setting on Display Panel. See User Interface Service Technician 2200SRM1336. If
problem is still present, go to Cause C.

CAUSE C - ORIFICES MISSING OR INSTALLED WRONG IN CYLINDER PORTS (ON AFTERMARKET CYL-
INDERS).
PROCEDURE OR ACTION:
1. Check cycle times. See aftermarket specifications.
Do cycle times meet specifications?
YES: Go to Cause D.
NO: Inspect and repair orifices in cylinder ports. See aftermarket Service Manuals.

CAUSE D - FAULTY MLCV FOR LOWERING FUNCTION ONLY.

PROCEDURE OR ACTION:
1. Check the lowering cycle times.
Are the lowering cycle times too fast?
YES: Repair or replace Mast Lowering Control Valve (MLCV). Depending on your lift truck see, Mast Repair
(S/N A270, A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast
Repair (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564)
4000SRM1338, or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause E.

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Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE E - UNLOADER VALVE PRODUCING TOO MUCH MARGIN PRESSURE.

PROCEDURE OR ACTION:
1. Test unloader valve. See Main Control Valve Unloader Margin Test.
Is margin pressure too high?
YES: Replace unloader valve spool spring. Depending on your left truck, see Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Perform operational check.

END SYMPTOM

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Hydraulic Systems Observed Symptoms-Gear Pump

Jump/Delay In Lift or Lower Activation After Moving MLM

(E-Valve)
POSSIBLE CAUSE
A. RAMP RATE NOT SET TO DESIRED LEVEL.
B. COIL NOT ATTACHED TO SOLENOID CORRECTLY.
C. AIR TRAPPED IN CIRCUIT.
D. OUTPUT THRESHOLD IS SET TOO HIGH.
E. MAST/ATTACHMENT IS BINDING.
F. STICKING UNLOADER SPOOL.
G. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

CAUSE A - RAMP RATE NOT SET TO DESIRED LEVEL.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Adjust function ramp setting on Display Panel. See User Interface Service Technician 2200SRM1336. If
problem is still present, go to Cause B.

CAUSE B - COIL NOT ATTACHED TO SOLENOID CORRECTLY.

PROCEDURE OR ACTION:
1. Inspect coil installation. Depending on your left truck, see Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is coil installed correctly to solenoid?
YES: Go to Cause C.
NO: Replace coil or solenoid. Coil cannot be repaired.

CAUSE C - AIR TRAPPED IN CIRCUIT.

PROCEDURE OR ACTION:
1. Remove air from circuit by cycling function at one second intervals, for E-Valve hoist and lower only. All other
functions, cycle fully for 5 - 10 times. If symptom is still present, go to Cause D.

CAUSE D - OUTPUT THRESHOLD IS SET TOO HIGH.

PROCEDURE OR ACTION:
1. Check current at Electro-Hydraulic Valve.
Is setting at valve correct?
YES: Go to Cause E.
NO: Decrease setting to specification or until operation is acceptable to operator.

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Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE E - MAST/ATTACHMENT IS BINDING.

PROCEDURE OR ACTION:
1. Check for mast or attachment binding.
Is mast or attachment binding?
YES: Repair mast or attachment. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause F.

CAUSE F - STICKING UNLOADER SPOOL.

PROCEDURE OR ACTION:
1. Inspect unloader valve for damage or contamination. Depending on your left truck, see Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is unloader free of contamination and in good condition?
YES: Go to Cause G.
NO: Clean or replace unloader valve.

CAUSE G - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

PROCEDURE OR ACTION:
1. Check LS pressure. See Main Control Valve LS Leakage Test (E-Valve).
Does LS pressure meet test specifications?
YES: See Observed Symptoms-Gear Pump, Lift Function Will Not Move With MLM Movement (E-Valve),
Page 9050-33-24.
NO: Clean or replace main relief valve. Depending on your left truck, see Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

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Hydraulic Systems Observed Symptoms-Gear Pump

Jump/Delay In Auxiliary Function Actuation After Moving MLM

(E-Valve)
POSSIBLE CAUSE
A. RAMP RATE NOT SET TO DESIRED LEVEL.
B. AIR TRAPPED IN CIRCUIT.
C. OUTPUT THRESHOLD IS SET TOO HIGH.
D. MAST/ATTACHMENT IS BINDING.
E. PILOT PRESSURE NOT BEING PRODUCED FAST ENOUGH.
F. STICKING VALVE SPOOL.
G. STICKING UNLOADER SPOOL.
H. VALVE SPOOL END SPRINGS TOO SOFT.

CAUSE A - RAMP RATE NOT SET TO DESIRED LEVEL.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Adjust function ramp setting on Display Panel. See User Interface Service Technician 2200SRM1336. If
problem is still present, go to Cause B.

CAUSE B - AIR TRAPPED IN CIRCUIT.

PROCEDURE OR ACTION:
1. Remove air from circuit by cycling function full stroke of hydraulic hoist cylinder at one second intervals. If
symptom is still present, go to Cause C.

CAUSE C - OUTPUT THRESHOLD IS SET TOO HIGH.

PROCEDURE OR ACTION:
1. Check current at valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is setting at valve correct?
YES: Go to Cause D.
NO: Decrease setting to specification or until operation is acceptable to operator.

CAUSE D - MAST/ATTACHMENT IS BINDING.

PROCEDURE OR ACTION:
1. Check for mast or attachment binding.
Is mast or attachment binding?
YES: Repair mast or attachment. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause E.

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Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE E - PILOT PRESSURE NOT BEING PRODUCED FAST ENOUGH.

PROCEDURE OR ACTION:
1. Inspect filter. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control Valves
2000SRM1439, or Electrical System 2200SRM1337.
Is filter clean and in good condition?
YES: Go to Cause F.
NO: Clean or replace filter.

CAUSE F - STICKING VALVE SPOOL.

PROCEDURE OR ACTION:
1. Inspect spool. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control Valves
2000SRM1439, or Electrical System 2200SRM1337.
Is spool clean and in good condition?
YES: Go to Cause G.
NO: Clean or replace spool.

CAUSE G - STICKING UNLOADER SPOOL.

PROCEDURE OR ACTION:
1. Inspect unloader valve for damage or contamination. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is unloader free of contamination and in good condition?
YES: Go to Cause H.
NO: Clean or replace unloader valve.

CAUSE H - VALVE SPOOL END SPRINGS TOO SOFT.

PROCEDURE OR ACTION:
1. Replace springs. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control
Valves 2000SRM1439, or Electrical System 2200SRM1337. If problem is still present, see Observed Symp-
toms-Gear Pump, Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move With MLM Movement (E-
Valve), Page 9050-33-37.

END SYMPTOM

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Hydraulic Systems Observed Symptoms-Gear Pump

Jump/Delay In Tilt Forward or Back Actuation (E-Valve)

POSSIBLE CAUSE
A. RAMP RATE NOT SET TO DESIRED LEVEL.
B. AIR TRAPPED IN CIRCUIT.
C. OUTPUT THRESHOLD IS SET TOO HIGH.

CAUSE A - RAMP RATE NOT SET TO DESIRED LEVEL.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Adjust function ramp setting on Display Panel. See User Interface Service Technician 2200SRM1336. If
problem is still present, go to Cause B.

CAUSE B - AIR TRAPPED IN CIRCUIT.

PROCEDURE OR ACTION:
1. Remove air from circuit by cycling function full stroke of hydraulic hoist cylinder at one second intervals. If
symptom is still present, go to Cause C.

CAUSE C - OUTPUT THRESHOLD IS SET TOO HIGH.

PROCEDURE OR ACTION:
1. Check current at E-Hydraulic Valve. See Hydraulic System 1900SRM1367.
Is setting at valve correct?
YES: Resume operation.
NO: Decrease setting to specification or until operation is acceptable to operator.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-11
Observed Symptoms-Gear Pump Hydraulic Systems

Forks Drop Slightly Before Lifting (E-Valve)

POSSIBLE CAUSE
A. EXCESSIVE LEAKAGE IN LOAD CHECK VALVE.

CAUSE A - EXCESSIVE LEAKAGE IN LOAD CHECK VALVE.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Check for contamination or damage to load check valve. Depending on your left truck see, Main Control
Valves 2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is load check valve in good condition?
YES: Clean lift low leak valve.
NO: Replace lift low leak valve.

END SYMPTOM

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Hydraulic Systems Observed Symptoms-Gear Pump

Forks Lower Without Command (E-Valve)

POSSIBLE CAUSE
A. MLM CONTROL MALFUNCTION.
B. EMERGENCY LOWER VALVE IS PARTIALLY OPEN.
C. EXCESSIVE LIFT CYLINDER LEAKAGE.

CAUSE A - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Ensure power is OFF. Operate lift/lower lever in both directions.
Does lever exhibit any binding/stickiness or not return to center position?
YES: Remove and replace lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .) Note: Inspect cassette rotary mechanism for dirt contamination.
NO: Go to Step 2.
2. Turn Power ON.
3. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
4. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Go to Cause B.
NO: Go to Step 5.
5. Power OFF. Replace lift/lower lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
6. Retest. Turn power ON.
7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
8. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Go to Cause B.
NO: Replace MLM PCB Cassette. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
9. Retest. Turn power ON.
10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
11. Move lever(s) to full stroke position and allow to snap back to the center position.
Display value = 0%?
YES: Repair Complete. Resume operation.
NO: Go to Cause B.

CAUSE B - EMERGENCY LOWER VALVE IS PARTIALLY OPEN.

PROCEDURE OR ACTION:

NOTE: Emergency lower valve has tee handle located on control valve. See Operating Manual for location and
correct use.

1. Check and close valve. If problem is still present, go to Cause C.

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Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE C - EXCESSIVE LIFT CYLINDER LEAKAGE.

PROCEDURE OR ACTION:
1. Do lift cylinder leakage test. See Lift Cylinder Leakage Test.
Is there leakage in the lift cylinder?
YES: Repair or replace lift cylinder.
NO: Resume operation.

END SYMPTOM

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Hydraulic Systems Observed Symptoms-Gear Pump

Forks Raise or Actuate Without Command (E-Valve)

POSSIBLE CAUSE
A. MLM CONTROL MALFUNCTION.
B. AIR TRAPPED IN CIRCUIT.

CAUSE A - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Ensure power is OFF. Operate lift/lower lever in both directions.
Does lever exhibit any binding/stickiness or not return to center position?
YES: Remove and replace lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .) Note: Inspect cassette rotary mechanism for dirt contamination.
NO: Go to Step 2.
2. Turn Power ON.
3. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
4. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Go to Cause B.
NO: Go to Step 5.
5. Power OFF. Replace lift/lower lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
6. Retest. Turn power ON.
7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
8. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Go to Cause B.
NO: Replace MLM PCB Cassette. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
9. Retest. Turn power ON.
10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
11. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Repair Complete. Resume Operation.
NO: Go to Cause B.

CAUSE B - AIR TRAPPED IN CIRCUIT.

PROCEDURE OR ACTION:
1. Remove air from circuit by cycling function at one-second intervals, for E-Valve hoist and lower only. All other
functions, cycle fully for 5 - 10 times.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-15
Observed Symptoms-Gear Pump Hydraulic Systems

Hydraulic Oil Cooler Not Functioning Correctly

POSSIBLE CAUSE
A. AIR FLOW THROUGH COOLER RESTRICTED OR INSUFFICIENT
B. HYDRAULIC OIL COOLER TEMPERATURE SWITCH NOT WORKING
C. HYDRAULIC OIL COOLER FANS NOT WORKING

COMPONENT OPERATIONAL CHECK

PROCEDURE OR ACTION:
1. Conduct a quick visual inspection of all connectors/wiring associated with the hydraulic oil cooler. Make sure
electrical connection is a good physical connection (i.e. sockets and pins are seated correctly; connector
"clicks" indicating locking tab works correctly).
Are any of the connectors/wiring damaged?
YES: Repair/replace connector or wiring associated with hydraulic oil cooler. Refer to appropriate Electrical
System manual, depending on lift truck model.
NO: Go to Cause B.

CAUSE A - AIR FLOW THROUGH COOLER RESTRICTED OR INSUFFICIENT

PROCEDURE OR ACTION:
1. Check the condition of the hydraulic oil cooler.
Is the hydraulic oil cooler fan shroud broken or hydraulic oil cooler blocked not allowing air flow
through the cooler?
YES: Replace hydraulic oil cooler fan shroud and/or remove any debris or blockage restricting air flow
through cooler. Clean hydraulic oil cooler and resume operation.
NO: Go to Cause C.

CAUSE B - HYDRAULIC OIL COOLER TEMPERATURE SWITCH NOT WORKING

PROCEDURE OR ACTION:
1. Warm up the hydraulic oil to a minimum of 60°C (140°F). Follow procedures in Hydraulic Warm-up Procedure.
Park lift truck and check condition of hydraulic cooler cooling fans.
Do the hydraulic cooler cooling fans turn on?
YES: Truck is operating to specification.
NO: Go to Step 2.
2. Turn lift truck OFF. Bypass the hydraulic oil cooler temperature switch with a jumper wire. Turn lift truck ON.
Do the hydraulic cooler cooling fans turn on?
YES: Replace faulty hydraulic oil cooler temperature switch with a new switch. Resume operation.
NO: Remove bypass jumper wire and return hydraulic oil cooler temperature switch to it's original condition.
Go to Cause D.

CAUSE C - HYDRAULIC OIL COOLER FANS NOT WORKING

PROCEDURE OR ACTION:
1. Turn lift truck OFF. Replace the hydraulic oil cooler fan(s) with a new fan(s). Be sure to install new fans in the
correct direction for air flow through oil cooler. Turn lift truck ON and operate lift truck until hydraulic oil tem-
perature is HOT. Park lift truck and raise hood.
Do the hydraulic cooler cooling fans turn on?
YES: Repeat Cause B. Check the level of the hydraulic oil in the hydraulic tank. Drain/fill as needed.
NO: Go to Step 2.
2. Using a DMM, check the condition of the power and ground circuit for the fans.

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9050-33-16 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Do the fans have a good ground and 12 volts?

YES: Replace inoperative fans. Be sure to install new fans in the correct direction for air flow through hy-
draulic oil cooler.
NO: Go to VSM 12 Volts Supply OORL/OORH.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-17
Observed Symptoms-Gear Pump Hydraulic Systems

Intermittent Activation (E-Valve) While Commanding Function

POSSIBLE CAUSE
A. LOOSE WIRES OR CONNECTORS ON VALVE HARNESS.
B. MAST/ATTACHMENT IS BINDING.
C. CONTAMINATION IN HYDRAULIC CONTROL VALVE.

CAUSE A - LOOSE WIRES OR CONNECTORS ON VALVE HARNESS.

PROCEDURE OR ACTION:
1. Check the Display Panel for DTC.
Is a DTC displayed?
YES: Go to DTC diagnostic procedure.
NO: Go to Step 2.
2. Check wire connection. See Wire Harness Repair 2200SRM1128. If problem is still present, go to Cause B.

CAUSE B - MAST/ATTACHMENT IS BINDING.

PROCEDURE OR ACTION:
1. Check for mast or attachment binding.
Is mast or attachment binding?
YES: Repair mast or attachment. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause C.

CAUSE C - CONTAMINATION IN HYDRAULIC CONTROL VALVE.

PROCEDURE OR ACTION:
1. Inspect and clean control valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

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9050-33-18 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Forks Tilt Forward Without Command (E-Valve)

POSSIBLE CAUSE
A. MLM CONTROL MALFUNCTION.
B. PPRV GETTING STRAY SIGNAL.
C. EXCESSIVE TILT CYLINDER LEAKAGE.
D. EXCESSIVE SPOOL LEAKAGE.
E. PISTON STUCK.
F. TILT CONTROL SPOOL DAMAGED OR LEAKING EXCESSIVELY.

CAUSE A - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Ensure power is OFF. Operate tilt lever in both directions.
Does lever exhibit any binding/stickiness or not return to center position?
YES: Remove and replace lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .) Note: Inspect cassette rotary mechanism for dirt contamination.
NO: Go to Step 2.
2. Turn power ON.
3. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
4. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Go to Cause B.
NO: Go to Step 5.
5. Power OFF. Replace tilt lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
6. Retest. Turn power ON.
7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
8. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0% at the center position and 92 to 100% at the full stroke position?
YES: Go to Cause B.
NO: Replace MLM PCB Cassette. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
9. Retest. Turn power ON.
10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
11. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Repair Complete. Resume operation.
NO: Go to Cause B.

CAUSE B - PPRV GETTING STRAY SIGNAL.

PROCEDURE OR ACTION:
1. Check for proper harness installation. See Wire Harness Repair 2200SRM1128.
Is valve harness installed wrong?
YES: Install valve harness properly.
NO: Go to Step 2.
2. Check for shorts in valve harness. See Wire Harness Repair 2200SRM1128.
Does valve harness have shorts?
YES: Repair or replace valve harness.
NO: Go to Cause C.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-19
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE C - EXCESSIVE TILT CYLINDER LEAKAGE.

PROCEDURE OR ACTION:
1. Do tilt cylinder leakage test. See Tilt Cylinder Leakage Test.
Is there leakage in the tilt cylinder?
YES: Repair or replace tilt cylinder.
NO: Go to Cause D.

CAUSE D - EXCESSIVE SPOOL LEAKAGE.

PROCEDURE OR ACTION:
1. Check spool for:
• Damage
• Free movement
• Debris or contamination
Is spool and mating bore in good condition?
YES: Go to Cause E.
NO: Replace damaged parts.

CAUSE E - PISTON STUCK.

PROCEDURE OR ACTION:
1. Inspect tilt control piston. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.
Does piston move freely in bore?
YES: Go to Cause F.
NO: Clean piston or replace valve section.

CAUSE F - TILT CONTROL SPOOL DAMAGED OR LEAKING EXCESSIVELY.

PROCEDURE OR ACTION:
1. Inspect valve section. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control
Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is spool in good condition?
YES: See Observed Symptoms-Gear Pump, Forks Raise or Actuate Without Command (E-Valve), Page
9050-33-15.
NO: Clean or replace spool.

END SYMPTOM

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9050-33-20 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Lift/Lower Function Maximum Speed Too Slow (E-Valve)

POSSIBLE CAUSE
A. MAX FUNCTION SPEED SETTING TOO LOW.
B. RAMP SETTING TOO LOW FOR FUNCTION.
C. OUTPUT THRESHOLD IS SET TOO LOW.
D. MAST/ATTACHMENT IS BINDING.
E. MLM CONTROL MALFUNCTION.
F. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN (LIFT FUNCTION ONLY).
G. EXCESSIVE PUMP LEAKAGE (LIFT FUNCTION ONLY).
H. UNLOADER NOT PRODUCING ENOUGH MARGIN PRESSURE (LIFT FUNCTION ONLY).
I. MAIN CONTROL VALVE LS (LOAD SENSE) LEAKAGE (LIFT FUNCTION ONLY).
J. FAULTY MAST LOWERING CONTROL VALVE.

CAUSE A - MAX FUNCTION SPEED SETTING TOO LOW.

PROCEDURE OR ACTION:
1. Adjust function speed setting on Display Panel. If problem is still present, go to Cause B.

CAUSE B - RAMP SETTING TOO LOW FOR FUNCTION.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Adjust function ramp setting on Display Panel. See User Interface Service Technician 2200SRM1336. If
problem is still present, go to Cause C.

CAUSE C - OUTPUT THRESHOLD IS SET TOO LOW.

PROCEDURE OR ACTION:
1. Check current at Display Panel.
Is setting at valve correct?
YES: Go to Cause D.
NO: Increase setting to specification or until operation is acceptable to operator.

CAUSE D - MAST/ATTACHMENT IS BINDING.

PROCEDURE OR ACTION:
1. Check for mast or attachment binding.
Is mast or attachment binding?
YES: Repair mast or attachment. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause E.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-21
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE E - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Turn power ON.
2. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
3. Move lever to full stroke position – both directions.
Is Display value >=92%?
YES: Go to Cause F.
NO: Go to Step 4.
4. Power OFF. Replace lift/lower Lever(s). See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .
5. Retest. Turn power ON.
6. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
7. Move lever to full stroke position – both directions.
Is Display value >=92%?
YES: Go to Cause F.
NO: Replace MLM PCB Cassette. See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .

CAUSE F - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN (LIFT FUNCTION ONLY).
PROCEDURE OR ACTION:
1. Install pressure gauge in hydraulic control valve. See Primary Relief Valve Test and Adjustment.
2. Hold lift function over relief.
Does relief pressure meet test specifications?
YES: Go to Cause G.
NO: Replace relief valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE G - EXCESSIVE PUMP LEAKAGE (LIFT FUNCTION ONLY).

PROCEDURE OR ACTION:
1. Test hydraulic pump for excessive leakage. See Hydraulic Pump Flow Test.
Does hydraulic pump have excessive leakage?
YES: Repair or replace pump. See Hydraulic System 1900SRM1333.
NO: Go to Cause H.

CAUSE H - UNLOADER NOT PRODUCING ENOUGH MARGIN PRESSURE (LIFT FUNCTION ONLY).
PROCEDURE OR ACTION:
1. Test unloader spool spring. See Main Control Valve Unloader Margin Test.
Does unloader valve pressure meet test specifications?
YES: Go to Cause I.
NO: Replace spring.

CAUSE I - MAIN CONTROL VALVE LS (LOAD SENSE) LEAKAGE (LIFT FUNCTION ONLY).
PROCEDURE OR ACTION:
1. Check LS pressure. See Main Control Valve LS Leakage Test (E-Valve).
Does LS pressure meet test specifications?
YES: See Observed Symptoms-Gear Pump, Lift Function Will Not Move With MLM Movement (E-Valve),
Page 9050-33-24.
NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

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9050-33-22 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

CAUSE J - FAULTY MAST LOWERING CONTROL VALVE.

PROCEDURE OR ACTION:
1. Inspect mast lowering control valve for blockage.
Is mast lowering control valve blocking flow?
YES: Repair or replace mast lowering control valve. Depending on your lift truck see, Mast Repair (S/N
A270, A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Re-
pair (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564)
4000SRM1338, or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
NO: Resume operation.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-23
Observed Symptoms-Gear Pump Hydraulic Systems

Lift Function Will Not Move With MLM Movement (E-Valve)

POSSIBLE CAUSE
A. PUMP NOT GENERATING ENOUGH FLOW.
B. LOAD IS GREATER THAN TRUCK CAPACITY.
C. MLM CONTROL MALFUNCTION.
D. EMERGENCY LOWER VALVE IS PARTIALLY OPEN.
E. LIFT SPEED IS SET AT 0%.
F. MAIN RELIEF VALVE IS SET TOO LOW.
G. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN.
H. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.
I. MAST LOWERING CONTROL VALVE BLOCKING FLOW.
J. UNLOADER SPOOL IS STUCK OPEN.
K. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

CAUSE A - PUMP NOT GENERATING ENOUGH FLOW.

PROCEDURE OR ACTION:
1. Do hydraulic pump flow check.
Does pump pass check?
YES: Pump is OK. Go to Cause B.
NO: Do Hydraulic Pump Flow Test before replacing pump.

CAUSE B - LOAD IS GREATER THAN TRUCK CAPACITY.

NOTE: See Serial Number plate or Operating Manual for lift capacity.

PROCEDURE OR ACTION:
1. Check load weight and compare to truck capacity rating. Adjust as necessary. If problem is still present, go to
Cause C.

CAUSE C - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Power ON and operator in seat. Operate lift/lower lever.
Is a hydraulic interlock message displayed?
YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2.
NO: Go to Cause D.
2. Observe value
Is Operator Presence sensor value greater than 1.8 volts?
YES: Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values, then go to Step 3.
NO: Go to Seat Sensor Out of Range Low (OORL).
3. Operate lift/lower lever in both directions.
Does lever exhibit any binding/stickiness or not return to center position?
YES: Remove and replace lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .) Note: Inspect cassette rotary mechanism for dirt contamination.
NO: Go to Step 4.
4. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0% at the center position and 92 to 100% at the full stroke position?
YES: Go to Cause D.
NO: Go to Step 5.

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9050-33-24 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

5. Power OFF. Replace lever(s). (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
6. Retest. Turn power ON.
7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
8. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0% at the center position and 92 to 100% at the full stroke position?
YES: Repair complete. Resume operation.
NO: Replace MLM PCB Cassette. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
9. Retest. Turn power ON.
10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
11. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0%? at the center position and 92 to 100% at the full stroke position?
YES: Repair complete. Resume Operation.
NO: Go to Cause D.

CAUSE D - EMERGENCY LOWER VALVE IS PARTIALLY OPEN.

PROCEDURE OR ACTION:

NOTE: Emergency lower valve has tee handle located on control valve. See Operating Manual for location and
correct use.

1. Check and close valve. If problem is still present, go to Cause E.

CAUSE E - LIFT SPEED IS SET AT 0%.

PROCEDURE OR ACTION:
1. Check current setting of lift hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.
Is Hydraulic Function set at 0%?
YES: Reset hydraulic function to appropriate level.
NO: Go to Cause F.

CAUSE F - MAIN RELIEF VALVE IS SET TOO LOW.

PROCEDURE OR ACTION:
1. Test and adjust pressure. See Primary Relief Valve Test and Adjustment.
Is relief set at specifications?
YES: Go to Cause G.
NO: Adjust pressure to test specifications.

CAUSE G - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN.

PROCEDURE OR ACTION:
1. Remove and inspect relief valve. Depending on your left truck see, Main Control Valves 2000SRM1334,
Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is relief valve damaged or stuck open?
YES: Install new relief valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Go to Cause H.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-25
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE H - SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.

PROCEDURE OR ACTION:

NOTE: This only affects hoist circuit when a auxiliary function is activated.

1. Test and adjust pressure. See Secondary Relief Valve Test and Adjustment.
Is relief set at specifications?
YES: Go to Cause I.
NO: Adjust pressure to test specifications.

CAUSE I - MAST LOWERING CONTROL VALVE BLOCKING FLOW.

PROCEDURE OR ACTION:
1. Inspect mast lowering control valve for blockage.
Is mast lowering control valve blocking flow?
YES: Repair or replace mast lowering control valve. Depending on your lift truck see, Mast Repair (S/N
A270, A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Re-
pair (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564)
4000SRM1338, or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause J.

CAUSE J - UNLOADER SPOOL IS STUCK OPEN.

PROCEDURE OR ACTION:
1. Inspect and repair unloader spool. Depending on your left truck see, Main Control Valves 2000SRM1334,
Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337. If problem is still present, go to
Cause K.

CAUSE K - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

PROCEDURE OR ACTION:
1. Check LS pressure. See Main Control Valve LS Leakage Test (E-Valve).
Does LS pressure meet test specifications?
YES: See Observed Symptoms-Gear Pump, Too Much MLM Movement (Deadband) to Start Function Moving
(E-Valve), Page 9050-33-44.
NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

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9050-33-26 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Lift/Lower Continues To Move For Awhile After MLM Is Released

(E-Valve)
POSSIBLE CAUSE
A. RAMP SETTINGS TO HIGH/LOW FOR OPERATION.

CAUSE A - RAMP SETTINGS TO HIGH/LOW FOR OPERATION.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Depending on associated hydraulic function, adjust ramp settings until operation is acceptable to operator.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-27
Observed Symptoms-Gear Pump Hydraulic Systems

Lift/Lower/Auxiliary Function Suddenly Jumps In Middle of Stroke

(E-Valve)
POSSIBLE CAUSE
A. STICKING VALVE SPOOL (AUXILIARY FUNCTIONS ONLY).
B. VALVE SPOOL END SPRINGS TOO SOFT (AUXILIARY FUNCTIONS ONLY).

CAUSE A - STICKING VALVE SPOOL (AUXILIARY FUNCTIONS ONLY).

PROCEDURE OR ACTION:
1. Remove and inspect spool. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is the spool undamaged and moves freely in bore?
YES: Cause B.
NO: Clean or replace valve spool.

CAUSE B - VALVE SPOOL END SPRINGS TOO SOFT (AUXILIARY FUNCTIONS ONLY).
PROCEDURE OR ACTION:
1. Replace springs. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control
Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

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9050-33-28 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Lower Function Will Not Move With MLM Movement (E-Valve)

POSSIBLE CAUSE
A. LOWER SPEED IS SET AT 0%.
B. MLM CONTROL MALFUNCTION.

CAUSE A - LOWER SPEED IS SET AT 0%.

PROCEDURE OR ACTION:
1. Check current setting of lower hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.
Is Hydraulic Function set at 0%?
YES: Reset hydraulic function to appropriate level.
NO: Go to Cause B.

CAUSE B - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Power ON and operator in seat. Operate lift/lower Lever.
Is a hydraulic interlock message displayed?
YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2.
NO: Go to Step 3.
2. Observe Value.
Is Operator Presence sensor value greater than 1.8 volts?
YES: Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values, then go to Step 3.
NO: Go to Seat Sensor Out of Range Low (OORL).
3. Operate lift/lower lever in both directions.
Does lever exhibit any binding/stickiness or not return to center position?
YES: Remove and replace lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .) Note: Inspect cassette rotary mechanism for dirt contamination.
NO: Go to Step 4.
4. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0% at the center position and 92 to 100% at the full stroke position?
YES: Repair complete. Resume operation
NO: Go to Step 5.
5. Power OFF. Replace lever(s). (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
6. Retest. Turn power ON.
7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
8. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does display value = 0% at the center position and 92 to 100% at the full stroke position?
YES: Repair complete. Resume operation.
NO: Replace MLM PCB Cassette. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
9. Retest.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-29
Observed Symptoms-Gear Pump Hydraulic Systems

Poor Metering on Lift or Lower Functions (E-Valve)

POSSIBLE CAUSE
A. AIR TRAPPED IN CIRCUIT.
B. RAMP SETTING TOO HIGH FOR FUNCTION.
C. OUTPUT THRESHOLD IS SET TOO HIGH.
D. MAST/ATTACHMENT IS BINDING.
E. MLM CONTROL MALFUNCTION.
F. MAST LOWERING CONTROL VALVE IS STICKING.
G. STICKING UNLOADER SPOOL (LIFT FUNCTION ONLY).
H. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

CAUSE A - AIR TRAPPED IN CIRCUIT.

PROCEDURE OR ACTION:
1. Remove air from circuit by cycling function full stroke of hydraulic hoist cylinder at one second intervals. If
symptom is still present, go to Cause B.

CAUSE B - RAMP SETTING TOO HIGH FOR FUNCTION.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Adjust function ramp setting on Display Panel. See User Interface Service Technician 2200SRM1336. If
problem is still present, go to Cause C.

CAUSE C - OUTPUT THRESHOLD IS SET TOO HIGH.

PROCEDURE OR ACTION:
1. Check current at E-Hydraulic Valve.
Is setting at valve correct?
YES: Go to Cause D.
NO: Decrease setting to specification or until operation is acceptable to operator.

CAUSE D - MAST/ATTACHMENT IS BINDING.

PROCEDURE OR ACTION:
1. Check for mast or attachment binding.
Is mast or attachment binding?
YES: Repair or lubricate mast or attachment. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause E.

CAUSE E - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Ensure power is OFF. Operate lift/lower lever in both directions.
Does lever exhibit any binding/stickiness or not return to center position?

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9050-33-30 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

YES: Remove and replace lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .) Note: Inspect cassette rotary mechanism for dirt contamination.
NO: Go to Step 2.
2. Turn Power ON.
3. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
4. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Go to Cause F.
NO: Go to Step 5.
5. Power OFF. Replace lift/lower lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
6. Retest. Turn power ON.
7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
8. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0% at the center position and 92 to 100% at the full stroke position?
YES: Go to Cause F.
NO: Replace MLM PCB Cassette. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
9. Retest.

CAUSE F - MAST LOWERING CONTROL VALVE IS STICKING.

PROCEDURE OR ACTION:
1. Inspect mast lowering control valve for proper operation. Depending on your lift truck see, Mast Repair (S/N
A270, A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Re-
pair (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564)
4000SRM1338, or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
Is mast lowering control valve sticking?
YES: Repair or replace mast lowering control valve.
NO: Go to Cause G.

CAUSE G - STICKING UNLOADER SPOOL (LIFT FUNCTION ONLY).

PROCEDURE OR ACTION:
1. Inspect unloader valve for damage or contamination. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is unloader free of contamination and in good condition?
YES: Go to Cause H.
NO: Clean or replace unloader valve.

CAUSE H - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

PROCEDURE OR ACTION:
1. Check LS pressure. See Main Control Valve LS Leakage Test (E-Valve).
Does LS pressure meet test specifications?
YES: See Observed Symptoms-Gear Pump, Lift Function Will Not Move With MLM Movement (E-Valve),
Page 9050-33-24.
NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-31
Observed Symptoms-Gear Pump Hydraulic Systems

Auxiliary Function Continues to Move for Awhile After MLM Is

Released (E-Valve)
POSSIBLE CAUSE
A. RAMP SETTINGS TO HIGH/LOW FOR OPERATION.
B. STICKING VALVE SPOOL.

CAUSE A - RAMP SETTINGS TO HIGH/LOW FOR OPERATION.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Depending on associated hydraulic function, adjust ramp settings for proper operation. See User Interface
Service Technician 2200SRM1336. If problem is still present, go to Cause B.

CAUSE B - STICKING VALVE SPOOL.

PROCEDURE OR ACTION:
1. Remove and inspect spool. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is the spool undamaged and moves freely in bore?
YES: Resume operation.
NO: Clean or replace valve spool.

END SYMPTOM

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9050-33-32 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Auxiliary Function Maximum Speed Too Slow (E-Valve)

POSSIBLE CAUSE
A. MAX FUNCTION SPEED SETTING TOO LOW.
B. RAMP SETTING TOO LOW FOR FUNCTION.
C. OUTPUT THRESHOLD IS SET TOO LOW.
D. MAST/ATTACHMENT IS BINDING.
E. MLM CONTROL MALFUNCTION.
F. ORIFICES INSTALLED IN CIRCUIT TOO SMALL (ON AFTERMARKET CYLINDERS).
G. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN.
H. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.
I. PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW.
J. STICKING SPOOL.
K. UNLOADER NOT PRODUCING ENOUGH MARGIN PRESSURE.
L. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

CAUSE A - MAX FUNCTION SPEED SETTING TOO LOW.

PROCEDURE OR ACTION:
1. Adjust function speed setting on Display Panel. If problem is still present, go to Cause B.

CAUSE B - RAMP SETTING TOO LOW FOR FUNCTION.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Adjust function ramp setting on Display Panel. See User Interface Service Technician 2200SRM1336. If
problem is still present, go to Cause C.

CAUSE C - OUTPUT THRESHOLD IS SET TOO LOW.

PROCEDURE OR ACTION:
1. Check current at Electro-Hydraulic Poppet Valve (EHPV). Depending on your left truck see, Main Control
Valves 2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is setting at valve correct?
YES: Go to Cause D.
NO: Increase setting until operation is acceptable to operator.

CAUSE D - MAST/ATTACHMENT IS BINDING.

PROCEDURE OR ACTION:
1. Check for mast or attachment binding.
Is mast or attachment binding?
YES: Lubricate or repair mast or attachment. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause E.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-33
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE E - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Turn power ON.
2. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
3. Move Lever to full stroke position – both directions.
Is Display value >=92%?
YES: Go to Cause F.
NO: Go to Step 4.
4. Power OFF. Replace Auxiliary Lever(s). (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
5. Retest. Turn power ON.
6. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
7. Move lever to full stroke position – both directions.
Is Display value >=92%?
YES: Go to Cause F.
NO: Replace MLM PCB Cassette. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)

CAUSE F - ORIFICES INSTALLED IN CIRCUIT TOO SMALL (ON AFTERMARKET CYLINDERS).

PROCEDURE OR ACTION:
1. Check cycle times. See aftermarket specifications.
Do cycle times meet specifications?
YES: Go to Cause G.
NO: Inspect and replace orifices in cylinder ports. See aftermarket service manuals.

CAUSE G - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN.

PROCEDURE OR ACTION:
1. Install pressure gauge in hydraulic control valve. See Primary Relief Valve Test and Adjustment.
2. Hold lift function over relief.
Does relief pressure meet test specifications?
YES: Go to Cause H.
NO: Replace relief valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE H - SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.

PROCEDURE OR ACTION:
1. Test and adjust pressure. See Secondary Relief Valve Test and Adjustment.
Is relief set at specifications?
YES: Go to Cause I.
NO: Adjust pressure to test specifications.

CAUSE I - PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW.

PROCEDURE OR ACTION:
1. Test Proportional Pressure Reducing Valve (PPRV) pressure.
Is PPRV pressure at specifications?
YES: Go to Cause J.
NO: Clean screen on PPRV. If problem is still present, replace PPRV. Depending on your left truck see, Main
Control Valves 2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9050-33-34 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

CAUSE J - STICKING SPOOL.

PROCEDURE OR ACTION:
1. Inspect spool. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control Valves
2000SRM1439, or Electrical System 2200SRM1337.
Is spool clean and in good condition?
YES: Go to Cause K.
NO: Clean or replace spool.

CAUSE K - UNLOADER NOT PRODUCING ENOUGH MARGIN PRESSURE.

PROCEDURE OR ACTION:
1. Test unloader spool spring. See Main Control Valve Unloader Margin Test.
Does unloader valve pressure meet test specifications?
YES: Go to Cause L.
NO: Replace spring.

CAUSE L - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

PROCEDURE OR ACTION:
1. Check LS pressure. See Main Control Valve LS Leakage Test (E-Valve).
Does LS pressure meet test specifications?
YES: Check for DTCs. See Electrical System, General Maintenance and Diagnostic Data, Diagnostic Trouble
Codes, Page 9030-03-6.
NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-35
Observed Symptoms-Gear Pump Hydraulic Systems

Auxiliary Function or Tilt Back Moves Without Command

(E-Valve)
POSSIBLE CAUSE
A. MLM CONTROL MALFUNCTION.
B. EXCESSIVE SPOOL LEAKAGE.

CAUSE A - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Ensure power is OFF. Operate lever in both directions.
Does lever exhibit any binding/stickiness or not return to center position?
YES: Remove and replace lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .) Note: Inspect cassette rotary mechanism for dirt contamination.
NO: Go to Step 2.
2. Turn power ON.
3. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
4. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Go to Cause B.
NO: Go to Step 5.
5. Power OFF. Replace lever. (See Electrical System 2200SRM1369 or Electrical System 2200SRM1337 .)
6. Retest. Turn power ON.
7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
8. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Go to Cause B.
NO: Replace MLM PCB Cassette. See Electrical System 2200SRM1369 or Electrical System
2200SRM1337.
9. Retest. Turn power ON.
10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
11. Move lever(s) to full stroke position and allow to snap back to the center position.
Does Display value = 0%?
YES: Repair Complete. Resume operation.
NO: Go to Cause B.

CAUSE B - EXCESSIVE SPOOL LEAKAGE.

PROCEDURE OR ACTION:
1. Check spool for items below. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
• Damage
• Free movement
• Debris or contamination
Is spool and mating bore in good condition?
YES: See Observed Symptoms-Gear Pump, Auxiliary Function Continues to Move for Awhile After MLM Is
Released (E-Valve), Page 9050-33-32.
NO: Replace damaged parts.

END SYMPTOM

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9050-33-36 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move
With MLM Movement (E-Valve)
POSSIBLE CAUSE
A. PUMP NOT GENERATING ENOUGH FLOW.
B. LOAD IS GREATER THAN TRUCK CAPACITY.
C. MLM CONTROL MALFUNCTION.
D. HYDRAULIC FUNCTION SPEED IS SET AT 0%.
E. SECONDARY RELIEF VALVE IS SET TOO LOW.
F. MAST/ATTACHMENT IS BINDING.
G. STUCK SPOOL IN CONTROL VALVE.
H. PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW.
I. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.
J. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN.
K. UNLOADER VALVE STUCK OPEN.
L. MAIN RELIEF LS (LOAD SENSE) STUCK OPEN.
M. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

CAUSE A - PUMP NOT GENERATING ENOUGH FLOW.

PROCEDURE OR ACTION:
1. Do hydraulic pump flow check.
Does pump pass check?
YES: Pump is OK. Go to Cause B.
NO: Perform Hydraulic Pump Flow Test before replacing pump.

CAUSE B - LOAD IS GREATER THAN TRUCK CAPACITY.

NOTE: See Serial Number plate or Operating Manual for lift capacity.

PROCEDURE OR ACTION:
1. Check load weight and compare to truck capacity rating. Adjust as necessary. If problem is still present, go to
Cause C.

CAUSE C - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Power ON and operator in seat. Operate lever/s.
Is a hydraulic interlock message displayed?
YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2.
NO: Go to Cause D.
2. Observe value.
Is Operator Presence sensor value greater than 1.8 volts?
YES: Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values, then go to Step 3.
NO: Go to Seat Sensor Out of Range Low (OORL).
3. Operate lever/s in both directions.
Does lever exhibit any binding/stickiness or not return to center position?
YES: Remove and replace lever. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .) Note: Inspect cassette rotary mechanism for dirt contamination.
NO: Go to Next Step.
4. Move lever(s) to full stroke position and allow to snap back to the center position. Observe Value. Move the
lever(s) to the full stroke position and hold. Observe Value.
Does Display value = 0% at the center position and 92 to 100% at the full stroke position?

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-37
Observed Symptoms-Gear Pump Hydraulic Systems

YES: Go to Cause D.
NO: Go to Step 5.
5. Power OFF. Replace lever(s). (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
6. Retest. Turn power ON.
7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
8. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0% at the center position and 92 to 100% at the full stroke position?
YES: Repair complete. Resume operation.
NO: Replace MLM PCB Cassette. (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337 .)
9. Retest. Turn power ON.
10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
11. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0%? at the center position and 92 to 100% at the full stroke position?
YES: Repair complete. Resume operation.
NO: Go to Cause D.

CAUSE D - HYDRAULIC FUNCTION SPEED IS SET AT 0%.

PROCEDURE OR ACTION:
1. Check current setting of tilt hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.
Is Hydraulic Function set at 0%?
YES: Reset hydraulic function to appropriate level.
NO: Go to Cause E.

CAUSE E - SECONDARY RELIEF VALVE IS SET TOO LOW.

PROCEDURE OR ACTION:
1. Test and adjust pressure. See Secondary Relief Valve Test and Adjustment.
Is relief set at specifications?
YES: Go to Cause F.
NO: Adjust pressure to test specifications.

CAUSE F - MAST/ATTACHMENT IS BINDING.

PROCEDURE OR ACTION:
1. Check for mast or attachment binding.
Is mast or attachment binding?
YES: Lubricate or repair mast or attachment. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause G.

CAUSE G - STUCK SPOOL IN CONTROL VALVE.

PROCEDURE OR ACTION:
1. Remove and inspect spool. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Does the spool move freely in bore and in good condition?
YES: Go to Cause H.

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9050-33-38 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

NO: Repair or replace valve spool or section.

CAUSE H - PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW.

PROCEDURE OR ACTION:
1. Test Proportional Pressure Reducing Valve (PPRV) pressure.
Is PPRV pressure at specifications?
YES: Go to Cause I.
NO: Clean screen on PPRV. If problem is still present, replace PPRV. Depending on your left truck see, Main
Control Valves 2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE I - SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.

PROCEDURE OR ACTION:

NOTE: This only affects hoist circuit when a auxiliary function is activated.

1. Test and adjust pressure. See Secondary Relief Valve Test and Adjustment.
Is relief set at specifications?
YES: Go to Cause J.
NO: Adjust pressure to test specifications.

CAUSE J - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN.

PROCEDURE OR ACTION:
1. Remove and inspect relief valve. Depending on your left truck see, Main Control Valves 2000SRM1334,
Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is relief valve damaged or stuck open?
YES: Install new relief valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Go to Cause K.

CAUSE K - UNLOADER VALVE STUCK OPEN.

PROCEDURE OR ACTION:
1. Remove and inspect unloader spool. Depending on your left truck see, Main Control Valves 2000SRM1334,
Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Does unloader spool move freely in bore and in good condition?
YES: Go to Cause L.
NO: Repair or replace unloader spool.

CAUSE L - MAIN RELIEF LS (LOAD SENSE) STUCK OPEN.

PROCEDURE OR ACTION:
1. Remove and inspect main relief valve. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is the LS relief clean and spring OK?
YES: Go to Cause M.
NO: Check for contamination. Clean or replace relief valve.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-39
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE M - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE.

PROCEDURE OR ACTION:
1. Check LS pressure. See Main Control Valve LS Leakage Test (E-Valve).
Does LS pressure meet test specifications?
YES: See Observed Symptoms-Gear Pump, Too Much MLM Movement (Deadband) to Start Function Moving
(E-Valve), Page 9050-33-44.
NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

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9050-33-40 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Tilt Forward or Tilt Back Function Continues to Move for Awhile

When MLM Is Released (E-Valve)
POSSIBLE CAUSE
A. RAMP SETTINGS TO HIGH/LOW FOR OPERATION.
B. STICKING VALVE SPOOL.
C. STICKING TILT CONTROL PISTON IN TILT SPOOL.

CAUSE A - RAMP SETTINGS TO HIGH/LOW FOR OPERATION.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Depending on associated hydraulic function, adjust ramp settings for proper operation. See User Interface
Service Technician 2200SRM1336. If problem is still present, go to Cause B.

CAUSE B - STICKING VALVE SPOOL.

PROCEDURE OR ACTION:
1. Remove and inspect spool. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is the spool undamaged and moves freely in bore?
YES: Go to Cause C.
NO: Clean or replace valve spool.

CAUSE C - STICKING TILT CONTROL PISTON IN TILT SPOOL.

PROCEDURE OR ACTION:
1. Inspect piston. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control Valves
2000SRM1439, or Electrical System 2200SRM1337.
Does piston move freely in bore?
YES: Resume operation.
NO: Clean piston or replace valve section.

END SYMPTOM

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-41
Observed Symptoms-Gear Pump Hydraulic Systems

Tilt Forward or Tilt Back Will Not Move With MLM Movement
(E-Valve)
POSSIBLE CAUSE
A. MLM CONTROL MALFUNCTION.
B. TILT SPEED IS SET AT 0%.
C. PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW.
D. STUCK SPOOL IN CONTROL VALVE.

CAUSE A - MLM CONTROL MALFUNCTION.

PROCEDURE OR ACTION:
1. Power ON and Operator in Seat. Operate Lever/s.
Is a hydraulic interlock message displayed?
YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2.
NO: Go to Cause B.
2. Observe value
Is Operator Presence sensor value greater than 1.8 volts?
YES: Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values, then go to Step 3.
NO: Go to Seat Sensor Out of Range Low (OORL).
3. Operate lever/s in both directions.
Does lever exhibit any binding/stickiness or not return to center position?
YES: Remove and replace lever. See Electrical System 2200SRM1369 or Electrical System
2200SRM1337. Note: Inspect cassette rotary mechanism for dirt contamination.
NO: Go to Step 4.
4. Move lever(s) to full stroke position and allow to snap back to the center position. Observe Value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0% at the center position and 92 to 100% at the full stroke position?
YES: Go to Cause B.
NO: Go to Step 5.
5. Power OFF. Replace lever(s). (See Electrical System 2200SRM1369 or Electrical System
2200SRM1337. .)
6. Retest. Turn power ON.
7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
8. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0% at the center position and 92 to 100% at the full stroke position?
YES: Repair complete. Resume operation.
NO: Replace MLM PCB Cassette. See Electrical System 2200SRM1369 or Electrical System
2200SRM1337.
9. Retest. Turn power ON.
10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values.
11. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the
lever(s) to the full stroke position and hold. Observe value.
Does Display value = 0%? at the center position and 92 to 100% at the full stroke position?
YES: Repair complete. Resume operation.
NO: Go to Cause B.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9050-33-42 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

CAUSE B - TILT SPEED IS SET AT 0%.

PROCEDURE OR ACTION:
1. Check current setting of tilt hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.
Is Hydraulic Function set at 0%?
YES: Reset hydraulic function to appropriate level.
NO: Go to Cause C.

CAUSE C - PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW.

PROCEDURE OR ACTION:
1. Test Proportional Pressure Reducing Valve (PPRV) pilot pressure.
Is PPRV pressure at specifications?
YES: Go to Cause D.
NO: Clean screen on PPRV. If problem is still present, replace PPRV. Depending on your left truck see, Main
Control Valves 2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE D - STUCK SPOOL IN CONTROL VALVE.

PROCEDURE OR ACTION:
1. Remove, disassemble, and inspect spool. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Does the spool move freely in bore and in good condition?
YES: See Observed Symptoms-Gear Pump, Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move
With MLM Movement (E-Valve), Page 9050-33-37.
NO: Repair or replace valve spool or section.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-43
Observed Symptoms-Gear Pump Hydraulic Systems

Too Much MLM Movement (Deadband) to Start Function Moving

(E-Valve)
POSSIBLE CAUSE
A. OUTPUT THRESHOLD IS SET TOO HIGH.

CAUSE A - OUTPUT THRESHOLD IS SET TOO HIGH.

PROCEDURE OR ACTION:
1. Check threshold at Display Panel.
Is setting at valve correct?
YES:
• For hoist/lower functions, see Observed Symptoms-Gear Pump, Jump/Delay In Lift or Lower Activation
After Moving MLM (E-Valve), Page 9050-33-7.
• For auxiliary functions, see Observed Symptoms-Gear Pump, Jump/Delay In Auxiliary Function Actua-
tion After Moving MLM (E-Valve), Page 9050-33-9.
• For tilt forward function, see Observed Symptoms-Gear Pump, Jump/Delay In Tilt Forward or Back Ac-
tuation (E-Valve), Page 9050-33-11.
NO: Decrease setting to specification or until operation is acceptable to operator.

END SYMPTOM

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9050-33-44 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Wrong Actuation Operates or Actuation is Backward (E-Valve)

POSSIBLE CAUSE
A. WIRING HARNESS INSTALLED WRONG.
B. HYDRAULIC HOSES INSTALLED WRONG.
C. WIRING HARNESS HAS FAILED.

CAUSE A - WIRING HARNESS INSTALLED WRONG.

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Inspect wiring harness. Depending on your lift truck, see Electrical System 2200SRM1369 or Electrical
System 2200SRM1337 .
Is harness installed correctly?
YES: Go to Cause B.
NO: Adjust or repair harness. See Wire Harness Repair 2200SRM1128.

CAUSE B - HYDRAULIC HOSES INSTALLED WRONG.

PROCEDURE OR ACTION:
1. Inspect hydraulic hose routing and correct as required. If problem is still present, go to Cause C.

CAUSE C - WIRING HARNESS HAS FAILED.

PROCEDURE OR ACTION:
1. Inspect harness for shorts.
Does harness have a short?
YES: Repair wiring harness. See Wire Harness Repair 2200SRM1128.
NO: Resume operation.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-45
Observed Symptoms-Gear Pump Hydraulic Systems

Actuation Exhibits Slight Movement in Opposite Direction Before

Moving (Manual Valve)
POSSIBLE CAUSE
A. AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM.
B. EXCESSIVE CONTROL VALVE SPOOL OR CYLINDER LEAKAGE.

CAUSE A - AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM.
PROCEDURE OR ACTION:
1. Check service record of lift truck.
Was hydraulic system repaired recently?
YES: Check the repaired hose connections and remove air from system by cycling function full stroke of
steering cylinder in each direction.
NO: Go to Cause B.

CAUSE B - EXCESSIVE CONTROL VALVE SPOOL OR CYLINDER LEAKAGE.

PROCEDURE OR ACTION:
1. Identify if problem is in lift cylinder or control valve. Do Lift Cylinder Leakage Test.
Does lift cylinder pass leakage test.
YES: Problem is in control valve. Clean and repair. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Repair or replace lift cylinder. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72,
A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.

END SYMPTOM

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9050-33-46 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Auxiliary Function is Slow or Does Not Function (Manual Valve)

POSSIBLE CAUSE
A. OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT.
B. PUMP NOT GENERATING ENOUGH FLOW.
C. LOAD IS GREATER THAN TRUCK CAPACITY.
D. AUXILIARY FUNCTION SPEED IS SET AT 0%.
E. SPOOL IS NOT FULLY ACTUATED.
F. SECONDARY RELIEF VALVE IS SET TOO LOW.
G. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.
H. MAIN RELIEF VALVE SET TOO LOW, DAMAGED, OR STUCK OPEN.
I. MAST/ATTACHMENT IS BINDING.
J. EXCESSIVE INTERNAL SPOOL LEAKAGE.

CAUSE A - OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT.

PROCEDURE OR ACTION:
1. Power ON and operator in seat. Operate auxiliary lever.
Is a hydraulic interlock message displayed?
YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2.
NO: Go to Cause B.
2. Observe value.
Is Operator Presence sensor value greater than 1.8 volts?
YES: Go to Cause B.
NO: Go to Seat Sensor Out of Range Low (OORL).

CAUSE B - PUMP NOT GENERATING ENOUGH FLOW.

PROCEDURE OR ACTION:
1. Do hydraulic pump flow check.
Does pump pass check?
YES: Pump is OK. Go to Cause C.
NO: Do Hydraulic Pump Flow Test before replacing pump.

CAUSE C - LOAD IS GREATER THAN TRUCK CAPACITY.

NOTE: See Serial Number plate or Operating Manual for lift capacity.

PROCEDURE OR ACTION:
1. Check load weight and compare to truck capacity rating. Adjust as necessary. If problem is still present, go to
Cause D.

CAUSE D - AUXILIARY FUNCTION SPEED IS SET AT 0%.

PROCEDURE OR ACTION:
1. Depending on associated hydraulic function, adjust ramp settings for proper operation. See User Interface
Service Technician 2200SRM1336. If problem is still present, go to Cause E.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-47
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE E - SPOOL IS NOT FULLY ACTUATED.

PROCEDURE OR ACTION:
1. Inspect linkage. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control
Valves 2000SRM1439, or Electrical System 2200SRM1337.
Does linkage prematurely contact dash?
YES: Repair or replace linkage.
NO: Go to Cause F.

CAUSE F - SECONDARY RELIEF VALVE IS SET TOO LOW.

PROCEDURE OR ACTION:
1. Test and adjust pressure. See Secondary Relief Valve Test and Adjustment.
Is relief set at specifications?
YES: Go to Cause G.
NO: Adjust pressure to test specifications.

CAUSE G - SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.

PROCEDURE OR ACTION:
1. Remove and inspect relief valve. See Hydraulic System 1900SRM1333.
Is relief valve damaged or stuck open?
YES: Install new relief valve.
NO: Go to Cause H.

CAUSE H - MAIN RELIEF VALVE SET TOO LOW, DAMAGED, OR STUCK OPEN.
PROCEDURE OR ACTION:

NOTE: This symptom only affects auxiliary functions when hoist function is activated.

1. Test and adjust pressure. See Primary Relief Valve Test and Adjustment.
Is relief set at specifications?
YES: Go to Cause I.
NO: Adjust pressure to test specifications and retest. If problem is still present, replace relief valve. See Hy-
draulic System 1900SRM1333.

CAUSE I - MAST/ATTACHMENT IS BINDING.

PROCEDURE OR ACTION:
1. Check for mast or attachment binding.
Is mast or attachment binding?
YES: Repair mast or attachment. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause J.

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9050-33-48 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

CAUSE J - EXCESSIVE INTERNAL SPOOL LEAKAGE.

PROCEDURE OR ACTION:
1. Replace spool or complete control valve. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-49
Observed Symptoms-Gear Pump Hydraulic Systems

Cycle Times Too Fast - Fast Actuation (Manual Valve)

POSSIBLE CAUSE
A. ORIFICES MISSING OR INSTALLED IN WRONG CYLINDER PORTS (ON AFTERMARKET CYLINDERS).
B. FAULTY MAST LOWERING CONTROL VALVE (MLCV) FOR LOWERING FUNCTION ONLY.

CAUSE A - ORIFICES MISSING OR INSTALLED IN WRONG CYLINDER PORTS (ON AFTERMARKET CYL-
INDERS).
PROCEDURE OR ACTION:
1. Check cycle times. See aftermarket specifications.
Are cycle times to specifications?
YES: Go to Cause B.
NO: Inspect and repair orifices in cylinder ports. Go to aftermarket Service Manuals.

CAUSE B - FAULTY MAST LOWERING CONTROL VALVE (MLCV) FOR LOWERING FUNCTION ONLY.
PROCEDURE OR ACTION:
1. Check the lowering cycle times.
Are the lowering cycle times too fast?
YES: Repair or replace MLCV. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
NO: Repeat lowering cycle times to make sure they are not too fast.

END SYMPTOM

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9050-33-50 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Function Continues to Activate After Returning to Neutral

POSSIBLE CAUSE
A. CONTROL LINKAGE BINDING (MANUAL VALVE).
B. VALVE SPOOL STICKING IN BORE (MANUAL VALVE).
C. MLM SWITCH PROBLEM (E-VALVE).
D. SPOOL STUCK OPEN.

CAUSE A - CONTROL LINKAGE BINDING (MANUAL VALVE).

PROCEDURE OR ACTION:

WARNING
Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until
problem has been repaired.

1. Inspect control linkage for sticking or binding. Repair or lubricate as required. If problem is still present, go to
Cause B.

CAUSE B - VALVE SPOOL STICKING IN BORE (MANUAL VALVE).

PROCEDURE OR ACTION:
1. Inspect valve spool. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control
Valves 2000SRM1439, or Electrical System 2200SRM1337.
Does valve spool move freely in bore?
YES: Replace spool end cap centering springs. If problem is still present, go to Cause C.
NO: Clean or replace valve spool.

CAUSE C - MLM SWITCH PROBLEM (E-VALVE).

PROCEDURE OR ACTION:
1. Check valve calibration.
Is control valve calibrated correctly?
YES: Go to Cause D.
NO: Calibrate control valve.

CAUSE D - SPOOL STUCK OPEN.

PROCEDURE OR ACTION:
1. Inspect valve spool. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control
Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is valve spool damaged or stuck open?
YES: Clean or replace valve spool.
NO: Valve has excessive leakage. Replace valve spool.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-51
Observed Symptoms-Gear Pump Hydraulic Systems

Lift Function Is Slow or Does Not Function (Manual Valve)

POSSIBLE CAUSE
A. OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT.
B. PUMP NOT GENERATING ENOUGH FLOW.
C. LOAD IS GREATER THAN TRUCK CAPACITY.
D. EMERGENCY LOWER VALVE IS PARTIALLY OPEN.
E. LIFT SPEED IS SET AT 0%.
F. LIFT SPOOL IS NOT FULLY ACTUATED.
G. MAIN RELIEF VALVE IS SET TOO LOW.
H. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN.
I. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.
J. MAST/ATTACHMENT IS BINDING.
K. EXCESSIVE INTERNAL SPOOL LEAKAGE.
L. MAST LOWERING CONTROL VALVE BLOCKING FLOW.

CAUSE A - OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT.

PROCEDURE OR ACTION:
1. Power ON and operator in seat. Operate lift/lower lever.
Is a hydraulic interlock message displayed?
YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2.
NO: Go to Cause B.
2. Observe value.
Is Operator Presence sensor value greater than 1.8 volts?
YES: Go to Cause B.
NO: Go to Seat Sensor Out of Range Low (OORL).

CAUSE B - PUMP NOT GENERATING ENOUGH FLOW.

PROCEDURE OR ACTION:
1. Do hydraulic pump flow check.
Does pump pass check?
YES: Pump is OK. Go to Cause C.
NO: Do Hydraulic Pump Flow Test before replacing pump.

CAUSE C - LOAD IS GREATER THAN TRUCK CAPACITY.

NOTE: See Serial Number plate or Operating Manual for lift capacity.

PROCEDURE OR ACTION:
1. Check load weight and compare to truck capacity rating. Adjust as necessary. If problem is still present, go to
Cause D.

CAUSE D - EMERGENCY LOWER VALVE IS PARTIALLY OPEN.

PROCEDURE OR ACTION:

NOTE: Emergency lower valve has tee handle located on control valve. See Operating Manual for location and
correct use.

1. Check and close valve. If problem is still present, go to Cause E.

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9050-33-52 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

CAUSE E - LIFT SPEED IS SET AT 0%.

PROCEDURE OR ACTION:
1. Check current setting of lift hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.
Is Hydraulic Function set at 0%?
YES: Reset hydraulic function to appropriate level.
NO: Go to Cause F.

CAUSE F - LIFT SPOOL IS NOT FULLY ACTUATED.

PROCEDURE OR ACTION:
1. Inspect linkage. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control
Valves 2000SRM1439, or Electrical System 2200SRM1337.
Does linkage prematurely contact dash?
YES: Repair or replace linkage.
NO: Go to Cause G.

CAUSE G - MAIN RELIEF VALVE IS SET TOO LOW.

PROCEDURE OR ACTION:
1. Test and adjust pressure. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is relief set at specifications?
YES: Go to Cause H.
NO: Adjust pressure to test specifications.

CAUSE H - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN.

PROCEDURE OR ACTION:
1. Remove and inspect relief valve. Depending on your left truck see, Main Control Valves 2000SRM1334,
Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is relief valve damaged or stuck open?
YES: Install new relief valve.
NO: Go to Cause I.

CAUSE I - SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN.

PROCEDURE OR ACTION:
1. Test and adjust pressure. See Secondary Relief Valve Test and Adjustment.
Is relief set at specifications?
YES: Go to Cause J.
NO: Adjust pressure to test specifications.

CAUSE J - MAST/ATTACHMENT IS BINDING.

PROCEDURE OR ACTION:
1. Check for mast or attachment binding.
Is mast or attachment binding?
YES: Repair mast or attachment. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
NO: Go to Cause K.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-53
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE K - EXCESSIVE INTERNAL SPOOL LEAKAGE.

PROCEDURE OR ACTION:
1. Replace spool or complete control valve. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE L - MAST LOWERING CONTROL VALVE BLOCKING FLOW.

PROCEDURE OR ACTION:
1. Inspect mast lowering control valve for blockage.
Is mast lowering control valve blocking flow?
YES: Repair or replace mast lowering control valve. Depending on your lift truck see, Mast Repair (S/N
A270, A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Re-
pair (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564)
4000SRM1338, or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
NO: Perform operational check.

END SYMPTOM

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9050-33-54 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Tilt Back Function Will Not Operate (Manual Valve)

POSSIBLE CAUSE
A. OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT.
B. TILT BACK SPEED IS SET AT 0%.
C. CONTROL VALVE PISTON IS STUCK IN OPEN POSITION.

CAUSE A - OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT.

PROCEDURE OR ACTION:
1. Power ON and operator in seat. Operate tilt back lever.
Is a hydraulic interlock message displayed?
YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2.
NO: Go to Cause B.
2. Observe value.
Is Operator Presence sensor value greater than 1.8 volts?
YES: Go to Cause B.
NO: Go to Seat Sensor Out of Range Low (OORL).

CAUSE B - TILT BACK SPEED IS SET AT 0%.

PROCEDURE OR ACTION:
1. Check current setting of tilt hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.
Is Hydraulic Function set at 0%?
YES: Reset hydraulic function to appropriate level.
NO: Go to Cause C.

CAUSE C - CONTROL VALVE PISTON IS STUCK IN OPEN POSITION.

PROCEDURE OR ACTION:
1. Inspect control valve piston and exhaust orifices. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Does the valve move freely and are exhaust orifices open?
YES: Valve is OK. See Observed Symptoms-Gear Pump, Auxiliary Function is Slow or Does Not Function
(Manual Valve), Page 9050-33-47.
NO: Replace control valve piston.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-55
Observed Symptoms-Gear Pump Hydraulic Systems

Tilt Forward or Tilt Back Will Not Function When Activated

(Manual Valve)
POSSIBLE CAUSE
A. OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT.
B. TILT SPEED IS SET AT 0%.
C. TILT CONTROL VALVE IS STUCK IN CLOSED POSITION.
D. TILT CONTROL VALVE EXHAUST HOLES PLUGGED IN VALVE.

CAUSE A - OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT.

PROCEDURE OR ACTION:
1. Power ON and operator in seat. Operate tilt forward/back lever.
Is a hydraulic interlock message displayed?
YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2.
NO: Go to Cause B.
2. Observe value.
Is Operator Presence sensor value greater than 1.8 volts?
YES: Go to Cause B.
NO: Go to Seat Sensor Out of Range Low (OORL).

CAUSE B - TILT SPEED IS SET AT 0%.

PROCEDURE OR ACTION:
1. Check current setting of tilt hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.
Is Hydraulic Function set at 0%?
YES: Reset hydraulic function to appropriate level.
NO: Go to Cause C.

CAUSE C - TILT CONTROL VALVE IS STUCK IN CLOSED POSITION.

PROCEDURE OR ACTION:
1. Inspect tilt control valve and exhaust orifices. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Does the control valve piston move freely and are exhaust orifices open?
YES: Go to Cause D.
NO: Clean or replace tilt control valve spool.

CAUSE D - TILT CONTROL VALVE EXHAUST HOLES PLUGGED IN VALVE.

PROCEDURE OR ACTION:
1. Inspect valve section. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control
Valves 2000SRM1439, or Electrical System 2200SRM1337.
Are exhaust holes open?
YES: Valve is OK. See Observed Symptoms-Gear Pump, Auxiliary Function is Slow or Does Not Function
(Manual Valve), Page 9050-33-47.
NO: Clean or replace valve.

END SYMPTOM

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9050-33-56 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

No Steering (All Other Hydraulic Functions OK)

POSSIBLE CAUSE
A. HYDRAULIC HOSES ARE NOT CONNECTED OR DAMAGED.
B. STEERING RELIEF VALVE IS SET TOO LOW.
C. TRANSAXLE/DRIVE UNIT IS BINDING.
D. PRIORITY FLOW DIVIDER VALVE IS CONTAMINATED.
E. STEERING CYLINDER PISTON SEALS ARE WORN OR DAMAGED.
F. SLEEVE AND SPOOL IN THE CONTROL UNIT WILL NOT MOVE.
G. STEERING CONTROL UNIT IS DAMAGED.

CAUSE A - HYDRAULIC HOSES ARE NOT CONNECTED OR DAMAGED.

PROCEDURE OR ACTION:
1. Look at Steering System component location drawing to identify steering hoses. Inspect hoses for wear, dam-
age, and correct installation.
Are steering hoses in good condition and installed correctly?
YES: Go to Cause B.
NO: Install new components as necessary.

CAUSE B - STEERING RELIEF VALVE IS SET TOO LOW.

PROCEDURE OR ACTION:
1. Perform Operational Diagnostic Procedures, Operational Checkout, Page 9010-05-13.
Is steering relief pressure set too low?
YES: Adjust steering relief pressure. See Steering Relief Pressure Test and Adjustment.
NO: Go to Cause C.

CAUSE C - TRANSAXLE/DRIVE UNIT IS BINDING.

PROCEDURE OR ACTION:
1. Inspect transaxle/drive unit for binding.
Is transaxle/drive unit binding?
YES: Replace transaxle/drive unit. Depending on your lift truck, see Transaxle 1300SRM1330 or Transaxle
1300SRM1370.
NO: Go to Cause D.

CAUSE D - PRIORITY FLOW DIVIDER VALVE IS CONTAMINATED.

PROCEDURE OR ACTION:
1. Perform Operational Diagnostic Procedures, Operational Checkout, Page 9010-05-8.
Does priority flow divider valve pass the check?
YES: Priority flow divider valve is OK. Go to Cause E.
NO:
• Cannot turn steering wheel, wheel locks up. Go to Cause F.
• Steering wheel turns but fails Priority Valve Flow Divider Valve Check. Remove and clean flow divider
spool. Depending on your lift truck see, Main Control Valves 2000SRM1334 or Main Control Valves
2000SRM1439.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-57
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE E - STEERING CYLINDER PISTON SEALS ARE WORN OR DAMAGED.

PROCEDURE OR ACTION:
1. Do Steering Cylinder Leakage Test.
Does steering cylinder pass leakage test?
YES: Cylinder is OK. Go to Cause G.
NO: Remove and repair steering cylinder. Depending on your lift truck, see Steering System 1600SRM1331
or Steering Axle 1600SRM1360.

CAUSE F - SLEEVE AND SPOOL IN THE CONTROL UNIT WILL NOT MOVE.
PROCEDURE OR ACTION:
1. Turn steering wheel with engine running.
Does steering wheel move?
YES: Sleeve and spool are not seized. Go to Cause G.
NO: Repair steering control unit. Replace components as required. Depending on your lift truck, see Steering
System 1600SRM1331 or Steering System 1600SRM1363.

CAUSE G - STEERING CONTROL UNIT IS DAMAGED.

PROCEDURE OR ACTION:
1. Inspect SCU.
Is steering control unit damaged?
YES: Install new SCU. Depending on your lift truck, see Steering System 1600SRM1331 or Steering Sys-
tem 1600SRM1363.
NO: Repair steering control unit. Replace components as required. Depending on your lift truck, see Steering
System 1600SRM1331 or Steering System 1600SRM1363.

END SYMPTOM

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9050-33-58 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Steering Is Slow or Difficult

POSSIBLE CAUSE
A. LOW PUMP FLOW.
B. STEERING RELIEF PRESSURE IS SET TOO LOW.
C. PRIORITY FLOW DIVIDER VALVE IS CONTAMINATED.
D. HYDRAULIC LINES ARE RESTRICTED.
E. SEAL IN THE STEERING CYLINDER LEAKS.
F. TRANSAXLE/DRIVE UNIT COMPONENTS ARE DAMAGED AND/OR BINDING.
G. SCU IS WORN, NOT ASSEMBLED CORRECTLY, OR DAMAGED.

CAUSE A - LOW PUMP FLOW.

PROCEDURE OR ACTION:
1. Do Hydraulic Pump Flow Test.
Are other hydraulic functions OK?
YES: Hydraulic pump output is OK. Go to Cause B.
NO: Test hydraulic system relief pressure. See Primary Relief Valve Test and Adjustment.

CAUSE B - STEERING RELIEF PRESSURE IS SET TOO LOW.

PROCEDURE OR ACTION:
1. Perform Operational Diagnostic Procedures, Operational Checkout, Page 9010-05-13.
Is steering relief pressure set too low?
YES: Adjust steering relief pressure. See Steering Relief Pressure Test and Adjustment.
NO: Go to Cause C.

CAUSE C - PRIORITY FLOW DIVIDER VALVE IS CONTAMINATED.

PROCEDURE OR ACTION:
1. Perform Operational Check, seeOperational Diagnostic Procedures, Operational Checkout, Page 9010-05-8.
Does priority flow divider valve pass check?
YES: Priority flow divider valve is OK. Go to Cause D.
NO:
• Flow divider valve spool is stuck. Remove and clean flow divider spool. Depending on your left truck
see, Main Control Valves 2000SRM1334, Main Control Valves 2000SRM1439, or Electrical Sys-
tem 2200SRM1337.
• LS signal pressure is leaking away. See Steering Control Unit LS Pressure Test.

CAUSE D - HYDRAULIC LINES ARE RESTRICTED.

PROCEDURE OR ACTION:
1. Look at Steering System component. Inspect hoses for wear, damage, and correct installation.
Are steering hoses in good condition and correctly installed?
YES: Go to Cause E.
NO: Install new hoses as necessary.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-59
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE E - SEAL IN THE STEERING CYLINDER LEAKS.

PROCEDURE OR ACTION:
1. Perform Steering Cylinder Leakage Test.
Does steering cylinder pass leakage test?
YES: Cylinder is OK. Go to Cause F.
NO: Remove and repair steering cylinder. Depending on your lift truck, see Steering System 1600SRM1331
or Steering System 1600SRM1363 ..

CAUSE F - TRANSAXLE/DRIVE UNIT COMPONENTS ARE DAMAGED AND/OR BINDING.

PROCEDURE OR ACTION:
1. Turn steering wheel stop to stop in both directions while observing tires.
Do tires shake or make noise while turning?
YES: Inspect and repair damage transaxle/drive unit components. Depending on your lift truck, see Steering
System 1600SRM1331 or Steering System 1600SRM1363 ..
NO: Go to Cause G.

CAUSE G - SCU IS WORN, NOT ASSEMBLED CORRECTLY, OR DAMAGED.

PROCEDURE OR ACTION:
1. Inspect SCU. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control Valves
2000SRM1439, or Electrical System 2200SRM1337.
Is steering control unit damaged?
YES: Install new SCU. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Control
Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: See Observed Symptoms-Gear Pump, Steering Operation Is Not Smooth, Page 9050-33-61.

END SYMPTOM

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9050-33-60 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Steering Operation Is Not Smooth

POSSIBLE CAUSE
A. AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM.
B. STEERING RELIEF PRESSURE SET TOO LOW.
C. HYDRAULIC STEER ACCUMULATOR IS NOT WORKING PROPERLY.
D. BINDING IN STEERING COLUMN.
E. LOW PUMP FLOW.
F. FAILED CENTERING SPRINGS IN SCU.
G. STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY, DAMAGED, OR CONTAMINATED.

CAUSE A - AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM.
PROCEDURE OR ACTION:
1. Check service record of lift truck.
Was hydraulic system repaired recently?
YES: Check the repaired hose connections and remove air from system by cycling of steering cylinder full
stroke in each direction.
NO: Go to Cause B.

CAUSE B - STEERING RELIEF PRESSURE SET TOO LOW.

PROCEDURE OR ACTION:
1. Perform Operational Check, seeOperational Diagnostic Procedures, Operational Checkout, Page 9010-05-13.
Is steering relief pressure set too low?
YES: Adjust steering relief pressure. See Steering Relief Pressure Test and Adjustment.
NO: Go to Cause C.

CAUSE C - HYDRAULIC STEER ACCUMULATOR IS NOT WORKING PROPERLY.

PROCEDURE OR ACTION:
1. Turn steering wheel slowly while operating a mast function over relief, then suddenly release the control lever.
Does steering wheel jerk abruptly?
YES: Replace the steering accumulator. See Hydraulic System 1900SRM1367
NO: Go to Cause D.

CAUSE D - BINDING IN STEERING COLUMN.

PROCEDURE OR ACTION:
1. Turn steering wheel stop to stop with engine running at slow idle.
Is steering shaft binding in steering column?
YES: Inspect and repair steering column. Depending on your lift truck, see Steering System 1600SRM1331
or Steering System 1600SRM1363 ..
NO: Go to Cause E.

CAUSE E - LOW PUMP FLOW.

PROCEDURE OR ACTION:
1. Do Hydraulic Pump Flow Test.
Are other hydraulic functions OK?
YES: Hydraulic pump output is OK. Go to Cause F.
NO: Test hydraulic system relief pressure. See Primary Relief Valve Test and Adjustment.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-61
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE F - FAILED CENTERING SPRINGS IN SCU.

PROCEDURE OR ACTION:
1. Inspect SCU.
Are the centering springs in good condition?
YES: Springs are OK. Go to Cause G.
NO: Replace centering springs. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE G - STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY, DAMAGED, OR CONTAMINATED.

PROCEDURE OR ACTION:
1. Inspect SCU.
Is SCU properly assembled and clean?
YES: Install new steering control unit. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Clean steering valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

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9050-33-62 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Steering Wheel End Lock Position Cannot Be Felt by Operator

POSSIBLE CAUSE
A. ANTI-KICKBACK VALVES ARE SAME PRESSURE SETTING AS RELIEF VALVE.
B. CONTAMINATION CAUSING IMPROPER SHOCK VALVE OPERATION.

CAUSE A - ANTI-KICKBACK VALVES ARE SAME PRESSURE SETTING AS RELIEF VALVE.

PROCEDURE OR ACTION:
1. Inspect SCU.
Are the anti-kickback valves in good condition?
YES: Anti-kickback valves OK. Go to Cause B.
NO: Replace anti-kickback valves. Depending on your left truck see, Main Control Valves 2000SRM1334,
Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE B - CONTAMINATION CAUSING IMPROPER SHOCK VALVE OPERATION.

PROCEDURE OR ACTION:
1. Inspect assembly of SCU.
Is SCU properly assembled and clean?
YES: Install new steering control unit. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Clean steering valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-63
Observed Symptoms-Gear Pump Hydraulic Systems

Steering Wheel Turns By Itself or Does Not Return To Neutral

POSSIBLE CAUSE
A. STEERING RELIEF PRESSURE SET TOO LOW.
B. BINDING IN STEERING COLUMN OR NO RESISTANCE.
C. FAILED CENTERING SPRINGS IN SCU.
D. DEFLECTION OF SPOOL AND SLEEVE CAUSED BY HIGH SYSTEM PRESSURE.
E. STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY OR IS DAMAGED.

CAUSE A - STEERING RELIEF PRESSURE SET TOO LOW.

PROCEDURE OR ACTION:
1. Perform Operational Diagnostic Procedures, Operational Checkout, Page 9010-05-13.
Is steering relief pressure set too low?
YES: Adjust steering relief pressure. See Steering Relief Pressure Test and Adjustment.
NO: Go to Cause B.

CAUSE B - BINDING IN STEERING COLUMN OR NO RESISTANCE.

PROCEDURE OR ACTION:
1. Turn steering wheel stop to stop with engine running at slow idle.
Is linkage binding in steering column?
YES: Inspect and repair steering column. Depending on your lift truck, see Steering System 1600SRM1331
or Steering System 1600SRM1363 ..
NO: Go to Cause C.

CAUSE C - FAILED CENTERING SPRINGS IN SCU.

PROCEDURE OR ACTION:
1. Inspect SCU.
Are the centering springs in good condition?
YES: Springs are OK. Go to Cause D.
NO: Replace centering springs. Depending on your left truck see, Main Control Valves 2000SRM1334, Main
Control Valves 2000SRM1439, or Electrical System 2200SRM1337.

CAUSE D - DEFLECTION OF SPOOL AND SLEEVE CAUSED BY HIGH SYSTEM PRESSURE.

PROCEDURE OR ACTION:
1. Perform Steering Relief Pressure Test and Adjustment.
Does steering relief pass check?
YES: Go to Cause E.
NO: Adjust relief pressure. See Steering Relief Pressure Test and Adjustment.

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Hydraulic Systems Observed Symptoms-Gear Pump

CAUSE E - STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY OR IS DAMAGED.

PROCEDURE OR ACTION:
1. Inspect SCU.
Is SCU properly assembled and clean?
YES: Install new steering control unit. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Clean steering valve. Depending on your left truck see, Main Control Valves 2000SRM1334, Main Con-
trol Valves 2000SRM1439, or Electrical System 2200SRM1337.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-65
Observed Symptoms-Gear Pump Hydraulic Systems

Steering Wheel Turns the Tires in the Wrong Direction

POSSIBLE CAUSE
A. HYDRAULIC HOSES ARE NOT CONNECTED CORRECTLY AT THE STEERING CYLINDER OR AT THE
SCU.

CAUSE A - HYDRAULIC HOSES ARE NOT CONNECTED CORRECTLY AT THE STEERING CYLINDER OR
AT THE SCU.
PROCEDURE OR ACTION:
1. Look at Steering System component to identify steering hoses.
Are hoses correctly installed?
YES: Problem is in SCU. Repair or replace SCU. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Correct steering hose routing at valve or steering cylinder.

END SYMPTOM

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9050-33-66 Confidential/Proprietary - Do Not Copy or Duplicate
Hydraulic Systems Observed Symptoms-Gear Pump

Actuations Do Not Act Simultaneously

POSSIBLE CAUSE
A. LOW PUMP FLOW.
B. SECONDARY RELIEF VALVE SET TOO LOW.

CAUSE A - LOW PUMP FLOW.

PROCEDURE OR ACTION:
1. Check cycle times of lift function.
Is lift function speed ok?
YES: Go to Cause B.
NO: Go to Observed Symptoms-Gear Pump, Abnormal Hydraulic Noise and/or Vibration, Page 9050-33-1.

CAUSE B - SECONDARY RELIEF VALVE SET TOO LOW.

PROCEDURE OR ACTION:
1. Test and adjust secondary relief pressure. See Secondary Relief Valve Test and Adjustment.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-67
Observed Symptoms-Gear Pump Hydraulic Systems

Oil Leaking/Component Life Too Short

POSSIBLE CAUSE
A. HYDRAULIC OIL TANK IS OVERFILLED.
B. LOOSE OR DAMAGED HARDWARE.
C. DAMAGED O-RING/ROD SEAL.
D. HYDRAULIC RELIEF PRESSURES SET TOO HIGH.
E. HYDRAULIC FLUID CONTAMINATED OR WRONG TYPE.
F. EXCESSIVE DEBRIS IN HYDRAULIC CIRCUIT.
G. HYDRAULIC OIL TANK OPEN TO ATMOSPHERE.
H. HYDRAULICS OPERATED ABOVE RECOMMENDED OPERATING RANGE.
I. WARPED COMPONENT SECTION OF HYDRAULIC CONTROL VALVE.
J. SEALS BETWEEN VALVE SECTIONS FAILED

CAUSE A - HYDRAULIC OIL TANK IS OVERFILLED.

PROCEDURE OR ACTION:
1. Check to see if hydraulic oil tank is overfilled.
Is hydraulic oil tank overfilled?
YES: Drain hydraulic oil to proper level.
NO: Go to Cause B.

CAUSE B - LOOSE OR DAMAGED HARDWARE.

PROCEDURE OR ACTION:
1. Locate source of oil leak by checking the following items. Depending on your left truck see, Main Control
Valves 2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
• Check torque on fittings.
• Check torque on tie rod at valve outlet housing.
• Check torque on hardware between SCU and valve.
Did leak stop after checking hardware?
YES: Problem solved.
NO: Go to Cause C.

CAUSE C - DAMAGED O-RING/ROD SEAL.

PROCEDURE OR ACTION:
1. Replace damaged O-ring or rod seal. Depending on your left truck see, Main Control Valves 2000SRM1334,
Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
Is problem fixed?
YES: Problem solved.
NO: Go to Cause D.

CAUSE D - HYDRAULIC RELIEF PRESSURES SET TOO HIGH.

PROCEDURE OR ACTION:
1. Check main and secondary relief pressures. Go to Primary Relief Valve Test and Adjustment.
Does relief pressure meet specifications?
YES: Go to Cause E.
NO: Adjust or replace relief valve.

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Hydraulic Systems Observed Symptoms-Gear Pump

CAUSE E - HYDRAULIC FLUID CONTAMINATED OR WRONG TYPE.

PROCEDURE OR ACTION:
1. Check hydraulic oil for contamination and correct type.
Is hydraulic oil contaminated or incorrect type used?
YES: Drain and refill hydraulic tank. Depending on your lift truck see, Periodic Maintenance 8000SRM1364,
Periodic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic Maintenance
8000SRM1373, or Periodic Maintenance 8000SRM1442.
NO: Go to Cause F.

CAUSE F - EXCESSIVE DEBRIS IN HYDRAULIC CIRCUIT.

PROCEDURE OR ACTION:
1. Check for plugged and bypassing hydraulic oil filter.
Is hydraulic oil filter plugged and bypassing?
YES: Clean or replace hydraulic oil filter.
NO: Go to Step 2.
2. Check for contaminated oil.
Is hydraulic oil contaminated?
YES: Drain and refill hydraulic tank. Depending on your lift truck see, Periodic Maintenance 8000SRM1364,
Periodic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic Maintenance
8000SRM1373, or Periodic Maintenance 8000SRM1442.
NO: Go to Cause G.

CAUSE G - HYDRAULIC OIL TANK OPEN TO ATMOSPHERE.

PROCEDURE OR ACTION:
1. Check hydraulic oil tank for missing breather or missing dipstick.
Is breather or dipstick missing from hydraulic oil tank?
YES: Replace breather or dipstick.
NO: Go to Cause H.

CAUSE H - HYDRAULICS OPERATED ABOVE RECOMMENDED OPERATING RANGE.

PROCEDURE OR ACTION:

NOTE: If lift truck is equipped with Hydraulic Oil Cooler, see Observed Symptoms-Gear Pump, Page 9050-33-16.

1. Inspect hydraulic components and oil for signs of excessive heat.

Do components and oil show signs of overheating?
YES: Replace damaged components and service hydraulic system. Depending on your lift truck see, Peri-
odic Maintenance 8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance
8000SRM1339, Periodic Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.
NO: Go to Cause I.

CAUSE I - WARPED COMPONENT SECTION OF HYDRAULIC CONTROL VALVE.

PROCEDURE OR ACTION:
1. Check hydraulic control valve for warped component section.
Does hydraulic control valve have warped component section?
YES: Replace hydraulic control valve. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Go to Cause J.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-69
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE J - SEALS BETWEEN VALVE SECTIONS FAILED

PROCEDURE OR ACTION:
1. Check hydraulic control valve for oil leakage between valve sections.
Is oil leaking between valve sections?
YES: Replace seals between valve sections. Depending on your left truck see, Main Control Valves
2000SRM1334, Main Control Valves 2000SRM1439, or Electrical System 2200SRM1337.
NO: Seals between valve sections OK.

END SYMPTOM

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Hydraulic Systems Observed Symptoms-Gear Pump

Abnormal Steer Axle Noise

POSSIBLE CAUSE
A. WHEEL IS LOOSE.
B. STEER WHEEL CONTACTING STEERING AXLE OR CHASSIS.
C. TIE ROD AND/OR BUSHINGS ARE WORN.
D. WHEEL OR SPINDLE BEARING LUBRICATION IS INADEQUATE.
E. WHEEL OR SPINDLE BEARING FAILURE.
F. STEERING AXLE BUSHINGS WORN.
G. STEERING AXLE DAMAGED.

CAUSE A - WHEEL IS LOOSE.

PROCEDURE OR ACTION:
1. Inspect wheels, lug nuts, and studs for damage.
Are wheels, lug nuts, and studs damaged or loose?
YES: If loose, tighten wheel lugs. Repair or replace damaged [Link] on your lift truck see, Periodic
Maintenance 8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance
8000SRM1339, Periodic Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.
NO: Go to Cause B.

CAUSE B - STEER WHEEL CONTACTING STEERING AXLE OR CHASSIS.

PROCEDURE OR ACTION:
1. Inspect steer wheels, steering axle, and chassis.
Are wheels contacting steering axle or chassis?
YES: Repair or replace steer wheel or steering axle, or repair chassis. Depending on your lift truck, see
Steering System 1600SRM1331 or Steering System 1600SRM1363 ..
NO: Go to Cause C.

CAUSE C - TIE ROD AND/OR BUSHINGS ARE WORN.

PROCEDURE OR ACTION:
1. Inspect tie rod and bushing.
Are tie rods and bushing in good condition?
YES: Go to Cause D.
NO: Repair or adjust tie rods or bushings. Depending on your lift truck, see Steering System 1600SRM1331
or Steering System 1600SRM1363 ..

CAUSE D - WHEEL OR SPINDLE BEARING LUBRICATION IS INADEQUATE.

NOTE: See Operating Manual for lubrication procedures.

PROCEDURE OR ACTION:
1. Lubricate wheel and spindle bearings.
Did the bearings lack lubrication?
YES: Service lift truck per Operating Manual instructions.
NO: Go to Cause E.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-71
Observed Symptoms-Gear Pump Hydraulic Systems

CAUSE E - WHEEL OR SPINDLE BEARING FAILURE.

PROCEDURE OR ACTION:
1. Inspect bearings and spindle.
Are the bearings and spindle in good condition?
YES: If bearings are OK, go to Cause F.
NO: Replace bearings and/or spindle. Depending on your lift truck, see Steering System 1600SRM1331 or
Steering System 1600SRM1363 ..

CAUSE F - STEERING AXLE BUSHINGS WORN.

PROCEDURE OR ACTION:
1. Inspect steering axle bushings for wear. Depending on your lift truck, see Steering System 1600SRM1331 or
Steering System 1600SRM1363 ..
Are the steering axle bushings in good condition?
YES: Go to Cause G.
NO: Replace bushings.

CAUSE G - STEERING AXLE DAMAGED.

PROCEDURE OR ACTION:
1. Inspect steering axle for damage.
Is steering axle in good condition?
YES: Resume operation while monitoring systems to locate source of noise.
NO: Repair as required. Depending on your lift truck, see Steering System 1600SRM1331 or Steering Sys-
tem 1600SRM1363 ..

END SYMPTOM

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Hydraulic Systems Observed Symptoms-Gear Pump

Abnormal Steering Wheel Vibration

POSSIBLE CAUSE
A. WORN TIRES.
B. LOW OIL LEVEL IN TANK.
C. AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM.
D. STEERING AXLE COMPONENTS WORN.

CAUSE A - WORN TIRES.

PROCEDURE OR ACTION:
1. Inspect tires.
Are tires worn?
YES: Replace tires. Depending on your lift truck see, Periodic Maintenance 8000SRM1364, Periodic Main-
tenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic Maintenance 8000SRM1373, or
Periodic Maintenance 8000SRM1442.
NO: Go to Cause B.

CAUSE B - LOW OIL LEVEL IN TANK.

PROCEDURE OR ACTION:

NOTE: Cavitation of a hydraulic pump will cause noise and it is caused by air in the hydraulic oil. The hydraulic
pump suction oil must be free of air and unrestricted to pump.

1. Check hydraulic oil level in tank.

Is oil at correct level?
YES: Go to Cause C.
NO: Add oil to correct level. See Operating Manual.

CAUSE C - AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM.
PROCEDURE OR ACTION:
1. Check service record of lift truck.
Was hydraulic system repaired recently?
YES: Check the repaired hose connections. Remove air from system by cycling function full stroke of steering
cylinder in each direction.
NO: Go to Cause D.

CAUSE D - STEERING AXLE COMPONENTS WORN.

PROCEDURE OR ACTION:
1. Operate truck to determine if vibration is hydraulic or mechanical.
Is the vibration caused by hydraulics?
YES: See Observed Symptoms-Gear Pump, Abnormal Hydraulic Noise and/or Vibration, Page 9050-33-1.
NO: Repair or replace worn or damaged steer axle components. Depending on your lift truck, see Steering
System 1600SRM1331 or Steering System 1600SRM1363 ..

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-73
Observed Symptoms-Gear Pump Hydraulic Systems

Back Lash/Kick Back in Steering Wheel

POSSIBLE CAUSE
A. LOOSE STEERING AXLE COMPONENTS.
B. SPLINES OR STEERING SHAFT UNIVERSAL JOINT IN STEERING COLUMN WORN OR BROKEN.
C. STEERING RELIEF PRESSURE IS NOT SET CORRECTLY.
D. FAILED CENTERING SPRINGS IN SCU.
E. STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY OR IS DAMAGED.

CAUSE A - LOOSE STEERING AXLE COMPONENTS.

PROCEDURE OR ACTION:
1. Turn steering wheel back and forth while observing steer axle wheels at slow idle.
Do the tires respond directly to steering wheel movement?
YES: Go to Cause B.
NO: Inspect wheel studs and steering axle components for damage. Repair as required. Depending on your
lift truck, see Steering System 1600SRM1331 or Steering Axle 1600SRM1360.

CAUSE B - SPLINES OR STEERING SHAFT UNIVERSAL JOINT IN STEERING COLUMN WORN OR BRO-
KEN.
PROCEDURE OR ACTION:
1. Turn steering wheel back and forth while observing steer axle wheels at slow idle.
Does the steer axle wheels movement match steering wheel movement in both directions?
YES: Go to Cause C.
NO: Inspect and repair steering column. Depending on your lift truck, see Steering System 1600SRM1331 or
Steering System 1600SRM1363.

CAUSE C - STEERING RELIEF PRESSURE IS NOT SET CORRECTLY.

PROCEDURE OR ACTION:
1. Do steering relief pressure test.
Is steering relief pressure set to specification?
YES: Adjust steering relief pressure. See Steering Relief Pressure Test and Adjustment.
NO: Go to Cause D.

CAUSE D - FAILED CENTERING SPRINGS IN SCU.

PROCEDURE OR ACTION:
1. Inspect SCU.
Are the centering springs in good condition?
YES: Springs are OK. Go to Cause E.
NO: Replace centering springs. Depending on your lift truck, see Steering System 1600SRM1331 or Steer-
ing System 1600SRM1363.

CAUSE E - STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY OR IS DAMAGED.

PROCEDURE OR ACTION:
1. Inspect SCU.
Is SCU properly assembled and clean?
YES: Replace the SCU. Depending on your lift truck, see Steering System 1600SRM1331 or Steering Sys-
tem 1600SRM1363.

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Hydraulic Systems Observed Symptoms-Gear Pump

NO: Repair steering control unit. Depending on your lift truck, see Steering System 1600SRM1331 or Steer-
ing System 1600SRM1363.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-33-75
 NOTES

9050-33-76
Hydraulic Systems Tests and Adjustments-Gear Pump

Group 43

Tests and Adjustments-Gear Pump

Hydraulic Warm-up Procedure

Use this procedure to get the hydraulic oil tempera- pressure before removing or installing test equip-
ture to test specification. Install the test equipment on ment.
lift truck before starting this procedure to reduce han-
dling of hot component or oil.
CAUTION
Table 9050-43-1. Test Specifications Do not permit dirt or other contaminants to enter
the hydraulic system. Disconnected hoses, tubes,
Oil Temperature 50 - 65°C (122 - 150 °F) open valves, cylinder fittings, and ports should be
protected with clean caps or plugs.
Table 9050-43-2. Service Tools
1. Install test equipment as called out in test.
Temperature Reader - Thermocouple
2. Insert thermocouple in dipstick hole.

WARNING 3. Turn key or keyless switch to the ON position.

Hot hydraulic oil can cause serious burns to skin.
Do not touch hydraulic components or oil during 4. Tilt the mast back and hold over relief for 20 sec-
test. Make sure hydraulic oil has cooled to safe onds, then release lever. Cycle both tilt and lift
temperature before installing or removing test cylinders to circulate oil and equalize temperature
equipment. in system.

5. Read temperature and compare to temperature

WARNING specifications of test to be performed.
Hydraulic oil under pressure can be injected into 6. Repeat Step 4 and Step 5 until oil temperature is
skin. Lower forks to ground and relieve all circuit at test specifications.

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Tests and Adjustments-Gear Pump Hydraulic Systems

Primary Relief Valve Test and Adjustment

3. Operate the hydraulic system until the oil temper-
CAUTION ature is at test specifications. See Hydraulic
Typically, the Main Relief Valve (MRV) should NOT Warm-up Procedure.
be adjusted in the field for general purposes. In-
creasing the setting of the MRV past its specified
WARNING
setting may damage truck.
Forks contacting overhead electrical wires or fix-
tures can cause serious injury or death. Make
sure area is clear of hazards before raising forks
WARNING to maximum height.
Hot hydraulic oil can cause serious burns to skin. 4. Raise the mast until it stops. Hold the lever and
Do not touch hydraulic components or oil during check the reading of the gauge when the relief
test. Make sure hydraulic oil has cooled to safe valve opens. Compare to specifications.
temperature before installing or removing test
equipment. 5. Replace primary relief valve, if not within specifi-
cation, by unscrewing the relief cartridge from the
inlet section and installing a new relief cartridge.
WARNING
Hydraulic oil under pressure can be injected into 6. Cycle lever over relief to verify the setting is within
skin. Lower forks to ground and relieve all circuit specification. Depending on your lift truck see,
pressure before removing test plugs from valve. Main Control Valves 2000SRM1334 or Main
Control Valves 2000SRM1439. .
1. Lower forks to ground and turn OFF key. Apply
park brake. 7. Remove test equipment and reinstall cap onto di-
agnostic port.
CAUTION
Do not permit dirt or other contaminants to enter Table 9050-43-3. Service Tools
the hydraulic system. Disconnected hoses, tubes,
open valves, cylinder fittings, and ports should be 275 - 345 MPa (4000 - 5000 psi) Pressure Gauge
protected with clean caps or plugs. Excess Flow (EF) Test SAE #4 O-ring Port
2. Remove panels that cover MRV. Remove cover Plug Port Size (7/16-20 UNF)
from diagnostic port and install pressure gauge.
See Figure 9050-43-42, Figure 9050-43-43 and
Figure 9050-43-45.

Table 9050-43-4. Test Specifications

Lift Truck Capacity Main Relief Pressure Pump Flow

J1.5-2.0XNT (J30-40XNT) 1.5-2.0 Tons 17.9 MPa 63.6 liter/min
(K160) (2596 psi) (16.8 gal/min)
A1.3-1.5XNT (A25-30XNT) 2.2-2.75 Tons 21.9 MPa 81.4 liter/min
(D203 E2.2-3.5XN (E45-70XN) (3176 psi) (21.5 gal/min)
(A268) J2.2-3.5XN (J40-70XN)
(A276)
E2.2-3.5XN (E45-70XN) (A268) 3.0-3.5 Tons 23.9 MPa 81.4 liter/min
J2.2-3.5XN (J40-70XN) (A276) (3466 psi) (21.5 gal/min)

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Hydraulic Systems Tests and Adjustments-Gear Pump

1. DIAGNOSTIC PORT WITH GAUGE

2. SECONDARY RELIEF VALVE LOCATION
3. PRIMARY RELIEF VALVE LOCATION

Figure 9050-43-43. Manual Valve for Lift Trucks

1. DIAGNOSTIC PORT WITH GAUGE E2.2-3.5XN (E45-70XN) (A268) and J2.2-3.5XN
2. OPTIONAL SECONDARY RELIEF VALVE LO- (J40-70XN) (A276) Shown
CATION
3. PRIMARY RELIEF VALVE LOCATION

Figure 9050-43-42. Manual Valve for Lift Trucks

J1.5-2.0XNT (J30-40XNT) (K160) and J1.6-2.0XN
(A935) Shown

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Tests and Adjustments-Gear Pump Hydraulic Systems

Legend for Figure 9050-43-44

1. DIAGNOSTIC FITTING WITH CAP

2. PRIMARY RELIEF VALVE

Figure 9050-43-44. E-Hydraulic Valve for Lift

Trucks A1.3XNT, A1.5XNT (A25XNT, A30XNT)
[D203]

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Hydraulic Systems Tests and Adjustments-Gear Pump

A. FRONT VIEW B. BOTTOM VIEW

1. DIAGNOSTIC PORT WITH GAUGE 3. PRIMARY RELIEF VALVE LOCATION
2. ANTI-CAVITATION CHECK 4. SECONDARY RELIEF VALVE LOCATION

Figure 9050-43-45. E-Hydraulic Valve for Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160), J1.6-2.0XN (A935),
E2.2-3.5XN (E45-70XN) (A268), and J2.2-3.5XN (J40-70XN) (A276) Shown

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Tests and Adjustments-Gear Pump Hydraulic Systems

Secondary Relief Valve Test and Adjustment

It may be necessary to adjust the setting of the Op- Table 9050-43-7. Service Tools
tional Relief Valve (ORV) depending on what attach-
ments are used for the auxiliary function. 0 - 35.0 MPa (0 - 5000 psi) Pressure Gauge
Excess Flow (EF) Test SAE #4 O-ring Port
NOTE: The Relief Pressure setting is the working Port Plug Size (7/16-20 UNF)
range that the secondary relief can be set to meet re-
quirements of attachments.

The Factory Default setting is the pressure that the

secondary relief is set at the factory.

NOTE: Secondary relief valves for manual control

valves on lift trucks J1.5-2.0XNT (J30-40XNT) (K160)
and J1.6-2.0XN (A935) are installed into auxiliary sec-
tions for special attachments. Standard relief pressure
for these lift trucks is set with primary relief valve only.

Table 9050-43-5. Test Specifications for Lift

Trucks J1.5-2.0XNT (J30-40XNT) (K160) and
J1.6-2.0XN (A935)

Oil 50 - 65°C (122 - 150 °F)

Temperature
Secondary 17.9 MPa (2596 psi)
Relief Pressure
Factory Default 15.0 - 16.0 MPa (2180 - 2320 psi)
Setting

Table 9050-43-6. Test Specifications for Lift

Trucks E2.2-3.5XN (E45-70XN) (A268) and
J2.2-3.5XN (J40-70XN) (A276) 1. DIAGNOSTIC PORT WITH GAUGE
2. OPTIONAL SECONDARY RELIEF VALVE LO-
Oil 50 - 65°C (122 - 150 °F) CATION
Temperature 3. PRIMARY RELIEF VALVE LOCATION
Secondary 15.0 - 16.0 MPa (2180 - 2320 psi) Figure 9050-43-46. Manual Control Valve for Lift
Relief Valve Trucks J1.5-2.0XNT (J30-40XNT) (K160) and
Setting J1.6-2.0XN (A935) Shown
Factory Default 15.0 - 16.0 MPa (2180 - 2320 psi)
Setting

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Hydraulic Systems Tests and Adjustments-Gear Pump

WARNING
Hydraulic oil under pressure can be injected into
skin. Lower forks to ground and relieve all circuit
pressure before removing test plugs from valve.

1. Lower forks to ground and turn key or keyless

switch to OFF position. Apply park brake.

CAUTION
Do not permit dirt or other contaminants to enter
the hydraulic system. Disconnected hoses, tubes,
open valves, cylinder fittings, and ports should be
protected with clean caps or plugs.

2. Remove covers. Install pressure gauge in control

valve diagnostic port. See Figure 9050-43-46.

CAUTION
1. DIAGNOSTIC PORT WITH GAUGE Setting relief valve above specification can cause
2. SECONDARY RELIEF VALVE LOCATION damage to hydraulic and mechanical components
3. PRIMARY RELIEF VALVE LOCATION of lift truck. Do not increase pressure above spec-
ifications.
Figure 9050-43-47. Manual Control Valve for Lift
Trucks E2.2-3.5XN (E45-70XN) (A268) and 3. Operate the hydraulic system until the oil temper-
J2.2-3.5XN (J40-70XN) (A276) Shown ature is at test specifications. See Hydraulic
Warm-up Procedure.
WARNING 4. Tilt the mast back until it stops. Hold the lever and
Hot hydraulic oil can cause serious burns to skin. check the reading of the gauge when the relief
Do not touch hydraulic components or oil during valve opens. Compare to test specifications.
test. Make sure hydraulic oil has cooled to safe
temperature before installing or removing test
equipment.

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Tests and Adjustments-Gear Pump Hydraulic Systems

A. FRONT VIEW B. BOTTOM VIEW

1. DIAGNOSTIC PORT WITH GAUGE 3. PRIMARY RELIEF VALVE LOCATION
2. ANTI-CAVITATION CHECK 4. OPTIONAL SECONDARY RELIEF VALVE LO-
CATION

Figure 9050-43-48. E-Hydraulic Control Valve for Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160) , J1.6-2.0XN
(A935) Shown

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Hydraulic Systems Tests and Adjustments-Gear Pump

A. FRONT VIEW B. BOTTOM VIEW

1. DIAGNOSTIC PORT WITH GAUGE 3. PRIMARY RELIEF VALVE LOCATION
2. ANTI-CAVITATION CHECK 4. SECONDARY RELIEF VALVE LOCATION

Figure 9050-43-49. E-Hydraulic Control Valve for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) , and
J2.2-3.5XN (J40-70XN) (A276) Shown

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Tests and Adjustments-Gear Pump Hydraulic Systems

NOTE: Cycling the tilt or auxiliary function over relief

after adjustment gives the relief valve spring opportu-
nity to reposition itself inside the valve. This must be
done after each adjustment until pressure is repeata-
ble on gauge.

5. If pressure is not within specifications, remove

hex plug (see Figure 9050-43-50), while holding
tilt hydraulics over relief, slowly turn the adjust-
ment screw, in (clockwise) to increase pressure,
out (counterclockwise) to reduce pressure. Cycle
the tilt or auxiliary control lever on and off against
the relief three times to see if pressure is repeata-
ble.

6. Insert hex plug. Cycle lever over relief a few more

times to verify the setting is still correct. If setting
does not stabilize, clean or replace relief valve.
Depending on your lift truck see, Main Control
Valves 2000SRM1334 or Main Control Valves
2000SRM1439.

7. If relief pressure cannot be maintained or adjus-

ted up, the control valve may have contamination 1. SEAT
or have excess leakage in Load Sense (LS) cir- 2. O-RING
3. BACKUP RING
cuit. See Main Control Valve LS Leakage Test (E- 4. POPPET
Valve). 5. SPRING
6. ADJUSTMENT SCREW
8. Remove test equipment and reinstall diagnostic 7. HEX PLUG
port cap. 8. RELIEF CARTRIDGE

Figure 9050-43-50. Optional/Secondary Relief

Valve

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Hydraulic Systems Tests and Adjustments-Gear Pump

Hydraulic Pump Flow Test

This test is done to accurately check the hydraulic 3. Operate the hydraulic system until the oil temper-
pump output. This will isolate if performance problems ature is to test specifications. See Hydraulic
are in hydraulic pump or elsewhere in hydraulic cir- Warm-up Procedure.
cuit.
4. Raise empty mast and hold over relief, record
NOTE: If a flowmeter is not available, use lift speed pump flow. Compare pump flow to specifications.
charts. Depending on your lift truck see, Periodic
5. Return forks to ground level and turn key or key-
Maintenance 8000SRM1364, Periodic Maintenance
less switch to OFF position.
8000SRM1372, Periodic Maintenance
8000SRM1339, Periodic Maintenance
8000SRM1373, or Periodic Maintenance Table 9050-43-8. Test Specifications
8000SRM1442. to determine pump output. If lift raise
times with capacity load on forks is more than 25% Oil 50 - 65°C (122 - 150 °F)
greater than specifications, the pump should be re- Temperature
placed. Minimum Pump Pump: 63.6 liter/min (16.8 gal/min)
Output for Lift
Truck
1. Lower forks to ground and turn key or keyless J1.5-2.0XNT
switch to the OFF position. Apply park brake. (J30-40XNT)
(K160) and
WARNING J1.6-2.0XN
(A935)
Hot hydraulic oil can cause serious burns to skin.
Do not touch hydraulic components or oil during Minimum Pump Pump: 81.4 liter/min (21.5 gal/min)
test. Make sure hydraulic oil has cooled to safe Output for Lift
temperature before installing or removing test Truck
equipment. E2.2-3.5XN
(E45-70XN)
(A268) and
CAUTION J2.2-3.5XN
Do not permit dirt or other contaminants to enter (J40-70XN)
the hydraulic system. Disconnected hoses, tubes, (A276)
open valves, cylinder fittings, and ports should be
Excess Flow Tilt Function Over Relief (Optional/
protected with clean caps or plugs.
(EF) Test Secondary Relief Valve Setting)
2. Remove floor panels. Remove hose assembly to Pressure
hydraulic pump and install flowmeter. Install hose
assembly from flow meter to hydraulic pump. In-
stall pressure gauge to the diagnostic port of con- Table 9050-43-9. Service Tools
trol valve if flowmeter does not have internal
gauge. See Figure 9050-43-51. 125 liter/min (33 gal/min) Flowmeter, Rated at 24.0
MPa (3500 psi)
0 - 35.0 MPa (0 - 5000 psi) Pressure Gauge
CAUTION
Excess Flow (EF) Test SAE #4 O-ring Port
Hydraulic pump will be damaged if flowmeter gate
Port Plug Size (7/16-20 UNF)
valve is closed. Open the gate valve all the way
open (counterclockwise) on the flowmeter before Steering Control Valve SAE #12 O-ring Port
running lift truck. Inlet Port Size (1-1/16-12 UNF)

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Tests and Adjustments-Gear Pump Hydraulic Systems

NOTE: A collapsed suction hose or plugged suction tem 1900SRM1367, or Hydraulic System
screen in hydraulic tank could affect pump flow. Be 1900SRM1333.
sure to check these components before replacing
pump. 7. Remove test equipment, reinstall hoses and floor
panel.
6. If the flow is less than the specifications, inspect
suction hoses to pump and suction screen in hy- 8. Check oil level in hydraulic tank. Add oil, as re-
draulic tank. If they are OK then replace pump. quired.
Depending on your lift truck, see Hydraulic Sys-

NOTE: CONTROL VALVE SHOWN IS FOR LIFT TRUCKS J1.5-2.0XNT (J30-40XNT) (K160) AND J1.6-2.0XN
(A935) .

1. DIAGNOSTIC PORT WITH GAUGE 3. FLOWMETER

2. HOSE ASSEMBLY 4. HYDRAULIC PUMP

Figure 9050-43-51. E-Hydraulic Pump Shown

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Hydraulic Systems Tests and Adjustments-Gear Pump

Main Control Valve LS Leakage Test (E-Valve)

This test is done to check if there is leakage in the 1. Check hydraulic temperature. If not within specifi-
Load-Sense (LS) pressure circuit. cations, see Hydraulic Warm-up Procedure. Oper-
ate until temperature is at test specifications.
Table 9050-43-10. Test Specifications
2. Turn key or keyless switch to ON position and ap-
Oil Temperature 50 - 65°C (122 - 150 °F) ply park brake.

3. Measure and record the lift rate with lift lever fully
WARNING actuated at:
Hot hydraulic oil can cause serious burns to skin. • No Load
Do not touch hydraulic components or oil during
• Rated Load
test. Make sure hydraulic oil has cooled to safe
temperature before installing or removing test 4. If the difference from specified rates in chart, it is
equipment. likely that the LS passage has an internal leakage
within the monoblock section. Replace the valve
WARNING monoblock section. Depending on your lift truck
see, Main Control Valves 2000SRM1334 or
Hydraulic oil under pressure can be injected into
Main Control Valves 2000SRM1439.
skin. Lower forks to ground and relieve all circuit
pressure before removing test plugs from valve.

Main Control Valve Unloader Margin Test

This test is done to check if unloader pressure margin Disconnected hoses, tubes, open valves, cylinder
is within test specification. fittings, and ports should be protected with clean
caps or plugs.
1. Lower forks to ground, turn key or keyless switch
to OFF position, and apply park brake. 3. Install a hose in load sense port and the other
hose in the reduced pressure port on the control
2. Remove floor plates that cover main control valve. valve. See Figure 9050-43-52.

NOTE: Test gauges must be calibrated. Gauge accu-

WARNING racy is very important for this test. A pressure differ-
Hot hydraulic oil can cause serious burns to skin. ential gauge or switching block should be used so
Do not touch hydraulic components or oil during both readings are on same gauge. If you do not have
test. Make sure hydraulic oil has cooled to safe this equipment, you will need to switch gauges to ver-
temperature before installing or removing test ify gauge readings.
equipment.
4. Check hydraulic temperature. If not within specifi-
cations, see Hydraulic Warm-up Procedure. Oper-
WARNING ate until temperature is at test specifications.
Hydraulic oil under pressure can be injected into
skin. Lower forks to ground and relieve all circuit 5. Measure pressure. If the pressure margin is be-
pressure before removing test plugs from valve. low specification, go to Step 6.

CAUTION
Do not permit dirt or other contaminants to enter
the hydraulic system.

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Tests and Adjustments-Gear Pump Hydraulic Systems

8. Remove test equipment and reinstall plugs in con-

Table 9050-43-11. Test Specifications trol valve.

Oil Temperature 50 to 65°C (122 to 150 °F)

Maximum 1034 to 1138 kPa (150 to
Unloader 165 psi)
Pressure Margin
Flow Rate For [A268], E2.2-3.5XN
(E45-70XN):
Primary Pump:
81.4 liter/min (21.5 gal/min)

For [A276], J2.2- 3.5XN

(J40-70XN):
Primary Pump:
81.4 liter/min (21.5 gal/min)

For [K160], J1.5-2.0XNT

(J30-40XNT):
Primary Pump:
63.6 liter/min (16.8 gal/min)

For [A935], J1.6-2.0XN:

Primary Pump:
63.6 liter/min (16.8 gal/min)

Table 9050-43-12. Service Tools

0-3450 kPa (0-500 psi) Pressure Gauge

6. If the pressure margin is below specification, pro-

ceed as follows:
• Remove unloader spool and check for a
broken spring or contamination. Depending
on your lift truck see, Main Control Valves
2000SRM1334 or Main Control Valves
2000SRM1439.
NOTE: E-HYDRAULIC CONTROL VALVE FOR LIFT
• Check main relief valve for contamination TRUCKS E2.2-3.5XN (E45-70XN) (A268) AND
or broken spring. Depending on your lift J2.2-3.5XN (J40-70XN) (A276) SHOWN.
truck see, Main Control Valves
2000SRM1334 or Main Control Valves A. LEFT VIEW
2000SRM1439. B. RIGHT VIEW
1. LOAD SENSE PORT WITH GAUGE
7. If actions performed in Step 6 do not solve the 2. REDUCED PRESSURE PORT WITH GAUGE
problem, replace hydraulic control valve inlet sec-
tion. Depending on your lift truck see, Main Con- Figure 9050-43-52. Unloader Valve Test Setup
trol Valves 2000SRM1334 or Main Control
Valves 2000SRM1439.

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Hydraulic Systems Tests and Adjustments-Gear Pump

E-Hydraulic Valve Leakage Test

This test is to determine if the E-Hydraulic Valve spool 3. Ensure that tank port is connected to the return
is damaged or if there is internal leakage between the line.
section housing and the spool. This test should only
be performed after doing the Lift Cylinder Leakage NOTE: Purge cool oil out of leakage hose until oil is
Test and leakage has been diagnosed to be in control 42°C (108°F) before connecting to the first work port.
valve.
NOTE: Work port leakage for port 1A must exceed
10 cc/min and ports 2A, 2B, 3A, 3B, 4A, and 4B must
1. Lower forks to ground, turn key or keyless switch
exceed 4 cc/min.
to ON position and apply park brake.
4. Connect "leakage" supply hose to each individual
2. Remove floor mats and floor plates.
work port while spools are in neutral.

WARNING 5. Operate hydraulic functions, read the pressure

and compare to specifications. Disconnect "leak-
Hot hydraulic oil can cause serious burns to skin.
age" supply hose from work port.
Do not touch hydraulic components or oil during
test. Make sure hydraulic oil has cooled to safe 6. Repeat Step 4 and Step 5 for each work port.
temperature before installing or removing test
equipment.
7. If the pressure is not within specification, replace
WARNING control valve section. Depending on your lift truck
see, Main Control Valves 2000SRM1334 or
Hydraulic oil under pressure can be injected into
Main Control Valves 2000SRM1439.
skin. Lower forks to ground and relieve all circuit
pressure before removing EHPV assembly. 8. Install floor plates and floor mats.

9. Lower forks to ground, turn key or keyless switch

CAUTION to OFF position and apply park brake.
Do not permit dirt or other contaminants to enter
the hydraulic system. Disconnected hoses, tubes,
open valves, cylinder fittings, and ports should be
protected with clean caps or plugs.

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Tests and Adjustments-Gear Pump Hydraulic Systems

Table 9050-43-13. Test Specifications

Oil Temperature 42°C (108°F) or Higher

Maximum Leakage
For J1.5-2.0XNT (J30-40XNT) (K160) 1A Port: 16.6 cc/min 2A or 2B Port: 12.2 3A or 3B Port: 14.4
and J1.6-2.0XN (A935) with 3-Function @ cc/min @ cc/min @
Control Valve 16.8 MPa (2450 psi) 6.8 MPa (1000 psi) 6.8 MPa (1000 psi)
For J1.5-2.0XNT (J30-40XNT) (K160) 1A Port: 16.6 cc/min 2A or 2B Port: 12.2 3A, 3B, 4A, or 4B Port:
and J1.6-2.0XN (A935) with 4-Function @ cc/min @ 14.4 cc/min @
Control Valve 16.8 MPa (2450 psi) 6.8 MPa (1000 psi) 6.8 MPa (1000 psi)
For E2.2-3.0XN (E45-60XN) (A268) 1A Port: 18.6 cc/min 2A or 2B Port: 22.0 3A or 3B Port: 14.4
J2.2-3.0XN (J40-60XN) (A276) with 3- @ cc/min @ cc/min @
Function Control Valve 19.6 MPa (2850 psi) 8.2 MPa (1200 psi) 6.8 MPa (1000 psi)
For E2.2-3.0XN (E45-60XN) (A268) 1A Port: 18.6 cc/min 2A or 2B Port: 22.0 3A, 3B, 4A, or 4B Port:
J2.2-3.0XN (J40-60XN) (A276) with 4- @ cc/min @ 14.4 cc/min @
Function Control Valve 19.6 MPa (2850 psi) 8.2 MPa (1200 psi) 6.8 MPa (1000 psi)
For E3.0-3.5XN (E60-70XN) (A268) 1A Port: 21.1 cc/min 2A or 2B Port: 22.0 3A or 3B Port: 14.4
J3.0-3.5XN (J60-70XN) (A276) with 3- @ cc/min @ cc/min @
Function Control Valve 21.3 MPa (3100 psi) 8.2 MPa (1200 psi) 6.8 MPa (1000 psi)
For E3.0-3.5XN (E60-70XN) (A268) J. 1A Port: 21.1 cc/min 2A or 2B Port: 22.0 3A, 3B, 4A, or 4B Port:
30-3.5XN (J60-70XN) (A276) with 4- @ cc/min @ 14.4 cc/min @
Function Control Valve 21.3 MPa (3100 psi) 8.2 MPa (1200 psi) 6.8 MPa (1000 psi)

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Hydraulic Systems Tests and Adjustments-Gear Pump

Figure 9050-43-53. E-Hydraulic Control Valve Fittings

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Tests and Adjustments-Gear Pump Hydraulic Systems

Legend for Figure 9050-43-53

A. 3-FUNCTION CONTROL VALVE FOR LIFT TRUCK MODELS J1.5-2.0XNT (J30-40XNT) (K160) AND
J1.6-2.0XN (A935)
B. 3-FUNCTION CONTROL VALVE FOR LIFT TRUCK MODELS E2.2-3.5XN (E45-70XN) (A268) AND
J2.2-3.5XN (J40-70XN) (A276)
C. 4-FUNCTION CONTROL VALVE FOR LIFT TRUCK MODELS J1.5-2.0XNT (J30-40XNT) (K160) AND
J1.6-2.0XN (A935)
D. 4-FUNCTION CONTROL VALVE FOR LIFT TRUCK MODELS E2.2-3.5XN (E45-70XN) (A268) AND
J2.2-3.5XN (J40-70XN) (A276)
1. TANK PORT 4. 3A, 3B, 4A, 4B PORTS (AUXILIARY)
2. 1A PORT (LIFT/LOWER) 5. DIAGNOSTIC PORT WITH GAUGE
3. 2A, 2B PORTS (TILT)

Steering Relief Pressure Test and Adjustment

1. Lower forks to ground and turn key or keyless
Table 9050-43-14. Test Specifications switch to OFF. Apply park brake.

Oil Temperature 50 to 65°C (122 to 150 °F)

Steering Relief For [A268], E2.2-3.5XN
WARNING
Pressure (E45-70XN): Hot hydraulic oil can cause serious burns to skin.
11.0 MPa (1595 psi) Do not touch hydraulic components or oil during
test. Make sure hydraulic oil has cooled to safe
For [A276], J2.2- 3.5XN temperature before installing or removing test
(J40-70XN): equipment.
12.4 MPa (1798 psi)
WARNING
For [K160], J1.5-2.0XNT
Hydraulic oil under pressure can be injected into
(J30-40XNT):
skin. Lower forks to ground and relieve all circuit
7.5 MPa (1088 psi)
pressure before removing test plugs from valve.
For [A935], J1.6-2.0XN: 2. Remove steering column covers, floor mat, and
7.5 MPa (1088 psi) floor plates.

CAUTION
Do not permit dirt or other contaminants to enter
the hydraulic system. Disconnected hoses, tubes,
Table 9050-43-15. Service Tools open valves, cylinder fittings, and ports should be
protected with clean caps or plugs.
0 - 35.0 MPa (0 to 5000 psi) Pressure Gauge
6 mm Hex wrench 3. Connect pressure gauge to steering hose as
shown in Figure 9050-43-55 and Fig-
8 mm Hex wrench ure 9050-43-56.
T-Fitting Hyster Part No. 8546398

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Hydraulic Systems Tests and Adjustments-Gear Pump

4. Operate hydraulic system until the oil temperature 7. If pressure is lower or higher than specifications,
is at test specifications. See Hydraulic Warm-up perform steps below: See Figure 9050-43-54.
Procedure.
a. Remove steering control unit (SCU) from steer-
5. Turn steering wheel to stop. Apply turning effort ing column. See Steering System
against stop, causing steering system pressure to 1600SRM1331 for lift truck model J1.5-2.0XNT
go over relief. (J30-40XNT) (K160) or Steering System
1600SRM1363 for lift truck models E2.2-3.5XN
6. Check pressure gauge reading. Compare reading (E45-70XN) (A268) , J2.2-3.5XN (J40-70XN)
to specifications. (A276) , and J1.6-2.0XN (J30-40XN) (A935) for
procedures.

b. If pressure is less than specifications, install

hex wrench (1) and turn relief valve adjuster
clockwise. See Figure 9050-43-54.

c. If pressure is higher than specifications, install

hex wrench (1) and turn relief valve adjuster
counterclockwise. See Figure 9050-43-54.

d. Install hex wrench (2) in placement shown in

Figure 9050-43-55 or Figure 9050-43-56. Apply
turning effort against stop causing steering sys-
tem pressure to go over relief.

e. Check pressure gauge reading. Compare read-

ing to specifications.

f. Repeat Step b through Step d. If pressure is to

specifications, install steering control unit
(SCU) onto steering column and remove test
1. STEERING CONTROL UNIT (SCU) equipment. Install test port and adjuster plug.
2. PLUG
3. RELIEF VALVE ADJUSTER
Figure 9050-43-54. SCU Adjustment

NOTE: Steering relief adjuster is very sensitive.

Make changes in 1/8 turn increments to avoid over
pressurizing system.

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Confidential/Proprietary - Do Not Copy or Duplicate 9050-43-19
Tests and Adjustments-Gear Pump Hydraulic Systems

A. PLACEMENT OF HEX WRENCH (2) TO TURN STEERING COLUMN.

1. TEST GAUGE HOSE
2. STEERING CONTROL UNIT (SCU) HOSE CONNECTIONS
3. T-FITTING

Figure 9050-43-55. Steer Relief Pressure for Lift Truck models J1.5-2.0XNT (J30-40XNT) (K160) and
J1.6-2.0XN (A935)

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Hydraulic Systems Tests and Adjustments-Gear Pump

A. PLACEMENT OF HEX WRENCH (2) TO TURN STEERING COLUMN.

1. TEST GAUGE HOSE 3. STEERING CONTROL UNIT (SCU)
2. STEER ACCUMULATOR 4. T-FITTING

Figure 9050-43-56. Steer Relief Pressure for Lift Truck models E2.2-3.5XN (E45-70XN) (A268) and
J2.2-3.5XN (J40-70XN) (A276)

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Tests and Adjustments-Gear Pump Hydraulic Systems

Steering Control Unit LS Pressure Test

This test checks if LS (Load-Sense) pressure is cor- temperature before installing or removing test
rect to operate the flow divider spool functions of the equipment.
Steering Control Unit (SCU).
WARNING
Table 9050-43-16. Test Specifications Hydraulic oil under pressure can be injected into
skin. Lower forks to ground and relieve all circuit
Oil Temperature 50 - 65°C (122 - 150 °F) pressure before removing test plugs from valve.
Minimum LS For [A268], E2.2-3.5XN
1. Lower forks to ground, turn key or keyless switch
Pressure (E45-70XN):
to OFF position, and apply park brake.
11.0 MPa (1595 psi)
2. Remove steering column covers to access Steer-
For [A276], J2.2- 3.5XN ing Control Unit (SCU); remove floor plates to ac-
(J40-70XN): cess main control valve and hydraulic lines.
12.4 MPa (1798 psi)

For [K160], J1.5-2.0XNT CAUTION

(J30-40XNT): Do not permit dirt or other contaminants to enter
7.5 MPa (1088 psi) the hydraulic system. Disconnected hoses, tubes,
open valves, cylinder fittings, and ports should be
For [A935], J1.6-2.0XN: protected with clean caps or plugs.
7.5 MPa (1088 psi)
3. Install one test hose in LS port and the other test
hose in fitting on (P) main pressure port hose of
Table 9050-43-17. Service Tools the SCU. See Figure 9050-43-57.

Pressure differential gauge or switching block 4. Check hydraulic temperature. If not within specifi-
cations. See Hydraulic Warm-up Procedure.
0 - 35.0 MPa (0 - 5000 psi) Pressure Gauge
Steering Control Unit SAE #4 O-ring Port (7/16-20 5. Hold steering over relief and measure relief pres-
(SCU) "P" & "LS" Test UNF) sure, then LS pressure and compare to specifica-
Port Size tions.
T-Fitting Hyster Part No. 8546398 6. If LS pressure is not within specifications, remove
SCU. Inspect and clean LS orifices. Depending
on your lift truck see, Main Control Valves
WARNING 2000SRM1334 or Main Control Valves
Hot hydraulic oil can cause serious burns to skin. 2000SRM1439.
Do not touch hydraulic components or oil during
test. Make sure hydraulic oil has cooled to safe 7. Remove test equipment and reinstall test plugs.

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Hydraulic Systems Tests and Adjustments-Gear Pump

NOTE: E-HYDRAULIC CONTROL VALVE FOR LIFT TRUCK MODEL J1.5-2.0XNT (J30-40XNT) (K160)
SHOWN.

1. "LS" LOAD SENSE PORT 3. T-FITTING

2. "P" MAIN PRESSURE PORT HOSE 4. TEST GAUGE HOSE

Figure 9050-43-57. SCU LS Pressure Test

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Tests and Adjustments-Gear Pump Hydraulic Systems

Lift Cylinder Leakage Test

Hydraulic leakage causes heat and poor performance
in a hydraulic system. This test is done to determine if WARNING
the leakage is in the cylinder or the hydraulic control Lowering of forks with load can cause personal
valve. injury. Do not place body parts under load.

Table 9050-43-18. Test Specifications 4. Put a capacity load on the forks, and raise and
lower the load several times. Lower the load and
Oil Temperature 50°C (122 °F) tilt the mast forward and backward several times.
Maximum Carriage Travel 102 mm (4.0 in.) Check for external cylinder or hose leaks.
in 10 minutes
5. Raise the carriage and load 2.5 m (8.2 ft). Ob-
serve load, if the carriage slowly lowers when the
Table 9050-43-19. Service Tools
control valve is in the neutral position, there are
Tape measure or ruler leaks in the hydraulic system. Go to Step 7.
Ball Valve rated at 24 MPa (3500 psi) minimum 6. If carriage is not dropping fast enough for visual
Control Valve Lift Port SAE #12 O-ring Port check, use a tape measure and record move-
Size (1-1/16 - 12 UNF) ment. Turn key or keyless switch to the OFF posi-
tion and let truck sit for 10 minutes. If movement
exceeds specifications, go to Step 7.
WARNING
7. To check the lift cylinders for internal leaks, close
Hot hydraulic oil can cause serious burns to skin.
the ball valve in the supply line between the main
Do not touch hydraulic components or oil during
control valve and the mast. Let truck sit for 10 mi-
test. Make sure hydraulic oil has cooled to safe
nutes and measure movement. If it does not meet
temperature before installing or removing test
specifications, the seals in the lift cylinders have
equipment.
leaks. Repair cylinder. Depending on your lift
truck see, Cylinder Repair (Mast S/N A270-72,
WARNING A551, A555, A559, A626, A627, A751-52, B551,
Hydraulic oil under pressure can be injected into B555, B586-91, B749-54, C661-63, C665,
skin. Lower forks to ground and relieve all circuit D507-09, D515, D562-64, E509, E564)
pressure before removing hoses from cylinders. 2100SRM1382 or Cylinder Repair (Mast S/N
B551, B555, B559) 2100SRM1440.
1. Lower forks to ground, turn key or keyless switch
to OFF position, and apply park brake. NOTE: Contamination in the hydraulic system can
cause the control valve to leak. Remove and clean
valve before replacing.
CAUTION
Do not permit dirt or other contaminants to enter 8. If the carriage does not move, open the ball valve
the hydraulic system. Disconnected hoses, tubes, and check the movement again. If the carriage
open valves, cylinder fittings, and ports should be lowers when the ball valve is open, check for
protected with clean caps or plugs. leaks in the hydraulic lines and fittings. If no leaks
are found, the main control valve could be worn,
2. Slowly loosen hose fitting to relieve pressure. Re- contaminated, or damaged. Remove and clean
move hose and install ball valve in the supply line hydraulic control valve. Depending on your lift
between the main control valve and the lift cylin- truck see, Main Control Valves 2000SRM1334
der. Open ball valve fully to allow maximum flow or Main Control Valves 2000SRM1439.
during warm-up procedure. See Fig-
ure 9050-43-58, Figure 9050-43-59, and Fig- 9. Remove the load from the forks and remove ball
ure 9050-43-60. valve.

3. Check hydraulic temperature. If not within specifi-

cations, see Hydraulic Warm-up Procedure.

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Hydraulic Systems Tests and Adjustments-Gear Pump

1. LIFT PORT
2. LIFT VALVE SECTION
1. LIFT PORT 3. TILT VALVE SECTION
2. LIFT VALVE SECTION 4. AUXILIARY VALVE SECTION
3. TILT VALVE SECTION 5. OPTIONAL RELIEF VALVE LOCATION
4. AUXILIARY VALVE SECTION 6. LIFT CYLINDER
5. OPTIONAL RELIEF VALVE LOCATION 7. BALL VALVE
6. LIFT CYLINDER 8. MAIN RELIEF VALVE
7. BALL VALVE
8. MAIN RELIEF VALVE Figure 9050-43-59. Lift Cylinder Leakage Test -
Manual Control Valve for Lift Trucks J1.6-2.0XNT
Figure 9050-43-58. Lift Cylinder Leakage Test - E-
(J30-40XNT) (K160) and J1.6-2.0XN (A935)
Hydraulic Control Valve

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Tests and Adjustments-Gear Pump Hydraulic Systems

Legend for Figure 9050-43-60

1. LIFT PORT
2. LIFT VALVE SECTION
3. TILT VALVE SECTION
4. AUXILIARY VALVE SECTION
5. OPTIONAL RELIEF VALVE LOCATION
6. LIFT CYLINDER
7. BALL VALVE
8. MAIN RELIEF VALVE

Figure 9050-43-60. Lift Cylinder Leakage Test -

Manual Control Valve for Lift Trucks E2.2-3.5XN
(E45-70XN) (A268) and J2.2-3.5XN (J40-70XN)
(A276)

Tilt Cylinder Leakage Test

Hydraulic leakage causes heat and poor performance 1. Lower forks to ground, turn key or keyless switch
in a hydraulic system. This test is done to determine if to OFF position, and apply park brake.
the leakage is in the cylinder or the hydraulic control
valve.
WARNING
Table 9050-43-20. Test Specifications Hot hydraulic oil can cause serious burns to skin.
Do not touch hydraulic components or oil during
Oil Temperature 50°C (122 °F) test. Make sure hydraulic oil has cooled to safe
Maximum Rod Travel in 5° rotation of mast temperature before installing or removing test
10 minutes equipment.

Table 9050-43-21. Service Tools WARNING

Angle Meter Hydraulic oil under pressure can be injected into
skin. Lower forks to ground and relieve all circuit
Ball Valve rated at 24 MPa (3500 psi) minimum
pressure before removing hoses from cylinders.
Tilt Valve Section Port SAE #8 O-ring Port
Size (3/4-16 UNF)

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Hydraulic Systems Tests and Adjustments-Gear Pump

8. To check the tilt cylinders for internal leaks, close

CAUTION the ball valve in the supply line between the main
Do not permit dirt or other contaminants to enter control valve and the tilt cylinders. Measure
the hydraulic system. Disconnected hoses, tubes, movement and compare to specifications.
open valves, cylinder fittings, and ports should be • If movement does not meet test specifica-
protected with clean caps or plugs. tions, the seals in the tilt cylinders have
leaks. Repair cylinder. Depending on your
2. Slowly loosen hose fitting to relieve pressure. Re-
lift truck see, Cylinder Repair (Mast S/N
move hose and install ball valve inline with hose
A270-72, A551, A555, A559, A626, A627,
on cylinder to be tested. Open ball valve fully to
A751-52, B551, B555, B586-91, B749-54,
allow maximum flow during warm-up procedure.
C661-63, C665, D507-09, D515, D562-64,
3. Check hydraulic temperature. If not within specifi- E509, E564) 2100SRM1382 or Cylinder
cations, see Hydraulic Warm-up Procedure. Oper- Repair (Mast S/N B551, B555, B559)
ate until temperature is at test specifications. 2100SRM1440.
NOTE:• Contamination in the hydraulic system can
4. Put a capacity load on the forks, and raise the ca- cause the control valve to leak, remove and clean
pacity load to 2.5 m (8.2 ft) and lower the load valve before replacement.
several times. Lower the load and slowly tilt the
mast forward to 90° to floor and backward several If the mast does not move, open the ball
times. valve and check the movement again. If
the mast moves when the ball valve is
5. Check for external cylinder or hose leaks. open, check for leaks in the hydraulic lines
and fittings. If no leaks are found, the main
6. Slowly tilt the mast forward to 90° to floor. If the
control valve can be worn or damaged. Re-
mast continues to slowly tilt forward when the
move and clean hydraulic control valve.
control valve is in the neutral position, there are
Depending on your lift truck see, Main
leaks inside the hydraulic system. Go to Step 8.
Control Valves 2000SRM1334 or Main
7. If mast is not dropping forward fast enough for Control Valves 2000SRM1439.
visual check, use angle meter to record mast
9. Remove the load from the forks and remove ball
movement. Stop lift truck and let machine sit for
valve. Reconnect all hoses.
10 minutes. If movement exceeds specifications
go to Step 8.

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Tests and Adjustments-Gear Pump Hydraulic Systems

1. LIFT VALVE SECTION

2. TILT VALVE SECTION
3. AUXILIARY VALVE SECTION
4. OPTIONAL RELIEF VALVE LOCATION
5. TILT PORT
6. TILT CYLINDERS
7. BALL VALVE
8. MAIN RELIEF VALVE

1. LIFT VALVE SECTION Figure 9050-43-62. Tilt Cylinder Leakage Test -

2. TILT VALVE SECTION Manual Control Valve for Lift Trucks J1.5-2.0XNT
3. AUXILIARY VALVE SECTION (J30-40XNT) (K160) and J1.6-2.0XN (A935)
4. OPTIONAL RELIEF VALVE LOCATION
5. TILT PORT
6. TILT CYLINDERS
7. BALL VALVE
8. MAIN RELIEF VALVE

Figure 9050-43-61. Tilt Cylinder Leakage Test - E-

Hydraulic Control Valve

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Hydraulic Systems Tests and Adjustments-Gear Pump

Legend for Figure 9050-43-63

1. LIFT VALVE SECTION

2. TILT VALVE SECTION
3. AUXILIARY VALVE SECTION
4. OPTIONAL RELIEF VALVE LOCATION
5. TILT PORT
6. TILT CYLINDERS
7. BALL VALVE
8. MAIN RELIEF VALVE

Figure 9050-43-63. Tilt Cylinder Leakage Test -

Manual Control Valve for Lift Trucks E2.2-3.5XN
(E45-70XN) (A268) and J2.2-3.5XN (J40-70XN)
(A276)

Steering Cylinder Leakage Test

Cylinder leakage causes heat and poor performance
in a steering system. This test is done to determine if WARNING
the leakage is in the steering cylinder or the steering Hot hydraulic oil can cause serious burns to skin.
control unit. Do not touch hydraulic components or oil during
test. Make sure hydraulic oil has cooled to safe
1. Lower forks to ground and turn steering wheel un- temperature before installing or removing test
til steer axle is against right axle stop. Turn key or equipment.
keyless switch to OFF position and apply park
brake.
Table 9050-43-22. Test Specifications
2. Remove floor plates to expose steering cylinder
hose connections. Oil Temperature 21 - 43°C (70 - 110 °F)
Maximum Leakage 10 ml (0.35 oz) Per
3. Check hydraulic temperature. If not within specifi- Minute
cations, see Hydraulic Warm-up Procedure.

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Tests and Adjustments-Gear Pump Hydraulic Systems

5. Attempt to turn the steering wheel by hand. If oil

Table 9050-43-23. Service Tools flows out of hose at noticeable rate (approxi-
mately 50% of test specification), steering cylinder
Container needs repair. Stop test and repair steering cylin-
Left and Right SAE #8 O-ring Port (3/4-16 UNF) der. If no oil flow, go to Step 6.
Work Port Size
T-Fitting Hyster Part No. 8546398 WARNING
A open steering port can expel hydraulic oil under
pressure and it can be injected into skin. Seal
SCU port with high pressure ORFS cap before
WARNING
turning lift truck on.
Hydraulic oil under pressure can be injected into
skin. Lower forks to ground and relieve all circuit 6. Turn key or keyless switch ON and hold steering
pressure before removing hoses from cylinders. against right axle stop. Measure oil after it starts
to flow from end of removed steering hose for 1
minute.
CAUTION
Do not permit dirt or other contaminants to enter 7. Turn key or keyless switch to OFF position and
the hydraulic system. Disconnected hoses, tubes, compare measured oil to test specifications.
open valves, cylinder fittings, and ports should be • If leakage is below specifications, the
protected with clean caps or plugs. steering cylinder is OK.
4. Slowly loosen left steering hose fitting that goes • If leakage is more than specifications, re-
into SCU top left port marked (L). Remove left move and repair steering cylinder. Depend-
steering hose and keep it elevated so oil is not ing on your lift truck, see Steering System
lost. Install O-ring Face Seal (ORFS) high pres- 1600SRM1331Steering System
sure cap on left port fitting of SCU to seal valve 1600SRM1363
against high pressure leakage when steering
wheel is turned. 8. Remove caps and reinstall hose and valve cov-
ers.
NOTE: Turning the steering wheel by hand with lift
truck off will generate hydraulic pressure in cylinder. If
leakage is noted at this lower pressure, cylinder has
excessive leakage.

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Hydraulic Systems Tests and Adjustments-Gear Pump

1. TEST GAUGE HOSE 2. FITTING

Figure 9050-43-64. Steering Cylinder Leakage Test

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 NOTES

9050-43-32
 SECTION 9060

OPERATORS STATION

TABLE OF CONTENTS

Group 10 - Principles of Operation

Operator Station General Description and Principles of Operation.........................................................9060-10-1
General Description and Location...................................................................................................... 9060-10-1
Display Panel.......................................................................................................................................... 9060-10-3
General Description............................................................................................................................ 9060-10-3
Display Panel Features.................................................................................................................. 9060-10-3
Display Panel..................................................................................................................................9060-10-4
LCD Screen and Warning and Indicator Lights.............................................................................. 9060-10-7
Programming - Menus.............................................................................................................................9060-10-7
Menu...................................................................................................................................................9060-10-8
Operator Cycle Main Menu.............................................................................................................9060-10-8
Supervisor/Service Cycle Main Menu.............................................................................................9060-10-8
Display Menu Flowchart..........................................................................................................................9060-10-9
Display Menu Flowchart..................................................................................................................... 9060-10-9
Manual Hydraulic Control Levers.......................................................................................................... 9060-10-33
General Description.......................................................................................................................... 9060-10-33
System Components........................................................................................................................ 9060-10-33
Lift/Lower......................................................................................................................................9060-10-33
Tilt.................................................................................................................................................9060-10-33
Auxiliary 1.....................................................................................................................................9060-10-33
Auxiliary 2.....................................................................................................................................9060-10-34
Emergency Disconnect Switch..................................................................................................... 9060-10-34
E-Hydraulic System Interface................................................................................................................9060-10-34
General Description to E-Hydraulic System Interface...................................................................... 9060-10-34
Lift/Lower......................................................................................................................................9060-10-34
Tilt.................................................................................................................................................9060-10-34
Auxiliary 1.....................................................................................................................................9060-10-36
Auxiliary 2.....................................................................................................................................9060-10-36
Emergency Disconnect Switch..................................................................................................... 9060-10-36
Lighting Control..................................................................................................................................... 9060-10-37
General Description.......................................................................................................................... 9060-10-37
Front Work Lights......................................................................................................................... 9060-10-38
Front Marker Lights...................................................................................................................... 9060-10-38
Front/Rear Turn Signal Lights...................................................................................................... 9060-10-38
Rear Tail Lights............................................................................................................................ 9060-10-38
Rear Work Light............................................................................................................................9060-10-38
Rear Backup Lights...................................................................................................................... 9060-10-38
Rear Stop Lights...........................................................................................................................9060-10-38
Strobe Light.................................................................................................................................. 9060-10-38
Dome Light................................................................................................................................... 9060-10-38
Cab Panels............................................................................................................................................9060-10-38
General Description.......................................................................................................................... 9060-10-38
Covers and Floor Plates...............................................................................................................9060-10-38
Hood and Seat..............................................................................................................................9060-10-38
Cab Heating System.....................................................................................................................9060-10-39

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 Wiper/Washer System..................................................................................................................9060-10-39

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Operators Station Principles of Operation

Group 10

Principles of Operation

Operator Station General Description and Principles of Operation

GENERAL DESCRIPTION AND LOCATION ements are not included in this section. Refer to the
Operating Manual for related information on common
The major components of the operator station for the systems. See Figure 9060-10-1.
lift truck are shown in Figure 9060-10-1. The conven-
tional hydraulic steering, braking, and drive system el-

A. E-HYDRAULIC CONTROL B. MANUAL HYDRAULIC CONTROL

1. HORN BUTTON 10. EMERGENCY DISCONNECT SWITCH
2. ACCELERATOR PEDAL (OPTIONAL) 11. MONOTROL® FOOT PEDAL PEDAL (OP-
3. DISPLAY PANEL TIONAL)
4. KEY SWITCH OR KEYLESS SWITCH 12. BRAKE PEDAL
5. LIGHT SWITCHES 13. AUTOMATIC PARKING BRAKE MANUAL
6. LIFT/LOWER CONTROL LEVER OVERRIDE HANDLE (OPTIONAL)
7. TILT CONTROL LEVER 14. STEERING WHEEL
8. CONTROL LEVER FOR AUXILIARY HY- 15. STEERING COLUMN TILT MEMORY LEVER
DRAULIC FUNCTIONS (3RD LEVER) 16. DIRECTION CONTROL SWITCH (OPTIONAL)
9. CONTROL LEVER FOR AUXILIARY HY-
DRAULIC FUNCTIONS (4TH LEVER)

Figure 9060-10-1. Operator Station Components

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Principles of Operation Operators Station

The components shown in Figure 9060-10-1 include Horn provides

multiple options which are customer determined. • Push the horn button to warn pedes-
These options are explained in greater detail in the trians and others when approaching in-
appropriate sections of this manual. The indicated de- tersections and other blind areas.
vices are used for various control inputs and opera-
tion of the lift truck systems. • If lift truck is equipped with E-Hydraulic
controls, there is another horn button lo-
Display Panel provides: cated on the armrest.
• Power ON/OFF selection Light Switches provides rocker switches for
• Display and Input for menu-driven data the following light functions:
entry, navigation, and readout • Front Driving/Brake/Reverse/Parking
Manual Hydraulic Levers (if equipped) pro- lights.
vides: • Rear Driving light and the Strobe light or
• Control of lift Strobe light only.
• Lower • Operator Compartment light (if equipped
• Tilt with a cab) or Strobe light only.

• Sideshift Tilt Memory Lever provides:

• Fork spread functions • The ability to move the steering column

so that the hood can be raised. Lift and
• Emergency disconnect switch hold the lever while moving the steering
• Directional Control Switch (Optional) column. Release the lever when the
Mini Lever Module (MLM) (if equipped) pro- steering column is in the desired posi-
vides: tion.

• Control of lift Standard Accelerator provides:

• Lower • Accelerator function for speed control on

lift trucks equipped with a FWD/REV Di-
• Tilt rectional Control Switch (DCS); which
• Sideshift may be located on the armrest of lift
• Fork spread functions trucks equipped with e-hydraulics, or on
the lift/lower hydraulic control lever of lift
• Emergency disconnect switch trucks equipped with manual hydraulics.
• Horn
MONOTROL® Pedal provides:
• Directional Control Switch (Optional)
• Foot pedal input control for FWD or REV
Vehicle System Manager (VSM) provides: travel.
• Controls or monitors most electrical op- • Accelerator function for speed control.
erations of the lift truck
The foot pedal direction control is configured
• Safe shutdown for critical faults with analog position sensors that input the di-
• Manages operator inputs and stores op- rection command to the VSM. Pressing on the
erational/fault data history right side of the pedal selects the REV direc-
tion with corresponding backup lights and
Steering Wheel provides:
backup alarm activated. Pressing the left side
• The steering wheel controls the move- of the pedal selects the FWD direction. The
ment of the steer wheels. Rotate the foot pedal direction control also serves as the
steering wheel clockwise to make a right accelerator pedal, pushing it down further will
turn, and counterclockwise to make a increase the speed of the truck in the applied
left turn. direction.

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Operators Station Principles of Operation

Service Brake Provides: The manual override handle is located

• Includes a hydraulically operated brake underneath the floor mat and floor plate
mechanism at the drive wheels. These and mounted to the front bulkhead.
wheel brakes are controlled by move- • The auto park brake will activate under
ment of the brake pedal, providing brak- the following condition when the opera-
ing proportional to the applied pedal tor:
force. - Gets up from the seat without ap-
• When the service brake is applied, the plying the parking brake and turn-
E-Boost feature is activated. This will di- ing the lift truck power OFF.
rect the traction system to brake the ve- - Takes his foot off of the accelera-
hicle.
tor pedal or MONOTROL® Pedal
NOTE: Further troubleshooting procedures for park (if equipped) while the lift truck is
brake can be found in Park Brake Troubleshooting moving.
Guide.
- The lift truck does not move for a
Parking Brake provides: period of 15 minutes.
• Mechanical brake operated through a - To release the auto park brake,
separate pedal; it applies parking-brake the operator needs to either re-
mechanisms at the two drive wheels turn to the seat or depress the
accelerator pedal or MONO-
Auto Park Brake provides:
TROL® Pedal (if equipped)
• Automatic braking to the traction motor;
slowing it down and eventually bringing
it to a stop.
• If the lift truck loses power and has to be
towed, there is a manual override han-
dle that will disable the auto park brake.

Display Panel
GENERAL DESCRIPTION • Preassigned operator passwords to control op-
erator access to the lift truck.
There is one display panel. See Figure 9060-10-2. • Four driving Performance Modes that are ac-
cessed through the key pad.
Display Panel Features
• Scheduled maintenance reminders to be pro-
• Liquid Crystal Display (LCD) grammed in and will alert the operator through
an audible and visual alarm when scheduled
• Numerical key pad maintenance is due.
• Battery Discharge Indicator (BDI) • Operator checklist where the operator must an-
• Diagnostic Trouble Codes (DTC) swer YES or NO to a set of questions before
• System time/date the lift truck can be operated.

• Hourmeter for the traction motor and hydraulic • Hydraulic fluid low icon. This icon will appear if
pump motor. the system detects low hydraulic fluid. Availa-
ble with the Hydraulic Fluid Level Monitoring
• Performance mode selection option.
• Password controls • Hydraulic filter restriction icon. This icon will
• Maintenance reminders appear if the system detects a restriction in the
• System interlocks hydraulic filter. This is an optional feature.

• Operator checklist

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Principles of Operation Operators Station

port the problem immediately. Injury to personnel

can occur if the instruments, levers, or pedals do
not operate as described. DO NOT operate the lift
truck until the problem is corrected.

The display panel is equipped with 10 numeric keys,

two arrow keys (left and right arrows) and two symbol
keys (the Star (*) Key and the Pound (#) Key).

If multiple keys are pressed at the same time, by de-

fault the display panel will ignore all keys. If a key has
already been pressed and a second one is pressed
immediately, the display panel will ignore the second
key.

All key presses are accepted for a single entry and

key entries cannot be repeated by holding down the
key. For example, holding the 5 key down while enter-
ing a password number, will only result in one in-
stance of 5 being entered regardless of how long the
user presses the 5 key. To enter multiple 5's, the user
must press the 5 key multiple times.
Figure 9060-10-2. Display Panel

Display Panel Each lift truck can be equipped with several different
options and configurations. Depending on the equip-
ment on the lift truck, the key functions described in
WARNING Table 9060-10-1 will vary and may not apply to your
If any of the instruments, levers, or pedals do not lift truck.
operate as described in the following tables, re-

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Operators Station Principles of Operation

Table 9060-10-1. Display Panel

Item No. Item Function

1 1 Key When an operator is in the Password Screen, if enabled, for entering
passwords, this key allows entry of the number 1 for password
purposes.

Once a password has been successfully entered, or if a password is not

required, the display panel will go to the Operator Screen. This screen
contains all the necessary components for normal operation of the lift
truck. In this screen Key 1 is enabled to decrease Performance Mode;
press the 1 key to go to the next lower level of performance; level 1
performance mode is the slowest and level 4 is the fastest.

When an operator, if authorized, is in any of the additional menus that

are available (Calibrations, Diagnostics, and Truck Setup menus) the 1
key is enabled to enter the number 1 for data entry purposes.
2 4 Key When an operator is in the Password Screen, if enabled, for entering
passwords, this key allows entry of the number 4 for password
purposes.

Once a password has been successfully entered, the display panel will
go to the Operator Screen. This screen contains all the necessary
components for normal operation of the lift truck. In this screen, Key 4 is
enabled to increase Performance Mode; press the 4 key to go to the
next highest level of performance; level 1 performance mode is the
slowest and level 4 is the fastest.

When an operator, if authorized, is in any of the additional menus that

are available (Calibrations, Diagnostics, and Truck Setup menus) the 4
key is enabled to enter the number 4 for data entry purposes.

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Principles of Operation Operators Station

Table 9060-10-1. Display Panel (Continued)

Item No. Item Function

3 2 and 3 Keys When an operator is in the Password Screen, if enabled, for entering
passwords, these keys allow entry of the number 2 and 3 for password
purposes.

Once a password has been successfully entered, or if a password is not

required, the display panel will go to the Operator Screen. When an
operator, if authorized, is in any of the additional menus that are
available (Calibrations, Diagnostics, and Truck Setup menus) the 2 and
3 keys allow the operator to scroll up or down within the menu. Press
the 2 key to scroll up and press the 3 key to scroll down.

When an operator, if authorized, is working in any of the menus, other

than the Password menu, is prompted to enter a data value that
contains numbers, the scrolling features of the 2 and 3 keys will be
disabled and keys 2 and 3 can be used to enter numeric values. Once
the numeric data value has been entered and the Enter key pressed, the
scrolling feature for keys 2 and 3 will be enabled again.
4 5 Key When an operator is in the Password Screen, if enabled, for entering
passwords, this key is enabled to enter the number 5 for password
purposes.

Once a password has been successfully entered, or if a password is not

required, the display panel will to the Operator Screen.

When an operator, if authorized, is in any of the additional menus that

are available (Calibrations, Diagnostics, and Truck Setup menus) the 5
key is enabled to enter the number 5 for data entry purposes.
5 Scroll Back (Left Arrow This key is used for the following functions:
Key)
• Scrolling backwards through a list of possible menu selections.
6 (#) Pound Key If the Operator Checklist is enabled on the lift truck, the (#) Pound Key is
used to indicate an issue with the current item in the list. See Operating
Manual for your lift truck to obtain more information on using the
Operator Checklist.
• Scrolling through a list of possible menu selections.
7 (*) Enter Key (STAR Key) This key is used for menu entry and menu navigation. Use the (*) STAR
key to select a menu to be viewed. Within the selected menu, use the (*)
STAR key to select sub menus associated with the selected menu.
• Scrolling through a list of possible menu selections.
8 Scroll Forward (Right This key is used for the following functions:
Arrow Key) • Scrolling forward through a list of possible menu selections.

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Operators Station Principles of Operation

Table 9060-10-1. Display Panel (Continued)

Item No. Item Function

9 6, 7, 8, 9, and 0 Keys The 6, 7, 8, 9, and 0 keys are enabled to enter the numbers 6, 7, 8, 9,
and 0 for data entry purposes.
10 Keyless Start Switch or The lift trucks covered in this manual can be equipped with either a key
Key Switch switch or keyless switch. Both options will have two positions:

• OFF position. Deenergizes all electric circuits except for the horn.
• ON position. Energizes all electric circuits. The key or keyless
switch will be in this position during normal operation.

LCD Screen and Warning and Indicator Lights See Figure 9060-10-3:

The LCD screen uses a series of icons and numeric

values to communicate important truck information to
the operator, supervisor, and service technician.

The warning and indicator icons appear when the

LCD screen is displaying the Operator Screen. The
Operator Screen contains all the components neces-
sary for normal operation of the lift truck. After 10 sec-
onds, the seat belt, low brake fluid, service due (if
equipped), motor temperature icons, and low hy-
draulic fluid (if equipped) will no longer be illuminated
and will illuminate again only if there is a problem in
that particular area. Detailed information for Warning
and Indicator lights can be found in the Operating
Manual.

The following icons are displayed at all times on the

LCD screen when the truck is running, and the LCD
screen is displaying the Operator Screen:
• The current performance mode the truck is op-
erating under 1. FASTEN SEAT BELT ICON,
2. DIRECTION INDICATOR ICON
• The Battery Display Indicator (BDI) 3. BATTERY DISPLAY INDICATOR (BDI) ICON
4. LOAD WEIGHT ICON
• The direction indicators showing which direc- 5. SYSTEM TIME ICON
tion the truck is traveling in 6. STEER TIRE ANGLE ICON
• The neutral/park brake indicator 7. SERVICE DUE ICON
8. MOTOR TEMPERATURE HIGH WARNING
• The truck hourmeter ICON
9. PERFORMANCE MODE ICON
• System time 10. LOW BRAKE FLUID ICON

Figure 9060-10-3. Display Panel - LCD Screen /

Warning and Information Icons

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Principles of Operation Operators Station

Programming - Menus
MENU Diagnostic

The On-Board Menu Structure is accessible while the • Fault Logs/Controllers/Other CAN Device
system power is on by pressing the “*” button. If ac- • Steering Sensor
cessed without a password or by an operator pass-
• Battery/Other Power Supplies
word, the menu structure will automatically exit if no
button presses have been detected for 30 seconds. • Mast Sensor
Unless otherwise specified, menu items are only ac- • Hydraulic Valve
cessible with a service password. See Display Menu
• Hydraulic Inputs
Flowchart for further details.
• Hydraulic Pump Motor
Operator Cycle Main Menu • Brakes
• Seat (Operator Presence)
• Operating Screen
• Traction Motor 2
• Password Entry
• Traction Motor 1
• Load Weight (Optional)
• Directional Indicator Operation
• Checklist (Optional
• Speedometer
Supervisor/Service Cycle Main Menu
Truck Set-Up
• Operating Screen
• Passwords
• Password Entry
• Restore Defaults
• Load Weight (Optional)
• Optional Hydraulic (Diverter Valve) ON/OFF
• Checklist (Optional
• Rear Lamp Assembly OFF/ON
• Activity Log
• Hydraulic Function
• Calibration
• Hydraulic Function 1a, 1b, 2a, 2b, 3a, 3b, 4a,
• Diagnostics
4b (E-Hydraulics Only)
• Truck Set-Up
• Hydraulic Function 1a, 1b, 2a, 2b, 3a, 3b, 4a,
• Truck Status 4b (Manual Hydraulics Only
• Display Adjustment • Motion Alarm OFF/ON
• Impact Thresholds
Activity Log
• Auto Power OFF
• Check List Log • Return To Set Tilt (RTST)
• Password Log • Traction Speed Limit
• Impact Log • Scheduled Maintenance (Deferred)
• Minimum Pump Speed
Calibration
• Check List
• Load Weight • Impact Shutdown
• Manual Hydraulic Valve • Hour Meter
• Steer Axle • Acceleration
• Steer Wheel • BDI Adjustment
• Hydraulic Valve Threshold • Battery
• Return to Set Tilt (RTST) • Braking

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Operators Station Principles of Operation

Truck Status • Serial Number

• Display Version
• VSM Version
• Impact Sensor Version Display Adjustments
• Light 1 Controller Version
• Date/Time Format
• Traction 2 Controller Version
• Units Selection (Imperial/Metric)
• Traction 1 Controller Version
• Date and Time
• Pump Controller Version
• Daylight Savings
• Hydraulic Input Controller Version
• Hour Meters

Display Menu Flowchart

DISPLAY MENU FLOWCHART
Note: This chart indicates all available menu options for this model series. Only those options ordered on your
specific truck will be displayed and accessible using the Service Level password.
DTC’s are stored in the DTC LOGS, where a history of repeat failures is maintained, until cleared by an author-
ized service technician. All DTC’s are to be cleared prior to operating the lift truck. DTC logs should only be
cleared once the data is recorded by a authorized service technician.↓

1. 1/Soft Key 6. 6 Key 11. Scroll (Right Arrow Key)

2. 4/Soft Key 7. 9 Key 12. 8 Key
3. (#) Pound Key/Soft Key 8. 2/Soft Key 13. 7 Key
4. Scroll Back (Left Arrow Key) 9. 3/Soft Key 14. 0 Key
5. 5 Key 10. (*) STAR Key Select/Enter/
Accept

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Principles of Operation Operators Station

DISPLAY MENU FLOWCHART (Con't)

Return to Previous Select/Enter/Accept * Enter/Accept *

Menu←

Scroll ← →

Scroll ← → Scroll Up/Down ↑ ↓ Increase/Decrease Per-

formance

Power ON Power OFF Hour Meter Displayed for 5 seconds

Power ON→ Operator Cycle→ Enter Password→ Supervisor/Service Cycle→ Power OFF→ Power ON→ Oper-
ator Cycle

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Operators Station Principles of Operation

OPERATOR CYCLE
Legend
A. Operating Screen E. Load Weight J. Display Adjustment
B. Password Entry F. Tare Weight K. Activity Log
C. Enter Password G. Checklist L. Truck Setup
D. Calibration H. Truck Status M. Diagnostics
Standard Load Weight Option Check List Option

SERVICE CYCLE

Truck-Setup Truck Status Display Adjustments Activity Logs Calibration Diagnostics

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Principles of Operation Operators Station

Table 9060-10-2. Activity Logs

ACTIVITY LOGS

Check List

F* No Logs Check List OK Check List Not OK

Password Log

F* No Logs Operator/Supervisor/Service

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Operators Station Principles of Operation

Impact Log

F* No Logs Soft Impact/Hard Impact

Table 9060-10-3. Calibration

CALIBRATION

Load Weight

F* No Load Entry F* Known Load En-

Test Load Entry F*
tryF*

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Principles of Operation Operators Station

Manual Hydraulic Valve

F* Move each lever to end of X = Calibration Fail I_touchup FontFamname="Wingd-

travel F*√ ings" 1 3 seconds F* Repeat Calibration

Steer Axle

F* Rotate Fully CCW F* Rotate Fully CW F*

Steer Wheel

F* Set Steering Wheel to desired (Spinner) Position F*

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Operators Station Principles of Operation

Hydraulic Valve Threshold

F* Operate Indicated Control until movement is de-

Repeat for each function F*
tected F*

Return To Set Tilt (RTST)

F* Set Tilt Angle F*

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Principles of Operation Operators Station

Table 9060-10-4. Diagnostics

DIAGNOSTICS

Fault Logs / Controllers / Other CAN Device

↓ Previous ↓ ↓ VSM ↓ ↓ Next ↓

Delete All Logs ↑ Navigation example ↑ Next Log Record Previous Log Re-
cord

F* VSM← → Traction 1← → Traction 2← → Pump← →

Light← → MLM← → Impact← → Display← →

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Operators Station Principles of Operation

Steering Sensor

F*

Battery / Other Power Supplies

F*

Mast Sensor

Hydraulic Valve

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Principles of Operation Operators Station

Hydraulic Inputs

Hydraulic Pump Motor

Brakes

Seat (Operator Presence)

Traction Motor 2

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Operators Station Principles of Operation

Traction Motor 1

Directional Indication Operation

Speedometer

Imperial Metric

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Principles of Operation Operators Station

Table 9060-10-5. Truck-Setup

TRUCK SETUP

Passwords

Incorrect HPassword Set Max Performance Delete Password

F* Enter / Re-Enter Password F* ↑ ↓ Select Operator / Supervisor / Service for Password

F*

Restore Defaults

F*To restore defaults

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Operators Station Principles of Operation

Optional Hydraulic (Diverter Valve) ON/OFF

F* F*E Valve ON/OFF

Rear Lamp Assembly OFF/ON

F* F* Rear Lamp F* Rear Lamp ON

OFF

Hydraulic Function 1a, 1b, 2a, 2b, 3a, 3b, 4a, 4b (E Hydraulics Only)

F* Scroll to Function ↑ ↓ F* To Select Enter Value Using Number But- Repeat for other func-
tons F* tions

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Principles of Operation Operators Station

Hydraulic Function 1a, 1b, 2a, 2b, 3a, 3b, 4a, 4b (Manual Hydraulics Only)

F* F* Enter Value Using Number Buttons F*

Motion Alarm OFF/ON

F* F* Motion Alarm OFF F* Motion Alarm ON

Impact Thresholds

F* Scroll to function ↑ ↓ F* To Se- Enter Value Using Number Buttons or Repeat for other func-

lect Scroll ↑ ↓ F* tions

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Operators Station Principles of Operation

Auto Power OFF

F* F*Enter Value Using Number Buttons F*

Return To Set Tilt (RTST)

F*Scroll to Func- F* E To Select ↑ ↓ Next Func-

tion
F* Enter Value Using Number Buttons ↑ ↓
tion ↑ ↓
F*

Traction Speed Limit

F* F* Enter Value Using Number Buttons F*

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Principles of Operation Operators Station

Scheduled Maintenance

Minimum Pump Speed

F* F* Enter Value 0 % to 100 % Using Number Buttons F*

Check List

F* Fü(*) Active F X (#) Inactive ↑ ↓ Scroll to Next Check List Item

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Operators Station Principles of Operation

Impact Shutdown

F*Scroll to Func- F* E To Select Next Function ↑ ↓

F* Enter Value Using Number Buttons ↑ ↓
tion ↑ ↓
F*

Hour Meter

F*Scroll to Func- F* To Select Enter Value Using Number Buttons Next Function ↑ ↓

tion ↑ ↓ F*

Acceleration

F*Scroll to Function ↑ ↓ F* E To Select Next Function ↑ ↓

F* Enter Value Using Number Buttons ↑ ↓
F*

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Principles of Operation Operators Station

BDI Adjustment

F* Scroll to Function ↑ ↓ F* To Select Enter Zero then desired number using Number But-
tons F*

Battery

F*Scroll to Func- F* To Select Enter Value Using Number But- Next Function ↑ ↓

tion ↑ ↓ tons F*

Braking

F*Scroll to Function ↑ ↓F* E To Select Next Function ↑ ↓

F* Enter Value Using Number Buttons ↑ ↓
F*

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Operators Station Principles of Operation

Table 9060-10-6. Truck Status

TRUCK STATUS

VSM Version

F* Hardware/Software Versions

Impact Sensor Version

Light 1 Controller Version

Traction 2 Controller Version

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Principles of Operation Operators Station

Traction 1 Controller Version

Pump Controller Version

F* Hardware/Software Versions

Hydraulic Input Controller Version

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Operators Station Principles of Operation

Hour Meters

F* Traction/Pump/Truck/Secure

Serial Number

F*

Display Version

F* Hardware/Software Versions

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Principles of Operation Operators Station

Table 9060-10-7. Display Adjustments

DISPLAY ADJUSTMENTS

Date/Time Format

F* Scroll to Function ↑ ↓ F*Select Scroll ↑ ↓ 12 - 24 F*

F* Scroll to Function↑ ↓ F*Select Scroll ↑ ↓ MM/DD/YY - DD/MM/YY - YY/MM/DD

F*

Units Selection (Imperial/Metric)

F* F* Scroll ↑ ↓ Imperial - Metric F* ←

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Operators Station Principles of Operation

Date and Time

F* Enter Hours F* Enter Minutes F* Scroll ↑ ↓ AM -

Enter Month F*
PM F*

*E Enter Year *EEnter Day

Daylight Savings

Daylight Savings OFF/ON F* F*E ↑ ↓ Scroll to other Setups

Daylight Savings Start Month F* Scroll to Month ↑ ↓ F*

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Principles of Operation Operators Station

Daylight Savings

Daylight Savings Start Day F* Scroll to Day ↑ ↓ F*

Daylight Savings End Month F* Scroll to Month ↑ ↓ F*

Daylight Savings End Day F* Scroll to Day ↑ ↓ F*

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Operators Station Principles of Operation

Manual Hydraulic Control Levers

GENERAL DESCRIPTION Push the lever forward to tilt the mast and forks for-
ward. Pull the lever backward toward operator to tilt
The Manual Control Levers (if installed) are used to the mast and forks backward.
control hydraulic operation of the mast lift/lower, tilt,
and auxiliary functions. Auxiliary 1

SYSTEM COMPONENTS The third control lever is installed to the right of the tilt
control lever. This lever can have two methods of op-
The control levers are located to the right of the oper- eration, depending on the attachment.
ator's seat. Each lever is explained below. See Fig- • Trucks with clamp attachment: To engage the
ure 9060-10-4. clamp attachment, press and hold the button
on the left top side of the lever and move lever
Lift/Lower forward. When finger is removed from the but-
ton, the lever is locked in the neutral position
The lift/lower control lever is the first lever to the right and cannot be moved. To disengage the clamp
of the operator's seat. Pull backward toward operator function, press the button again and move
to raise the carriage and forks. Push forward to lower lever backward.
the carriage and forks.
• Trucks without clamp attachment: The lever is
Tilt operated by moving it forward and backward.
The lever is spring loaded to return to the neu-
The tilt control lever is the second lever to the right of tral position when released.
the operator's seat.

1. LIFT/LOWER CONTROL LEVER (1ST LEVER) 4. CONTROL LEVER FOR AUXILIARY HY-
2. TILT CONTROL LEVER (2ND LEVER) DRAULIC FUNCTIONS (4TH LEVER)
3. CONTROL LEVER FOR AUXILIARY HY- 5. EMERGENCY DISCONNECT SWITCH
DRAULIC FUNCTIONS (3RD LEVER)

Figure 9060-10-4. Manual Hydraulic Control Levers

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Principles of Operation Operators Station

Auxiliary 2 Emergency Disconnect Switch

The fourth control lever is installed to the right of the NOTE: The emergency disconnect switch does not
third control lever. This lever can have two methods of remove power to the front or rear service lights.
operation, depending on the attachment.
The emergency disconnect switch, is located behind
• Trucks with clamp attachment: To engage the the Auxiliary 2 lever.
clamp attachment, press and hold the button
on the left top side of the lever and move lever The operator can disconnect all electrical power to the
forward. When finger is removed from the but- lift truck by pushing the emergency disconnect switch
ton, the lever is locked in the neutral position in until it clicks. To reset the emergency disconnect
and cannot be moved. To disengage the clamp switch and energize the electrical circuits, the opera-
function, press the button again and move tor must turn the switch clockwise until it pops out.
lever backward.
• Trucks without clamp attachment: The lever is
operated by moving it forward and backward.
The lever is spring loaded to return to the neu-
tral position when released.

E-Hydraulic System Interface

GENERAL DESCRIPTION TO E- Faults or interlock conflicts are detected by the VSM
HYDRAULIC SYSTEM INTERFACE which sends an error message (fault codes) to the
Display Panel for operator awareness and correction.
Lift trucks may be equipped with an optional Electro-
Hydraulic (E-Hydraulic) system. It controls hydraulic The MLM consists of up to four individual proportional
operation of the mast lift/lower, tilt, and auxiliary func- levers and may have additional momentary switches.
tions. This E-Hydraulic option replaces the manual
control levers with simple, single-handed, finger-oper- The control levers are located on the armrest. See
ated electronic controls, located on the right-hand Figure 9060-10-5.
armrest. The E-Hydraulic system is controlled by the
VSM that provides drive commands to the hydraulic Lift/Lower
valves based on the operator inputs. This system au-
tomatically adjusts the flow control based on condi- The electronic lift/lower control lever is the first mini-
tions such as speed, load, and functions activated, lever to the right of the operator's seat. Pull backward
etc., to provide better controllability, and flexibility with toward operator to raise the carriage and forks. Push
the controls necessary to operate the E-Hydraulics. forward to lower the carriage and forks.
The VSM also monitors the performance of the sys-
tem and reports faults to the operator through the Dis- Tilt
play Panel (DP).
The electronic tilt control lever is the second mini-
To operate the Mini Lever Module (MLM), the opera- lever to the right of the operator's seat. Push the lever
tor must be positioned on the seat. forward to tilt the mast and forks forward. Pull the
lever backward toward operator to tilt the mast and
The MLM commands are sent to the VSM through the forks backward.
CANbus. The VSM supplies proportional commands
to drive the electro-hydraulic valves. The VSM moni-
tors the input and outputs signals, hydraulic response,
and adjust the system performance as required.

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9060-10-34 Confidential/Proprietary - Do Not Copy or Duplicate
Operators Station Principles of Operation

Return-To-Set-Tilt (RTST) 3. Waits for the RTST time delay of 0.1 to 3 sec-
onds to time out, at which time the tilt control
Optional: Return-To-Set-Tilt (RTST) — The RTST will be enabled and the mast will continue to tilt
option assists the operator in positioning the mast at a in the direction the control lever is pushed.
predetermined set point. Note that the RTST function
does not provide for "hands free" activation of the tilt If the RTST override button is depressed before push-
valve. The operator must manually control both tilt ing the tilt lever, and the RTST override button is de-
speed and direction of the mast toward the set point. pressed for 1/20th of a second and the tilt lever is
When the mast is far away from the stop point, the moved out of neutral within one second of the button
operator is allowed to tilt at the maximum tilt flow rate. being released, the RTST control will not stop the
When the mast is close to the set point, the maximum mast at the set point. Once the lever is returned to
tilt flow rate is limited. neutral the override command will be cancelled and
the RTST control will become active.
If the RTST override button is not depressed before
pushing the tilt lever. The RTST control soft stops the NOTE: The following time delay adjustments are
mast at the set point and disables the tilt valve even if available:
the operator command is not at neutral. Once stopped
• Disable RTST
the system waits for one of three options:
• 8 increments of time delay from 0.1 to 3.0 sec-
1. Return the tilt control lever back to neutral posi-
onds
tion, which places the tilt control to neutral.
• "Continuous" time delay. If the time delay is set
2. Depress the RTST override button, which will
to continuous the operator MUST press the
override the RTST control and allow the tilt
override button to resume tilt control.
control to function. If the delay time is set to
"continuous", the operator MUST press the
A service technician may adjust the time delay.
override button to resume tilt control past the
set point.

1. LIFT/LOWER MINI-LEVER (1ST LEVER) 4. MINI-LEVER FOR AUXILIARY HYDRAULIC

2. TILT MINI-LEVER (2ND LEVER) FUNCTIONS (4TH LEVER)
3. MINI-LEVER FOR AUXILIARY HYDRAULIC 5. EMERGENCY DISCONNECT SWITCH
FUNCTIONS (3RD LEVER)
Figure 9060-10-5. E-Hydraulic Mini Lever Module

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Principles of Operation Operators Station

Auxiliary 1 • Trucks with clamp attachment: To engage the

clamp, move the mini-lever backward. To dis-
The third mini-lever is installed to the right of the tilt engage the clamp, press the override button lo-
control lever. This lever can have two methods of op- cated directly behind the mini-levers, and push
eration, depending on the attachment. the mini-lever forward.
• Trucks with clamp attachment: To engage the • Trucks without clamp attachment, four levers,
clamp, move the mini-lever backward. To dis- and four function control valve: The lever is op-
engage the clamp, press the override button lo- erated by moving it forward and back. The
cated directly behind the mini-levers, and push lever is spring loaded to return to the neutral
the mini-lever forward. position when released.
• Trucks without clamp attachment three levers, • Trucks with clamp attachment, four levers, and
and three function control valve: The lever is five function control valve: The third lever be-
operated by moving it forward and back. The comes a dual function lever. Move the lever
lever is spring loaded to return to the neutral forward and back to operate the auxiliary 1
position when released. function. Press and hold the lever down and
• Trucks with clamp attachment, three levers, move lever either forward or backward to oper-
and four function control valve: The third lever ate the auxiliary 2 function. Remove hand from
becomes a dual function lever. Move the lever lever to disable the auxiliary 2 function and re-
forward and back to operate the auxiliary 1 turn lever to auxiliary 1 position. Do not press
function. Press and hold the lever down and the override button. If the override button is
move lever either forward or backward to oper- pressed, the clamp will be engaged.
ate the auxiliary 2 function. Remove hand from
lever to disable the auxiliary 2 function and re- Emergency Disconnect Switch
turn lever to auxiliary 1 position. Do not press NOTE: The emergency disconnect switch does not
the override button. If the override button is remove power to the front or rear service lights.
pressed, the clamp will be engaged.
The emergency disconnect switch, is located on the
Auxiliary 2 right side of the armrest.
NOTE: If truck is equipped with four function control
valve, four levers and clamp attachment, the last (4th) The operator can disconnect all electrical power to the
lever controls clamp functions. If truck is equipped lift truck by pushing the emergency disconnect switch
with five function control valve, four levers and clamp in until it clicks. To reset the emergency disconnect
attachment, the clamp is the fifth function and the last switch and energize the electrical circuits, the opera-
(4th) lever controls clamp functions. tor must turn the switch clockwise until it pops out.

The fourth mini-lever is installed to the right of the

control lever. This lever can have two methods of op-
eration, depending on the attachment.

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Operators Station Principles of Operation

Lighting Control
GENERAL DESCRIPTION Make sure wire connectors do not touch the other
metal terminals or wire connectors, metal brack-
ets, or the bracket mounting nuts. Make sure the
WARNING wires are not pulled tight and are not touching
Before replacing any of the lights, fully lower the other parts to damage the insulation.
mast and tilt the mast forward until the tips of the
forks touch the ground. This action will prevent There are several different options for lights used on
the mast from lowering suddenly if the control the lift trucks. See Figure 9060-10-6. Your lift truck
lever is accidently moved. may not be equipped with all the lights.
Never have any metal on your fingers, arms, or
The lighting control system consists of work lights,
neck. These metal items can cause short circuit
marker lights, strobe light, turn signal lights, stop/
and possible damage or injury.
backup lights and dome light. The work lights are con-
trolled by rocker switches located on the right side of
CAUTION the dash; turn signal lights are controlled by a lever on
A short circuit and damage can occur if wires are the steering column.
not installed correctly.

NOTE: LIGHT LOCATION ON LIFT TRUCK MODELS E2.2-3.5XN (E45-70XN) (A268), J2.2- 3.5XN [J45-70XN]
(A276), J1.5-2.0XNT (J30-40NT) (K160), AND J1.6-2.0XN (A935) ARE THE SAME. J1.5-2.0XNT (J30-40NT)
(K160) IS SHOWN.

A. FRONT VIEW B. REAR VIEW

1. FRONT WORK LIGHTS 4. LED TAIL, BACKUP, AND BRAKE LIGHTS
2. FRONT MARKER/TURN SIGNAL LIGHTS* 5. REAR WORK LIGHT
3. STROBE LIGHT

* FRONT MARKER/TURN SIGNAL LIGHTS USED ONLY ON J2.2- 3.5XN [J45-70XN] (A276), J1.5-2.0XNT
(J30-40NT) (K160), AND J1.6-2.0XN (A935) LIFT TRUCK MODELS.

Figure 9060-10-6. Lights Arrangement

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Principles of Operation Operators Station

Front Work Lights If the power is turned OFF, the work lights will con-
tinue to operate until the light switch on the dash is
The front work lights rocker switch is located on the turned OFF.
right side of the dash. The front work lights can be op-
erated when the truck system power is ON or OFF. If Rear Backup Lights
the power is turned OFF, the work lights will continue
to operate until the light switch on the dash is turned The rear backup lights operate when Reverse direc-
OFF. tion is selected.

Front Marker Lights Rear Stop Lights

The front marker lights operate with the front work The rear stop lights operate when the brake pedal is
lights. pressed.

Front/Rear Turn Signal Lights Strobe Light

The front/rear turn signal lights are activated by a The strobe light operate when the truck power is ON
lever mounted on the left of the steering column. The or when a programmed function is selected.
activated signal light will continue to operate until the
lever is manually returned to the center position or un- Dome Light
til system power is turned to OFF.
The dome light is located on the left behind the opera-
Rear Tail Lights tor. There is an ON/OFF switch on the dome light.
The dome light is powered through an unswitched
The rear tail light operate with the operation of the battery source and will operate with or without system
front work lights. power turned ON.

Rear Work Light

The rear work light switch is located on the right side

of the dash. The rear work lights can only be operated
when the truck system power is ON or OFF.

Cab Panels
GENERAL DESCRIPTION A cover on the top of the counterweight provides ac-
cess to the hydraulic tank, hydraulic pump and motor
Cab panels are offered as an option with the lift truck. assembly, and the hoist controller.
The cab unit consists of individual panels installed on
the overhead guard using cap screws. The panels in- Hood and Seat
clude, a roof, side doors, front and rear windows.
Front and rear window wipers, and heater system are Hood
available.
The hood is a stamped steel battery cover. Two
Covers and Floor Plates hinges at the back attach to the overhead guard.

Various covers and floor plates provide access to The hood is the platform for the seat assembly and is
components during service and securely cover areas located above the battery. It functions as a battery re-
during normal operation. Covers in the floor of the op- straint that completely covers the battery compart-
erator compartment allow access to the traction con- ment.
trollers, AC drive motors, service and parking brakes.

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Operators Station Principles of Operation

Seat Control Panel

The seat assembly slides on seat rails that are fas- Controls the speed of the heater fan. The operator
tened to the hood by four capscrews. A lever at the may choose to have the fan off or select from three
left front side of the base controls the adjustment of fan speeds (low, medium, or high).
the seat to the forward and backward positions. Op-
tional seats are available in cloth or vinyl with features Plastic casing 85 x 72 x 25mm, for retractable or
such as non-suspension, full suspension, and limited standalone mounting. 2 digits indicate selected tem-
swivel. perature. The selected fan speed is indicated with a
LED ladder.
All seats have a seat switch installed in the bottom
cushion that senses operator presence. When the op- Quartz crystal controlled microprocessor with program
erator is not on the seat, the seat switch opens and memory of flash type and EEPROM memory for oper-
interrupts the controller stopping operation of the lift ating parameters.
truck.
Operating voltage 12VDC from control board. Com-
Cab Heating System munication via RS- 485 interface. Different cable
lengths up to 4m are available.
If included, the cab heater is located on the right hand
door. The optional cab heater consists of the main Heater Core
plenum assembly, motor, fan, wiring harness, control
unit with keypad, primary filter media, secondary filter Functions as a heat exchanger allowing air that
media, and mounting hardware. passes through the core to be heated. Battery power
heats the elements within the core.
The fan draws outside air through the cab vent and
into both filters before finally entering the plenum. A Heater Fan
thermostat regulates operation of the electric heating
element. Cab air is heated until plenum air tempera- Consists of a motor and two drum fans. Air is drawn in
ture reaches a maximum of 35°C (95°F). At this maxi- from outside the cab and is directed to flow across the
mum temperature the thermostat will automatically cut heater core. The air is warmed by the heater core and
power to the element as a protective measure. flows out through adjustable vents located on the inte-
rior RH door housing.
Operator keypad inputs command the control unit ON
or OFF, change temperature and fan speed. Temper- 24 VDC max 80W, of commutator or brush-less type.
ature settings can be adjusted in 1° increments shown Driven by DC-DC converter with 8 speed levels at
on corresponding LCD screen. Operators can choose 14-24V
to display temperature in Celsius (C) or Fahrenheit
(F). Fan speed is also adjusted using the keypad and Wiper/Washer System
corresponding displayed on a segmented graph.
The wiper/washer system consists of the wiper mo-
By monitoring input voltage and current flow through tors, wiper arms, wiper blades and a washer bottle
components this heater will trigger error codes in the and pump. The front wiper and washer is operated by
event of a malfunction. Basic onboard diagnostics switches located on the dash. The rear wiper and
guide service personnel in troubleshooting by display- washer switch is located in the headliner on the right
ing a variety of error codes. For details see Opera- side of the truck.
tor's Cab 0100SRM1446.

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Confidential/Proprietary - Do Not Copy or Duplicate 9060-10-39
 NOTES

9060-10-40
 SECTION 9070

FRONT END (MAST) AND CHASSIS

TABLE OF CONTENTS

Group 10 - Principles of Operation

Front End, Mast.......................................................................................................................................9070-10-1
Description..........................................................................................................................................9070-10-1
Carriages.................................................................................................................................................9070-10-2
Description..........................................................................................................................................9070-10-2
Principles of Operation....................................................................................................................... 9070-10-2
Integral Sideshift Carriage..............................................................................................................9070-10-2
Mast Mounts............................................................................................................................................9070-10-3
Description..........................................................................................................................................9070-10-4
Principles of Operation....................................................................................................................... 9070-10-4
Two-Stage Full Free-Lift (FFL) Mast....................................................................................................... 9070-10-4
Description..........................................................................................................................................9070-10-4
Principles of Operation....................................................................................................................... 9070-10-5
Two-Stage Limited Free-Lift (LFL) Mast................................................................................................. 9070-10-6
Description..........................................................................................................................................9070-10-6
Principles of Operation....................................................................................................................... 9070-10-7
Three-Stage Full Free-Lift (FFL) Mast.................................................................................................... 9070-10-8
Description..........................................................................................................................................9070-10-8
Principles of Operation....................................................................................................................... 9070-10-9
Four-Stage Full Free-Lift (FFL) Mast.................................................................................................... 9070-10-10
Description........................................................................................................................................9070-10-11
Principles of Operation..................................................................................................................... 9070-10-12
Cylinder Cushion During Lifting Sequence........................................................................................... 9070-10-14
Description........................................................................................................................................9070-10-14
Principles of Operation..................................................................................................................... 9070-10-14
Cylinder Cushion During Lowering Sequence...................................................................................... 9070-10-15
Description........................................................................................................................................9070-10-15
Principles of Operation..................................................................................................................... 9070-10-15
Tilt and Sideshift Cylinders....................................................................................................................9070-10-16
Description........................................................................................................................................9070-10-16
Tilt Cylinder...................................................................................................................................9070-10-16
Sideshift Cylinder..........................................................................................................................9070-10-16
Lowering Control Valves....................................................................................................................... 9070-10-16
Description........................................................................................................................................9070-10-16
Principles of Operation..................................................................................................................... 9070-10-16
Chassis................................................................................................................................................. 9070-10-18
Description........................................................................................................................................9070-10-18
Overhead Guard ..........................................................................................................................9070-10-18
Counterweight.............................................................................................................................. 9070-10-18
Group 30 - Observed Symptoms
Abnormal Channel Wear.........................................................................................................................9070-30-1
Abnormal Hose Wear..............................................................................................................................9070-30-4
Abnormal Mast Noise..............................................................................................................................9070-30-6
Body Panels Making Noise..................................................................................................................... 9070-30-9
External Leakage From Free-Lift or Main Lift Cylinders........................................................................9070-30-10

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 FFL Mast Banging During Phasing....................................................................................................... 9070-30-12
High Tire Wear - Drive Axle.................................................................................................................. 9070-30-14
High Tire Wear - Steer Axle.................................................................................................................. 9070-30-15
Hoses Not Tracking Correctly............................................................................................................... 9070-30-17
Integral Sideshift Moving Too Fast........................................................................................................9070-30-19
Integral Sideshift Not Moving or Slow................................................................................................... 9070-30-20
Fork Positioner Not Moving or Slow......................................................................................................9070-30-23
Mast is Loose........................................................................................................................................ 9070-30-26
Mast Lift Chains Are Loose................................................................................................................... 9070-30-28
Mast or Carriage Binding...................................................................................................................... 9070-30-29
Mast/Carriage Bounces or is Spongy....................................................................................................9070-30-31
Misphasing of Full Free-Lift Mast.......................................................................................................... 9070-30-32
Overhead Guard Loose or Damaged....................................................................................................9070-30-34
Racking During Lift................................................................................................................................9070-30-35
Racking During Tilt................................................................................................................................9070-30-37
Truck Feels Unstable............................................................................................................................ 9070-30-38
Truck Wanders, Does Not Track Straight or Steer Well........................................................................9070-30-39
Wheel Studs Breaking...........................................................................................................................9070-30-40

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Front End (Mast) and Chassis Principles of Operation

Group 10

Principles of Operation

Front End, Mast

DESCRIPTION The mast has two movements controlled by hydraulic
cylinders: forward and backward tilt, and the lifting
This section provides general Principles of Operation and lowering of the mast and carriage. The outer
for front end components. Therefore, the illustrations mast tilts on the pivot pins at the mast mounts. The
used are intended to provide only a general descrip- operation of the tilt cylinders causes the mast to tilt
tion of front end components. Since many details and forward and backward. The tilt cylinders are fastened
specific repair procedures, vary, depending on your between the frame of the lift truck and the outer mast.
lift truck, see Mast Repair (S/N A270, A271, A272) Hydraulic lift cylinders are installed vertically in the
4000SRM1386, Mast Repair (S/N C661, C662, mast. The lift cylinders raise and lower the intermedi-
C663, C665) 4000SRM1405, Mast Repair (S/N ate/inner masts and the carriage.
A551, A555, A559, B551, B555, D507, D562, D508,
D563, D509, D564, D515, E509, E564) There are four types of masts available:
4000SRM1338, or Mast Repair (S/N B551, B555, • Two-Stage Limited Free-Lift
and B559) 4000SRM1441. Depending on your lift
truck, the description and repair for the tilt cylinders • Two-Stage Full Free-Lift
see, Cylinder Repair (Mast S/N A270-72, A551, • Three-Stage Full Free-Lift
A555, A559, A626, A627, A751-52, B551, B555, • Four-Stage Full Free-Lift.
B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Each type of mast is described separately in this sec-
Repair (Mast S/N B551, B555, B559) tion.
2100SRM1440.

The mast is used to lift a load vertically.

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Principles of Operation Front End (Mast) and Chassis

Carriages
DESCRIPTION
The carriage is a part of the mast assembly and
moves within the vertical channels of the inner weld-
ment. Load rollers, attached to the carriage, travel in
the channels of the inner weldment. Forks or other
types of load handling equipment are attached to the
carriage. A load backrest extension is attached to the
carriage and adds support for a load that has multiple
pieces. See Figure 9070-10-1.

PRINCIPLES OF OPERATION
Integral Sideshift Carriage

The integral sideshift carriage lets the operator move

the forks and load from side to side. This function
makes it easier for the operator to align the forks with
a load or align the load with a stack. The integral side-
shift carriage is a complete inner carriage and outer
frame assembly. The sideshift cylinder moves the
outer frame assembly on the inner carriage. The fork
spread control lever is the fourth manual lever. PUSH
the lever FORWARD to move the forks apart. PULL
the lever BACKWARD toward the operator to move
the forks together. See Figure 9070-10-2. 1. STANDARD CARRIAGE
2. FORKS
3. LOAD BACKREST EXTENSION

Figure 9070-10-1. Carriage

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Front End (Mast) and Chassis Principles of Operation

1. INNER CARRIAGE 12. LUBE FITTING

2. OUTER FRAME 13. PIN
3. SIDESHIFT CYLINDER 14. CHAIN ANCHOR
4. UPPER BEARING 15. SNAP RING
5. LOWER BEARING 16. PIN
6. LOWER HOOK 17. COTTER PIN
7. CAPSCREW 18. LOAD ROLLER
8. WASHER 19. SHIMS
9. CLEVIS PIN 20. SPACER
10. HAIRPIN 21. SNAP RING
11. PIN 22. SPACER

Figure 9070-10-2. Integral Sideshift Carriage

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Principles of Operation Front End (Mast) and Chassis

Mast Mounts
DESCRIPTION
The lower crossmember of the outer mast has cast-
ings to mount the mast mounting stubshaft. The
mounting stubshafts are installed in the castings and
the mast is hung on the hangers of the drive axle
housing. Capscrews secure the mounting stubshaft to
the drive axle housing. See Figure 9070-10-3.

The mast tilt cylinders are attached to the mast upper

attachment castings using rod end fittings. Pins attach
the rod end fittings to the casting and are secured
with anchor pins and capscrews.

PRINCIPLES OF OPERATION
The mast and attached forks can tilt forward and
backward. Tilt cylinders are fastened between the lift
truck frame and the outer mast upper attachment
points. The operator uses the Mini Lever Module con- 1. RETAINER CAP
2. CAPSCREWS
trols to extend or retract the tilt cylinders, changing 3. SHIM
the angle of the mast that pivots on the mounting 4. BUSHING
stubshafts mounted on the drive axle housing. 5. MAST MOUNT STUBSHAFT
6. GREASE FITTING

Figure 9070-10-3. Mast Mounts

Two-Stage Full Free-Lift (FFL) Mast

DESCRIPTION The top of each lift cylinder rod fits into a guide on the
top crossmember of the inner mast. The free-lift cylin-
The Two-Stage Full Free-Lift Mast has an inner mast der is installed in the inner mast. Each of the lift cylin-
and an outer mast. See Figure 9070-10-4. It is called ders has an internal lowering control valve. A single
a full free-lift mast because the carriage can travel to external lowering control valve is connected by tubing
the top of the inner mast without extending the inner and hoses to all the lift cylinders.
mast. The full free-lift mast has the same load roller
and strip bearing arrangements as the two-stage, limi- The free-lift chains connect at one end to the mid-
ted free-lift mast. crossmember of the inner mast. Two chain sheaves
are installed on a crosshead on the rod of the free-lift
The two main lift cylinders are installed at the back of cylinder. The chains go over sheaves on the cross-
the outer mast. The base of each lift cylinder sits in a head and connect to the carriage.
mount on the bottom crossmember of the outer mast.

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Front End (Mast) and Chassis Principles of Operation

Legend for Figure 9070-10-4

NOTE: TYPICAL MAST ASSEMBLY IS SHOWN.

1. OUTER MAST
2. INNER MAST
3. FREE-LIFT CHAIN
4. FREE-LIFT CYLINDER
5. MAIN LIFT CYLINDER(S)
6. LOWERING CONTROL VALVE (EXTERNAL)

PRINCIPLES OF OPERATION
The three lift cylinders are connected by hoses and
tubing as shown in Figure 9070-10-5. When the mast
is extended, oil flows from the main control valve to
the base of the main lift cylinders. The oil flows
through the left-hand cylinder rod and through tubing
to the base of the free-lift cylinder. The free-lift cylin-
der raises only the carriage. When the free-lift cylinder
is fully extended, the two main lift cylinders extend the
inner mast. The free-lift cylinder extends first because
it has less weight to lift and a lower operating pres-
sure. When the load is lowered, the main lift cylinders
lower first because they have a greater load and a
higher operating pressure. The oil flows from the main
lift cylinders, through the lowering control valve to the
hydraulic tank. Oil from the free-lift cylinder flows from
the cylinder through tubing to the left-hand main lift
cylinder rod. The oil flows from the left-hand main lift
cylinder to the hydraulic tank.

The free-lift cylinder must have 150 cc (5 oz) of oil

above the piston. This oil provides a hydraulic cushion
when the cylinder reaches the top of its stroke. An ori-
fice system in the piston provides the hydraulic cush-
ioning. When the cylinder is fully extended, any ex-
cess oil above the piston is forced through the check
valve in the piston.

The right-hand main lift cylinder has an orifice system

in the bottom of the rod assembly. This system pro-
vides a hydraulic cushion when the cylinder reaches
the bottom of its stroke.

Figure 9070-10-4. Two-Stage (FFL) Mast

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Principles of Operation Front End (Mast) and Chassis

1. RIGHT-HAND LIFT CYLINDER 7. OUTER MAST

2. LEFT-HAND LIFT CYLINDER 8. INNER MAST
3. FREE-LIFT CYLINDER 9. FREE-LIFT CHAINS
4. LOWERING CONTROL VALVE (INTERNAL) 10. CARRIAGE
5. LOWERING CONTROL VALVE (EXTERNAL) 11. CHAIN SHEAVES
6. TO/FROM MAIN CONTROL VALVE

Figure 9070-10-5. Operation of Two-Stage (FFL) Mast

Two-Stage Limited Free-Lift (LFL) Mast

DESCRIPTION The strip bearings are installed at the top of the outer
mast. The strip bearings can be adjusted by shims to
The Two-Stage Limited Free-Lift Mast has an outer help keep the correct clearance between the outer
mast, an inner mast, and two lift cylinders. See Fig- mast and the inner mast.
ure 9070-10-6. At the base of the inner mast there is
one load roller on each side. These load rollers travel The two single-stage lift cylinders are installed at the
along the flanges inside the outer mast channel. At back of the outer mast. The base of each lift cylinder
the top of the outer mast there is also one load roller sits in a mount on the bottom crossmember of the
on each side. These load rollers travel along the outer mast. The top of each lift cylinder rod fits into a
flanges on the outside of the inner mast. The angle of guide on the top crossmember of the inner mast. Op-
the load rollers permits them to control the forces from eration of the lift cylinders extends and retracts the in-
the front, back, and sides of the mast. ner mast. See Figure 9070-10-7.

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Front End (Mast) and Chassis Principles of Operation

Legend for Figure 9070-10-6

NOTE: TYPICAL MAST ASSEMBLY IS SHOWN.

1. OUTER MAST
2. INNER MAST
3. LIFT CHAIN(S)
4. LIFT CYLINDER(S)
5. LOWERING CONTROL VALVE (EXTERNAL)

PRINCIPLES OF OPERATION
Two lift chains move the carriage. The chains fasten
to mounts that are near the top of the lift cylinder
shells as shown in Figure 9070-10-7. The chains go
up and over the chain sheaves and connect to the
carriage. The chain sheaves are installed at the top
crossmember of the inner mast. When the lift cylin-
ders extend, the lift chains transfer the force from the
lift cylinders to the carriage. The inner mast and car-
riage raise a small amount before the overall height of
the mast increases. During lifting, the inner mast
moves at the same speed as the lift cylinders. The
carriage moves at twice the speed of the inner mast/
lift cylinders.

When the lift cylinders retract, the weight of the load,

carriage, forks, load backrest extension and attach-
ment, and inner mast pushes the oil from the lift cylin-
ders. The oil flows from the lowering control valves in
the lift cylinders, through the external lowering control
valve to the hydraulic tank.

Each cylinder has a check valve in the bottom of the

rod assembly. When the cylinder is fully extended,
any oil above the piston is forced through the check
valve.

Figure 9070-10-6. Two-Stage (LFL) Mast

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Principles of Operation Front End (Mast) and Chassis

1. LIFT CYLINDER 6. INNER MAST

2. LOWERING CONTROL VALVE (INTERNAL) 7. LIFT CHAINS
3. LOWERING CONTROL VALVE (EXTERNAL) 8. CARRIAGE
4. TO/FROM MAIN CONTROL VALVE 9. CHAIN SHEAVES
5. OUTER MAST

Figure 9070-10-7. Operation of Two-Stage (LFL) Mast

Three-Stage Full Free-Lift (FFL) Mast

DESCRIPTION The load rollers are installed at the top of the outer
and intermediate masts. Load rollers are also used at
The Three-Stage Full Free-Lift Mast has three masts: the bottom of the intermediate and inner masts.
outer, intermediate, and inner. See Figure 9070-10-8. These load rollers travel along the flanges of the mast
Two single-stage main lift cylinders and a free-lift cyl- channels. The angle of the load rollers permits them
inder are used to raise the carriage and extend the in- to control the forces from the front, back, and sides of
termediate and inner mast. It is called a full free-lift the mast. The strip bearings are installed at the top of
mast because the carriage can travel to the top of the the outer and intermediate masts and help keep the
inner mast without extending the inner mast. The correct clearance between the masts. The load rollers
masts are telescopic and have the load roller and strip and strip bearings are adjustable with shims.
bearing arrangements similar to the two-stage mast.

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Front End (Mast) and Chassis Principles of Operation

The two main lift cylinders are installed at the back of

the outer mast. The base of each main lift cylinder sits
in a mount on the bottom crossmember of the outer
mast. The top of each main lift cylinder rod fits into a
guide in the top crossmember of the intermediate
mast. The free-lift cylinder is installed to the inner
mast. Each lift cylinder has an internal lowering con-
trol valve. A single external lowering control valve is
connected by tubing and hoses to all of the lift cylin-
ders.

The two main lift chains are connected to mounts that

are welded near the top of the main lift cylinder shells.
The lift chains go over sheaves at the top of the inter-
mediate mast and fasten at the bottom of the inner
mast.

The free-lift chains connect at one end to the mid-

crossmember of the inner mast. Two chain sheaves
are installed on a crosshead on the cylinder rod of the
free-lift cylinder. The chains go over sheaves on the
crosshead and connect to the carriage.

PRINCIPLES OF OPERATION
The three hydraulic cylinders are connected by hoses
and tubing as shown in Figure 9070-10-9. When the
mast is extended, oil from the main control valve flows
to all cylinders at the same time. The free-lift cylinder
extends first because it lifts the least amount of weight
and has a lower operating pressure. The free-lift cylin-
der raises only the carriage. After the free-lift cylinder
reaches the end of its stroke, the main lift cylinders
NOTE: TYPICAL MAST ASSEMBLY IS SHOWN.
begin to extend. As the main lift cylinders extend, the
intermediate mast is raised by the main lift cylinders 1. OUTER MAST
and the inner mast is raised by the main lift chains. 2. INTERMEDIATE MAST
3. INNER MAST
During lowering, the main lift cylinders lower first be- 4. FREE-LIFT CHAIN
5. MAIN LIFT CHAIN(S)
cause they have a greater load and higher operating 6. FREE-LIFT CYLINDER
pressure. After the main lift cylinders have retracted, 7. MAIN LIFT CYLINDER(S)
the free-lift cylinder lowers. All oil from the lift cylin- 8. LOWERING CONTROL VALVE (EXTERNAL)
ders flows through the lowering control valves to the
hydraulic tank. Figure 9070-10-8. Three-Stage (FFL) Mast

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Principles of Operation Front End (Mast) and Chassis

The free-lift cylinder must have 150 cc (5 oz) of oil Each main lift cylinder has an orifice system and a
above the piston. This oil provides a hydraulic cushion check valve in the bottom of the rod assembly. When
when the cylinder reaches the top of its stroke. An ori- the cylinder is fully extended, any oil between the rod
fice system in the piston provides the hydraulic cush- end and the gland is forced through the check valve.
ioning. When the cylinder is fully extended, any ex- The orifice system provides a hydraulic cushion when
cess oil above the piston is forced through the check the cylinder reaches the bottom of its stroke.
valve.

1. LIFT CYLINDER 7. INTERMEDIATE MAST

2. FREE-LIFT CYLINDER 8. INNER MAST
3. LOWERING CONTROL VALVE (INTERNAL) 9. MAIN LIFT CHAINS
4. LOWERING CONTROL VALVE (EXTERNAL) 10. CARRIAGE
5. TO/FROM MAIN CONTROL VALVE 11. FREE-LIFT CHAINS
6. OUTER MAST 12. CHAIN SHEAVES

Figure 9070-10-9. Operation of Three-Stage (FFL) Mast

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Front End (Mast) and Chassis Principles of Operation

Four-Stage Full Free-Lift (FFL) Mast

DESCRIPTION The free-lift chains connect at one end to the mid-
crossmember of the inner mast. Two chain sheaves
The Four-Stage Full Free-Lift (FFL) Mast has four are installed on a crosshead on the cylinder rod of the
masts: outer, first intermediate, second intermediate, free-lift cylinder. The chains then go over sheaves on
and inner. See Figure 9070-10-10. Two single-stage the crosshead and connect to the carriage.
main lift cylinders and a free-lift cylinder are used to
raise the carriage and extend the intermediate and in-
ner masts. It is called a full free-lift mast because the
carriage can travel to the top of the inner mast without
extending the inner mast.

The masts are telescopic and have load roller and

strip bearing arrangements similar to the three-stage
mast. The load rollers are installed at the top of the
outer, first, and second intermediate masts. Load roll-
ers are also used at the bottom of the first and second
intermediate masts and the inner mast. These load
rollers travel along the flanges of the mast channels.
The angle of the load rollers permits them to control
the forces from the front, back, and sides of the mast.
The strip bearings are installed at the top of the outer,
first, and second intermediate masts and help keep
the correct clearance between the masts. The load
rollers and strip bearings are adjustable with shims.

The two main lift cylinders are installed at the back of

the outer mast. The base of each main lift cylinder sits
in a mount on the bottom crossmember of the outer
mast. The top of each main lift cylinder rod fits into a
guide in the top crossmember of the first intermediate
mast. The free-lift cylinder is installed to the inner
mast. The free-lift and left-hand main lift cylinder has
an internal lowering control valve. A single external
lowering control valve is connected by tubing and ho-
ses to all of the lift cylinders.

The main lift chains connect to mounts that are near

the top of the outer mast. The lift chains then go over
sheaves at the top of the first intermediate mast and
fasten at the bottom of the second intermediate mast.

The intermediate lift chains connect to mounts that

are near the top of the first intermediate mast. The lift
chains then go over sheaves at the top of the second
intermediate mast and fasten at the bottom of the in-
ner mast.
Figure 9070-10-10. Four-Stage (FFL) Mast

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Principles of Operation Front End (Mast) and Chassis

Legend for Figure 9070-10-10 The top of the right-hand cylinder is connected to the
left-hand main cylinder by a tube. When the main cyl-
1. OUTER MAST inders are fully extended, any oil between the rod end
2. FIRST INTERMEDIATE MAST
3. SECOND INTERMEDIATE MAST and the gland is forced through the check valve in the
4. INNER MAST bottom of the left-hand main cylinder. The orifice sys-
5. FREE-LIFT CHAINS tem in the bottom of the left-hand main cylinder pro-
6. FREE-LIFT CYLINDER vides a hydraulic cushion when the cylinder reaches
7. MAIN LIFT CYLINDERS the bottom of its stroke.
8. LIFT CHAINS

PRINCIPLES OF OPERATION
The three hydraulic cylinders are connected by hoses
and tubing as shown in Figure 9070-10-11. When the
mast is extended, oil flows from the main control valve
to the base of the main cylinders. The oil flows
through the right-hand cylinder rod and through a tube
and hose to the base of the free-lift cylinder. The free-
lift cylinder extends first because it lifts the least
amount of weight and has a lower operating pressure.
The free-lift cylinder raises only the carriage. After the
free-lift cylinder reaches the end of its stroke, the
main lift cylinders begin to extend. As the main lift cyl-
inders extend, the first intermediate mast is raised by
the main lift cylinders. The second intermediate and
inner masts are raised by the main and intermediate
lift chains. See Figure 9070-10-12.

During lowering, the main lift cylinders lower first be-

cause they have a greater load and higher operating
pressure. After the main lift cylinders have retracted,
the free-lift cylinder lowers. All oil from the lift cylin-
ders flows through the lowering control valves to the
hydraulic tank.
1. MAIN LIFT CYLINDER (LEFT-HAND)
2. FREE-LIFT CYLINDER
The free-lift cylinder must have 150 cc (5 oz) of oil 3. MAIN LIFT CYLINDER (RIGHT-HAND)
above the piston. This oil provides a hydraulic cushion 4. SECONDARY LOWERING CONTROL VALVE
when the cylinder reaches the top of its stroke. An ori- (EXTERNAL)
fice system in the piston provides the hydraulic cush- 5. PRIMARY LOWERING CONTROL VALVE (EX-
TERNAL)
ioning. When the cylinder is fully extended, any ex- 6. TO/FROM MAIN CONTROL VALVE
cess oil above the piston is forced through the check
valve in the piston. Figure 9070-10-11. Hydraulic Schematic for Mast
Cylinders
The left-hand main cylinder has an orifice system and
check valve in the bottom of the rod assembly.

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Front End (Mast) and Chassis Principles of Operation

Figure 9070-10-12. Operation of Four-Stage (FFL) Mast

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Principles of Operation Front End (Mast) and Chassis

Legend for Figure 9070-10-12

A. LOWERED C. FULLY RAISED

B. FREE-LIFT
1. MAIN LIFT CYLINDER 7. CARRIAGE
2. OUTER MAST 8. FORK
3. FIRST INTERMEDIATE MAST 9. MAIN LIFT CHAINS
4. SECOND INTERMEDIATE MAST 10. INTERMEDIATE LIFT CHAINS
5. FREE-LIFT CYLINDER 11. FREE-LIFT CHAINS
6. INNER MAST 12. CHAIN SHEAVES

Cylinder Cushion During Lifting Sequence

DESCRIPTION
The hydraulic action at the end of the free-lift stroke
provides a cushion effect for the free-lift cylinder and
a smooth transition between the free-lift phase and
the mast extension phase (main cylinder extension).
All masts with a free-lift cylinder in this section use
this design.

PRINCIPLES OF OPERATION
There is hydraulic oil on the rod side of the piston of
the free-lift cylinder. When the cylinder rod extends to
the last 25 mm (1.0 in.) of its stroke, the gland at the
top of the cylinder closes the larger hole. During this
part of the cylinder stroke, the hydraulic oil must flow
through the orifice to the air cavity. This action increa-
ses the hydraulic pressure so the main lift cylinders
begin to extend. See Figure 9070-10-13.
1. CYLINDER ROD
2. CYLINDER SHELL
3. LARGE ORIFICE
4. SMALL ORIFICE
5. PISTON
6. INTERNAL CHECK VALVE
7. AIR CAVITY

Figure 9070-10-13. Free-Lift Cylinder Operation

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Front End (Mast) and Chassis Principles of Operation

Cylinder Cushion During Lowering Sequence

DESCRIPTION
This cushion effect prevents a sudden stop of the
main cylinders, which causes smoother operation dur-
ing lowering. All masts in this section, except Two-
Stage Limited Free-Lift Masts, use this design in the
main lift cylinders.

PRINCIPLES OF OPERATION
NOTE: An internal check valve is not used on the
Two-Stage Full Free-Lift Mast.

When the main lift cylinders retract, the hydraulic oil

flows out of the cylinder through the hydraulic port un-
til the cushion ring moves past the hydraulic port. Dur-
ing the last 20 mm (0.79 in.) of the retraction stroke,
the hydraulic oil must flow through the orifice. See
Figure 9070-10-14. This action causes the cylinder
rod to move much more slowly at the end of the re-
traction stroke.

NOTE: LEFT-HAND LIFT CYLINDER SHOWN.

1. CYLINDER ROD
2. CYLINDER SHELL
3. PISTON
4. INTERNAL CHECK VALVE
5. HYDRAULIC PORT
6. ORIFICE
7. PISTON SEAL
8. CUSHION RING

Figure 9070-10-14. Main Lift Cylinder Operation

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Principles of Operation Front End (Mast) and Chassis

Tilt and Sideshift Cylinders

DESCRIPTION Sideshift Cylinder

Tilt Cylinder The sideshift cylinder is removable for service. It is a

double-acting, non-differential, piston-type cylinder,
The tilt cylinders are used to move the mast forward which allows the sideshift to attain the same speed
and backward. To extend the cylinder rod (tilt for- moving either left or right. The cylinder also has flow
ward), oil enters the tilt cylinder port behind the piston. restricting orifices in the ports.
The oil pressure pushes the cylinder rod out of the
cylinder. Oil in front of the piston returns to the hy-
draulic tank. To retract the cylinder rod (tilt backward),
the oil enters the port in front of the piston. The oil
pressure pushes the cylinder rod into the tilt cylinder.
The oil behind the piston returns to the hydraulic tank.

Lowering Control Valves

DESCRIPTION der moves the orifice sleeve. The orifice sleeve
moves away from the larger inner diameter area of
The lowering control system permits easy entry of hy- the bore in the valve body. This movement makes a
draulic oil into the cylinder during lifting, but restricts restriction to the oil flow. As the pressure increases,
flow when rod is retracted to limit the speed at which the plunger begins to move against the spring. The
a load maybe lowered. A pressure-compensated low- movement begins to close the openings of the large
ering control valve regulates the lowering speed to a holes in the main sleeve. Additional pressure will push
more uniform value over the entire capacity range. the plunger against the main sleeve to close the large
The two types of lowering control valves used are holes completely. All the oil must then go through the
designated as primary and secondary. small holes to the center of the main sleeve. This re-
striction permits the piston rod to lower only at a maxi-
PRINCIPLES OF OPERATION mum controlled speed. See Figure 9070-10-15.

The Primary lowering control valve limits the lowering The Secondary lowering control valve is installed in
speed of the mast to a maximum controlled rate over each cylinder and is used only for emergency lower-
the full range of loads. This valve is mounted exter- ing. In the event an hydraulic line ruptures, this valve
nally on the middle crossmember of the outer mast. will lower the mast at a controlled rate. This type of
This type of lowering control valve uses these basic lowering control valve uses these parts: (1) special fit-
parts: (1) valve body, (2) spring, (3) special washer, ting for the valve body, (2) spring, (3) special washer,
(5) orifice sleeve, (6) plunger, and (7) main sleeve. and (4) cylinder. There is a variation in the shapes of
The orifice sleeve position is controlled completely by the special washer. The volume of the hydraulic oil
oil flow. The plunger position is controlled by oil pres- flowing through the inlet port controls the shape of the
sure and spring tension. During lifting, oil entering the special washer. When the piston rod is lowered, the
lift cylinder goes through the center of the main sleeve oil flow pushes against the special washer and spring.
to the large holes. The oil flow through the plunger When the oil flow reaches the limit, the special
and bore moves the orifice sleeve to the end of the washer is moved against the special fitting. The oil
plunger. The flange of the orifice sleeve is then then flows only through the hole in the center of the
aligned with the large part of the bore in the body. special washer. This restriction permits the piston rod
This alignment lets the oil flow past the orifice sleeve to lower only at a maximum controlled speed. See
to the cylinder. During lowering, oil from the lift cylin- Figure 9070-10-16.

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Front End (Mast) and Chassis Principles of Operation

A. LIFTING C. FREE FLOW

B. LOWERING D. RESTRICTED FLOW
1. SPECIAL FITTING OR VALVE BODY 5. ORIFICE SLEEVE
2. SPRING 6. PLUNGER
3. SPECIAL WASHER 7. MAIN SLEEVE
4. NOT SHOWN, CYLINDER (SECONDARY ONLY)

Figure 9070-10-15. Primary Lowering Control Valve

A. LIFTING C. FREE FLOW

B. LOWERING D. RESTRICTED FLOW
1. SPECIAL FITTING OR VALVE BODY 3. SPECIAL WASHER
2. SPRING 4. CYLINDER (SECONDARY ONLY)

Figure 9070-10-16. Secondary Lowering Control Valve

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Principles of Operation Front End (Mast) and Chassis

Chassis
DESCRIPTION structed view while maintaining structural integrity.
Removal of the battery is simplified by the slot in the
The chassis consists of the following components as overhead guard. This provides access to the battery
shown in Figure 9070-10-17. The frame is one weld- with an overhead lifting device without removing the
ment which includes the hydraulic tank which can be overhead guard. See Figure 9070-10-17.
accessed with removal of the counterbalance. The
counterweight is attached to the frame and varies in Counterweight
weight depending on truck capacity.
A one-piece, cast iron counterweight is used to offset
Overhead Guard the weight of the load and attached to the rear sus-
pension of the lift truck. See Figure 9070-10-17.
The overhead guard is designed to provide protection
to the operator from falling objects and in the event of
a tip over. A high visibility design allows for an unob-

1. OVERHEAD GUARD 4. STEER AXLE AND WHEEL

2. COUNTERWEIGHT 5. DRIVE AXLE AND WHEEL
3. STEER AXLE MOUNTS 6. DRIVE AXLE MOUNTS

Figure 9070-10-17. Chassis Component Location

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Front End (Mast) and Chassis Observed Symptoms

Group 30

Observed Symptoms

Abnormal Channel Wear

POSSIBLE CAUSE
A. MAST DAMAGED
B. MAST CHANNELS LACK LUBRICATION
C. CHAINS ARE LOOSE OR NOT EQUAL
D. MAST IS SHIMMED INCORRECTLY
E. LOAD ROLLERS ARE NOT ROTATING FREELY WITHIN CHANNEL
F. DAMAGED OR WORN LOAD ROLLERS OR STRIP BEARINGS
G. LIFT CYLINDER BINDING

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - MAST CHANNELS LACK LUBRICATION

PROCEDURE OR ACTION:
1. Inspect grease on mast channels.
Is a thin coat of grease spread evenly on channels?
YES: Go to Cause C.
NO: Apply grease to mast sliding surfaces. Depending on your lift truck see, Periodic Maintenance
8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic
Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.

CAUSE C - CHAINS ARE LOOSE OR NOT EQUAL

PROCEDURE OR ACTION:
1. Inspect lift chains. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272) 4000SRM1386,
Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555, A559, B551,
B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Repair (S/N
B551, B555, and B559) 4000SRM1441.
Are chains adjusted correctly and in good condition?
YES: Go to Cause D.
NO: Adjust or repair chains.

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Observed Symptoms Front End (Mast) and Chassis

CAUSE D - MAST IS SHIMMED INCORRECTLY

PROCEDURE OR ACTION:

NOTE: A mast that is shimmed too loose will cause the rollers to ride up on the flange edge and produce a flaring
wear pattern.

1. Inspect mast and carriage shimming. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Is mast shimmed correctly?
YES: Go to Cause E.
NO: Adjust or repair as required.

CAUSE E - LOAD ROLLERS ARE NOT ROTATING FREELY WITHIN CHANNEL

PROCEDURE OR ACTION:
1. Inspect mast channel rollers. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Do the rollers rotate freely?
YES: Go to Cause F.
NO: Replace load rollers. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE F - DAMAGED OR WORN LOAD ROLLERS OR STRIP BEARINGS

PROCEDURE OR ACTION:
1. Inspect load rollers and strip bearings. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
Are the load rollers and strip bearings in good condition?
YES: Go to Cause G.
NO: Adjust, repair, or replace load rollers and strip bearings as required. Depending on your lift truck see,
Mast Repair (S/N A270, A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665)
4000SRM1405, Mast Repair (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564,
D515, E509, E564) 4000SRM1338, or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE G - LIFT CYLINDER BINDING

PROCEDURE OR ACTION:
1. Remove and repair cylinder. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.
2. Manually extend cylinder exterior.
Does cylinder extend freely?
YES: Mast is loose. See Observed Symptoms, Mast is Loose, Page 9070-30-26.

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Front End (Mast) and Chassis Observed Symptoms

NO: Service or replace cylinder. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72,
A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.

END SYMPTOM

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Observed Symptoms Front End (Mast) and Chassis

Abnormal Hose Wear

POSSIBLE CAUSE
A. MAST DAMAGED
B. HOSES RUBBING ON COMPONENTS
C. IMPROPER HOSE ROUTING
D. HYDRAULIC RELIEF PRESSURE SET TOO HIGH
E. TOO HIGH/LOW HYDRAULIC OIL TEMPERATURE

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause D.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - HOSES RUBBING ON COMPONENTS

PROCEDURE OR ACTION:
1. Inspect hoses for wear and tension.
Is hose tension correct?
YES: Go to Cause C.
NO: Adjust or replace hoses or sheaves as required. Depending on your lift truck see, Mast Repair (S/N
A270, A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Re-
pair (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564)
4000SRM1338, or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE C - IMPROPER HOSE ROUTING

PROCEDURE OR ACTION:
1. Inspect and adjust lift cylinder hoses. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Are the hoses in good condition and adjusted correctly?
YES: Go to Cause D.
NO: Adjust or replace hoses as required.

CAUSE D - HYDRAULIC RELIEF PRESSURE SET TOO HIGH

PROCEDURE OR ACTION:
1. Test hydraulic relief pressure. See Main System Relief Test and Adjustment. Depending on your lift truck see,
Main Control Valves 2000SRM1334 or Main Control Valves 2000SRM1439.
Is pressure within test specifications?
YES: Go to Cause E.
NO: Adjust pressure to test specifications. See Primary Relief Valve Test and Adjustment.

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9070-30-4 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

CAUSE E - TOO HIGH/LOW HYDRAULIC OIL TEMPERATURE

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Insure that hydraulic oil temperature is within the recommended operating range for the lift truck.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-5
Observed Symptoms Front End (Mast) and Chassis

Abnormal Mast Noise

POSSIBLE CAUSE
A. MAST DAMAGED
B. LOOSE OR MISSING MAST MOUNTING HARDWARE
C. LOOSE FORK FIT TO CARRIAGE
D. DAMAGED CHAIN SHEAVES
E. AIR IN HYDRAULIC SYSTEM
F. MAST CHANNELS LACK LUBRICATION
G. MAST MOUNTING BUSHINGS LACK LUBRICATION OR DAMAGED
H. MAST TILT BUSHINGS LACK LUBRICATION OR DAMAGED
I. CHAINS LOOSE OR NOT EQUAL
J. WORN LOAD ROLLERS OR STRIP BEARINGS
K. MAST CHANNELS ARE WORN
L. NOISY LIFT CYLINDER SEALS

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - LOOSE OR MISSING MAST MOUNTING HARDWARE

PROCEDURE OR ACTION:
1. Inspect mast mounting hardware.
Is hardware in good condition and torqued correctly?
YES: Go to Cause C.
NO: Replace mast mounting hardware. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE C - LOOSE FORK FIT TO CARRIAGE

PROCEDURE OR ACTION:
1. Inspect carriage bar and fork hooks for wear.
Do forks fit correctly and in good condition?
YES: Go Cause D.
NO: Replace carriage or forks if worn. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

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9070-30-6 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

CAUSE D - DAMAGED CHAIN SHEAVES

PROCEDURE OR ACTION:
1. Inspect chain sheaves.
Do chain sheaves rotate freely without noise?
YES: Go to Cause E.
NO: Replace chain sheaves. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE E - AIR IN HYDRAULIC SYSTEM

PROCEDURE OR ACTION:
1. Inspect oil condition and level in hydraulic tank.
Is the hydraulic oil level in the operating range and in good condition?
YES: Cause F.
NO: If oil level is low, add oil. If hydraulic oil is aerated, locate source of suction side leak and repair.

CAUSE F - MAST CHANNELS LACK LUBRICATION

PROCEDURE OR ACTION:
1. Inspect grease on mast channels.
Is a thin coat of grease spread evenly on channels?
YES: Go to Cause G.
NO: Apply grease to mast sliding surfaces. Depending on your lift truck see, Periodic Maintenance
8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic
Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.

CAUSE G - MAST MOUNTING BUSHINGS LACK LUBRICATION OR DAMAGED

PROCEDURE OR ACTION:
1. Inspect mast bushings. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Are the mast bushings greased and in good condition?
YES: Go Cause H.
NO: Lubricate mast bushings. Depending on your lift truck see, Periodic Maintenance 8000SRM1364, Peri-
odic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic Maintenance
8000SRM1373, or Periodic Maintenance 8000SRM1442.

CAUSE H - MAST TILT BUSHINGS LACK LUBRICATION OR DAMAGED

PROCEDURE OR ACTION:
1. Inspect mast tilt bushings. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Are the mast tilt bushings greased and in good condition?
YES: Go to Cause I.
NO: Lubricate mast tilt bushings. Replace as required. Depending on your lift truck see, Periodic Mainte-
nance 8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Peri-
odic Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-7
Observed Symptoms Front End (Mast) and Chassis

CAUSE I - CHAINS LOOSE OR NOT EQUAL

PROCEDURE OR ACTION:
1. Inspect chains. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272) 4000SRM1386, Mast
Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555, A559, B551, B555,
D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Repair (S/N B551,
B555, and B559) 4000SRM1441.
Are chains adjusted correctly and in good condition?
YES: Go to Cause J.
NO: Adjust or repair chains. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE J - WORN LOAD ROLLERS OR STRIP BEARINGS

PROCEDURE OR ACTION:
1. Inspect load rollers and strip bearings. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
Are the load rollers and strip bearings in good condition?
YES: Go to Cause K.
NO: Adjust, repair, or replace load rollers and strip bearings as required.

CAUSE K - MAST CHANNELS ARE WORN

PROCEDURE OR ACTION:
1. Inspect mast channels for wear or damage. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
Are the mast channels in good condition?
YES: Go to Cause L.
NO: Repair or replace worn mast components.

CAUSE L - NOISY LIFT CYLINDER SEALS

NOTE: Confirm that correct hydraulic oil is being used, see Operating Manual.

PROCEDURE OR ACTION:
1. On 2-Stage LFL, 3-Stage FFL, and 4-Stage FFL, apply thin film of hydraulic oil on cylinder rods.
Does the noise stop?
YES: Remove gland and add hydraulic oil. Depending on your lift truck see, Periodic Maintenance
8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic
Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.
NO: Install new cylinder seal. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.

END SYMPTOM

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9070-30-8 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

Body Panels Making Noise

POSSIBLE CAUSE
A. ATTACHING HARDWARE IS LOOSE
B. FAILED LATCHES OR HINGES

CAUSE A - ATTACHING HARDWARE IS LOOSE

PROCEDURE OR ACTION:
1. Visually inspect mounting points for damage and loose or missing hardware. Depending on your lift truck see,
Periodic Maintenance 8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance
8000SRM1339, Periodic Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.
Are body panels and attaching hardware in good condition?
YES: Inspect and repair hinges and latches. Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck, see Frame 0100SRM1329 or
Frame 0100SRM1342.

CAUSE B - FAILED LATCHES OR HINGES

PROCEDURE OR ACTION:
1. Inspect hinges and latches for correct operation.
Are the hinges and latches in good condition?
YES: Operating lift truck too fast on rough surface, reduce speed.
NO: Adjust or repair latches and hinges as required. Depending on your lift truck, see Frame 0100SRM1329
or Frame 0100SRM1342.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-9
Observed Symptoms Front End (Mast) and Chassis

External Leakage From Free-Lift or Main Lift Cylinders

POSSIBLE CAUSE
A. MAST DAMAGED
B. CYLINDER HOSES OR FITTINGS LOOSE OR DAMAGED
C. CYLINDER SEAL DAMAGE OR INCORRECT INSTALLATION
D. CYLINDER ROD DAMAGE

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - CYLINDER HOSES OR FITTINGS LOOSE OR DAMAGED

PROCEDURE OR ACTION:
1. Inspect hoses and fittings for damage and proper torque.
Are hose and fittings in good condition and torqued correctly?
YES: Go to Cause C.
NO: Adjust or replace hoses or fittings as required. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE C - CYLINDER SEAL DAMAGE OR INCORRECT INSTALLATION

PROCEDURE OR ACTION:
1. Inspect lift cylinder seals.
Are the seals in good condition and installed correctly?
YES: Go to Cause D.
NO: Adjust or replace seals as required. Depending on your lift truck see, Cylinder Repair (Mast S/N
A270-72, A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665,
D507-09, D515, D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559)
2100SRM1440.

CAUSE D - CYLINDER ROD DAMAGE

PROCEDURE OR ACTION:
1. Inspect cylinder rod for damage.
Is cylinder rod in good condition?
YES: Problem solved. Resume operations.

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9070-30-10 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

NO: Replace cylinder rod or cylinder. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72,
A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-11
Observed Symptoms Front End (Mast) and Chassis

FFL Mast Banging During Phasing

POSSIBLE CAUSE
A. MAST DAMAGED
B. FREE-LIFT CYLINDER TOP STROKE CUSHIONING NOT OPERATING
C. MAIN CYLINDER CUSHION NOT OPERATING WHEN FULLY LOWERED
D. CARRIAGE BINDING IN INNER MAST
E. CARRIAGE CONTACTS STOP AT TOP OF INNER MAST

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - FREE-LIFT CYLINDER TOP STROKE CUSHIONING NOT OPERATING

PROCEDURE OR ACTION:
1. Confirm that cushioning oil is on top side of cylinder piston. Depending on your lift truck see, Cylinder Repair
(Mast S/N A270-72, A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63,
C665, D507-09, D515, D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555,
B559) 2100SRM1440.
Is cushioning oil level correct?
YES: Go to Cause C.
NO: Add oil.

CAUSE C - MAIN CYLINDER CUSHION NOT OPERATING WHEN FULLY LOWERED

PROCEDURE OR ACTION:
1. Operate lift lower and note speed as cylinder reached end of stroke.
Does cylinder speed slow during final 25 mm (1.0 in.) of cylinder stroke?
YES: Go to Cause D.
NO: Repair or replace cylinder. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.

CAUSE D - CARRIAGE BINDING IN INNER MAST

PROCEDURE OR ACTION:
1. Observe carriage travels to the end of free lift cylinder stroke.
Does the carriage go to end of free lift cylinder stroke?
YES: Go to Cause E.
NO: Shim carriage rollers. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

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9070-30-12 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

CAUSE E - CARRIAGE CONTACTS STOP AT TOP OF INNER MAST

PROCEDURE OR ACTION:
1. Inspect free lift chains. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Can lift chains be adjusted?
YES: Adjust chains.
NO: Replace free lift chains. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-13
Observed Symptoms Front End (Mast) and Chassis

High Tire Wear - Drive Axle

POSSIBLE CAUSE
A. RUNNING OVER OIL/SOLVENTS AND DEBRIS
B. LOW PNEUMATIC TIRE INFLATION
C. HIGH PNEUMATIC TIRE INFLATION
D. EXCESSIVE SPEED ON TURNS AND STOPS
E. EXCESSIVE LOADS
F. FAILED WHEEL BEARINGS

CAUSE A - RUNNING OVER OIL/SOLVENTS AND DEBRIS

PROCEDURE OR ACTION:
1. Visually inspect work area for contaminates and debris.

CAUSE B - LOW PNEUMATIC TIRE INFLATION

PROCEDURE OR ACTION:
1. Check and adjust tire inflation. See Operating Manual.

CAUSE C - HIGH PNEUMATIC TIRE INFLATION

PROCEDURE OR ACTION:
1. Check and adjust tire inflation. See Operating Manual.

CAUSE D - EXCESSIVE SPEED ON TURNS AND STOPS

PROCEDURE OR ACTION:
1. Reduce speed and spinning of wheels.

CAUSE E - EXCESSIVE LOADS

NOTE: See Serial Number plate or Operating Manual for lift capacity.

PROCEDURE OR ACTION:
1. Check load weight and compare to truck capacity rating.

CAUSE F - FAILED WHEEL BEARINGS

PROCEDURE OR ACTION:
1. Inspect wheel bearings.
Are bearings in good condition?
YES: Tires are defective. See tire manufacture for warranty.
NO: Replace wheel bearing. Depending on your lift truck, see Transaxle 1300SRM1330, Transaxle
1300SRM1370, or Drive Axle, Speed Reducer, and Differential 1300SRM1366.

END SYMPTOM

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9070-30-14 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

High Tire Wear - Steer Axle

POSSIBLE CAUSE
A. RUNNING OVER OIL/SOLVENTS AND DEBRIS
B. EXCESSIVE SPEED ON TURNS AND STOPS
C. TURNING WITH MACHINE STOPPED OR NO LOAD ON FORKS
D. LOW PNEUMATIC TIRE INFLATION
E. HIGH PNEUMATIC TIRE INFLATION
F. FAILED WHEEL BEARINGS
G. LOOSE TIE RODS

CAUSE A - RUNNING OVER OIL/SOLVENTS AND DEBRIS

PROCEDURE OR ACTION:
1. Visually inspect work area for contaminates and debris.

CAUSE B - EXCESSIVE SPEED ON TURNS AND STOPS

PROCEDURE OR ACTION:
1. Reduce speed and spinning of wheels.

CAUSE C - TURNING WITH MACHINE STOPPED OR NO LOAD ON FORKS

PROCEDURE OR ACTION:

NOTE: Steering without load on forks puts the highest load on steer axle because of counterweight. Avoid steer-
ing wheels when not moving to reduce tire wear.

1. Steer while moving whenever possible.

CAUSE D - LOW PNEUMATIC TIRE INFLATION

PROCEDURE OR ACTION:
1. Check and adjust tire inflation. See Operating Manual.

CAUSE E - HIGH PNEUMATIC TIRE INFLATION

PROCEDURE OR ACTION:
1. Check and adjust tire inflation. See Operating Manual.

CAUSE F - FAILED WHEEL BEARINGS

PROCEDURE OR ACTION:
1. Inspect wheel bearings.
Are bearings in good condition?
YES: Tires are defective. See tire manufacturer for warranty.
NO: Replace wheel bearing. Depending on your lift truck, see Transaxle 1300SRM1330 or Steering Axle
1600SRM1360.

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-15
Observed Symptoms Front End (Mast) and Chassis

CAUSE G - LOOSE TIE RODS

PROCEDURE OR ACTION:
1. Inspect joint where tie rods are attached to pinion assembly.
Is the tie rod tight in bore?
YES: See wheels appear to be tipped or misaligned.
NO: Replace tie rod. Depending on your lift truck, see Transaxle 1300SRM1330 or Steering Axle
1600SRM1360.

END SYMPTOM

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9070-30-16 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

Hoses Not Tracking Correctly

POSSIBLE CAUSE
A. MAST DAMAGED
B. IMPROPER HOSE TENSION
C. IMPROPER HOSE ROUTING
D. HOSES WORN

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - IMPROPER HOSE TENSION

PROCEDURE OR ACTION:
1. Check hose tension. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272) 4000SRM1386,
Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555, A559, B551,
B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Repair (S/N
B551, B555, and B559) 4000SRM1441.
Is hose tension correct?
YES: Go to Cause C.
NO: Adjust hose tension.

CAUSE C - IMPROPER HOSE ROUTING

PROCEDURE OR ACTION:
1. Inspect lift cylinder hoses. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Are the hoses in good condition and adjusted correctly?
YES: Go to Cause D.
NO: Adjust or replace hoses as required.

CAUSE D - HOSES WORN

PROCEDURE OR ACTION:
1. Inspect hoses for uneven or excessive wear.
Are hoses wearing evenly?
YES: Locate cause of hoses wear. See Observed Symptoms, Abnormal Hose Wear, Page 9070-30-4.
NO: Adjust or replace hoses as required. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-17
Observed Symptoms Front End (Mast) and Chassis

A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

END SYMPTOM

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9070-30-18 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

Integral Sideshift Moving Too Fast

POSSIBLE CAUSE
A. ORIFICES IN SIDESHIFT CYLINDER MISSING OR INSTALLED BACKWARD
B. ELECTRO-HYDRAULIC CONTROL VALVE OUT OF CALIBRATION

CAUSE A - ORIFICES IN SIDESHIFT CYLINDER MISSING OR INSTALLED BACKWARD

PROCEDURE OR ACTION:

CAUTION
Cylinder orifices are made from soft metal and can be easily damaged. Do not alter cylinder orifice size
while cleaning.

1. Inspect cylinder port orifices. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.
Are the orifices clean and installed correctly?
YES: Reduce engine speed or control lever speed of movement to slow function. See Parts Manual to see if
smaller size orifices are available.
NO: Adjust or install orifices.

CAUSE B - ELECTRO-HYDRAULIC CONTROL VALVE OUT OF CALIBRATION

PROCEDURE OR ACTION:
1. Check electro-hydraulic control valve calibration. Install Service Tool.
Is valve calibration correct?
YES: Calibrate valve to operator's preference or reduce engine speed to slow function.
NO: Resume operation.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-19
Observed Symptoms Front End (Mast) and Chassis

Integral Sideshift Not Moving or Slow

POSSIBLE CAUSE
A. NO OIL OR NOT ENOUGH OIL IN HYDRAULIC TANK
B. LINKAGE TO CONTROL VALVE DISCONNECTED OR DAMAGED (MANUAL CONTROL VALVE)
C. WIRING CONNECTOR LOOSE OR DISCONNECTED ON CONTROL VALVE (E-VALVE)
D. INTEGRAL SIDESHIFT CARRIAGE DAMAGED
E. CLAMP BLOCKS TOO TIGHT
F. CONTAMINATION OR LACK OF LUBRICATION IS BINDING BEARINGS
G. DAMAGED CARRIAGE BEARINGS
H. HOSES NOT INSTALLED CORRECTLY
I. NO OIL FLOW TO SIDESHIFT CYLINDER
J. INCORRECT HYDRAULIC RELIEF PRESSURE SETTING
K. INSUFFICIENT OIL FLOW TO CYLINDER
L. DEFECTIVE SIDESHIFT CYLINDER

CAUSE A - NO OIL OR NOT ENOUGH OIL IN HYDRAULIC TANK

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Check hydraulic tank oil level and adjust as required.

CAUSE B - LINKAGE TO CONTROL VALVE DISCONNECTED OR DAMAGED (MANUAL CONTROL VALVE)

PROCEDURE OR ACTION:
1. Inspect valve linkage.
Is the linkage moving the valve spool full travel?
YES: Go to Cause D.
NO: Repair or adjust linkage. Depending on your lift truck see, Main Control Valves 2000SRM1334 or Main
Control Valves 2000SRM1439.

CAUSE C - WIRING CONNECTOR LOOSE OR DISCONNECTED ON CONTROL VALVE (E-VALVE)

PROCEDURE OR ACTION:
1. Inspect wiring connections at valve and MLM controller.
Are the connectors in good condition and installed correctly?
YES: Go to Cause D.
NO: Repair or replace wiring connectors. See Wire Harness Repair 2200SRM1128.

CAUSE D - INTEGRAL SIDESHIFT CARRIAGE DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect carriage for damage.
Is the carriage in good condition?
YES: Go to Cause E.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9070-30-20 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

CAUSE E - CLAMP BLOCKS TOO TIGHT

PROCEDURE OR ACTION:
1. Adjust clamp blocks. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272) 4000SRM1386,
Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555, A559, B551,
B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Repair (S/N
B551, B555, and B559) 4000SRM1441.

CAUSE F - CONTAMINATION OR LACK OF LUBRICATION IS BINDING BEARINGS

PROCEDURE OR ACTION:
1. Inspect bearings. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272) 4000SRM1386,
Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555, A559, B551,
B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Repair (S/N
B551, B555, and B559) 4000SRM1441.
Are bearings worn or need lubrication?
YES: Lubricate or replace bearings.
NO: Go to Cause G.

CAUSE G - DAMAGED CARRIAGE BEARINGS

PROCEDURE OR ACTION:
1. Disassemble outer frame. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Are bearings in good condition?
YES: Go to Cause H.
NO: Service or replace bearings.

CAUSE H - HOSES NOT INSTALLED CORRECTLY

NOTE: Check maintenance records to determine last repairs done to truck.

PROCEDURE OR ACTION:
1. Inspect hose routing and connections. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Are hoses adjusted correctly and in good condition?
YES: Go to Cause I.
NO: Adjust or repair hoses.

CAUSE I - NO OIL FLOW TO SIDESHIFT CYLINDER

PROCEDURE OR ACTION:
1. Remove pin from rod end of cylinder. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
2. Slowly operate sideshift cylinder control and observe cylinder rod movement.
Does the cylinder rod move when controls are activated?
YES: Install cylinder rod pin. Go to Cause J.
NO: Determine if problem is in cylinder or control valve. Go to Cause K.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-21
Observed Symptoms Front End (Mast) and Chassis

CAUSE J - INCORRECT HYDRAULIC RELIEF PRESSURE SETTING

PROCEDURE OR ACTION:
1. Test secondary relief valve pressure. Depending on your lift truck see, Main Control Valves 2000SRM1334
or Main Control Valves 2000SRM1439.
Is the secondary relief pressure at specifications?
YES: Go to Cause K.
NO: Adjust or replace secondary relief valve.

CAUSE K - INSUFFICIENT OIL FLOW TO CYLINDER

PROCEDURE OR ACTION:
1. Perform Cycle Times. Depending on your lift truck, see Capacities and Specifications 8000SRM1340, Ca-
pacities and Specifications 8000SRM1374, Capacities and Specifications 8000SRM1376, Capacities
And Specifications 8000SRM1375, or Capacities and Specifications 8000SRM1443.
Is the sideshift the only hydraulic function that is slow.
YES: Go to Step 2.
NO: Problem is in hydraulic pump circuit. See Hydraulic Pump Flow Test.
2. Check electro-hydraulic control valve calibration. Install Service Tool.
Is valve calibration correct?
YES: Go to Cause L.
NO: Calibrate valve to operator's preference. Depending on your lift truck see, Cylinder Repair (Mast S/N
A270-72, A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665,
D507-09, D515, D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559)
2100SRM1440.

CAUSE L - DEFECTIVE SIDESHIFT CYLINDER

PROCEDURE OR ACTION:

CAUTION
Cylinder orifices are made from soft metal and can be easily damaged. Do not alter cylinder orifice size
while cleaning.

1. Inspect and clean cylinder port orifices. Depending on your lift truck see, Cylinder Repair (Mast S/N
A270-72, A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665,
D507-09, D515, D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559)
2100SRM1440.
Are the orifices clean and installed correctly?
YES: Remove and repair cylinder.
NO: Adjust or replace orifices.

END SYMPTOM

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9070-30-22 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

Fork Positioner Not Moving or Slow

POSSIBLE CAUSE
A. NO OIL OR NOT ENOUGH OIL IN HYDRAULIC TANK
B. LINKAGE TO CONTROL VALVE DISCONNECTED OR DAMAGED (MANUAL CONTROL VALVE)
C. HYDRAULIC CONTROL VALVE CALIBRATED WRONG (E-VALVE)
D. WIRING CONNECTOR LOOSE OR DISCONNECTED ON CONTROL VALVE (E-VALVE)
E. SIDESHIFT CARRIAGE DAMAGED
F. CONTAMINATION OR LACK OF LUBRICATION IS BINDING BEARINGS
G. DAMAGED CARRIAGE BEARINGS
H. HOSES NOT INSTALLED CORRECTLY
I. NO OIL FLOW TO FORK POSITIONER CYLINDER
J. INCORRECT HYDRAULIC RELIEF PRESSURE SETTING
K. INSUFFICIENT OIL FLOW TO CYLINDER
L. DEFECTIVE FORK POSITIONER CYLINDER

CAUSE A - NO OIL OR NOT ENOUGH OIL IN HYDRAULIC TANK

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Check hydraulic tank oil level and adjust as required.

CAUSE B - LINKAGE TO CONTROL VALVE DISCONNECTED OR DAMAGED (MANUAL CONTROL VALVE)

PROCEDURE OR ACTION:
1. Inspect valve linkage.
Is the linkage moving the valve spool full travel?
YES: Go to Cause E.
NO: Repair or adjust linkage. Refer to the appropriate Main Control Valve SRM .

CAUSE C - HYDRAULIC CONTROL VALVE CALIBRATED WRONG (E-VALVE)

PROCEDURE OR ACTION:
1. Check electro-hydraulic control valve calibration. Install Service Tool.
Is valve calibration correct?
YES: Calibrate valve to operator's preference or reduce engine speed to slow function.
NO: Calibrate valve to operator's preference. Refer to the appropriate Calibration Procedures SRM .

CAUSE D - WIRING CONNECTOR LOOSE OR DISCONNECTED ON CONTROL VALVE (E-VALVE)

PROCEDURE OR ACTION:
1. Inspect wiring connections at valve and joystick/MLM controller.
Are the connectors in good condition and installed correctly?
YES: Go to Cause E.
NO: Repair or replace wiring connectors. Refer to the appropriate Wire Harness Repair SRM .

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-23
Observed Symptoms Front End (Mast) and Chassis

CAUSE E - SIDESHIFT CARRIAGE DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect carriage for damage.
Is the carriage in good condition?
YES: Go to Cause F.
NO: Repair or replace damaged components. Refer to the appropriate Mast Repair SRM .

CAUSE F - CONTAMINATION OR LACK OF LUBRICATION IS BINDING BEARINGS

PROCEDURE OR ACTION:
1. Inspect bearings. Refer to the appropriate Mast Repair SRM .
Are bearings worn or need lubrication?
YES: Lubricate or replace bearings.
NO: Go to Cause G.

CAUSE G - DAMAGED CARRIAGE BEARINGS

PROCEDURE OR ACTION:
1. Disassemble outer frame. Refer to the appropriate Mast Repair SRM .
Are bearings in good condition?
YES: Go to Cause H.
NO: Service or replace bearings.

CAUSE H - HOSES NOT INSTALLED CORRECTLY

NOTE: Check maintenance records to determine last repairs done to truck.

PROCEDURE OR ACTION:
1. Inspect hose routing and connections. Refer to the appropriate Mast Repair SRM .
Are hoses adjusted correctly and in good condition?
YES: Go to Cause I.
NO: Adjust or repair hoses.

CAUSE I - NO OIL FLOW TO FORK POSITIONER CYLINDER

PROCEDURE OR ACTION:
1. Remove pin from rod end of cylinder. Refer to the appropriate Mast Repair SRM .
2. Slowly operate sideshift cylinder control and observe cylinder rod movement.
Does the cylinder rod move when controls are activated?
YES: Install cylinder rod pin. Go to Cause J.
NO: Determine if problem is in cylinder or control valve. Go to Cause K.

CAUSE J - INCORRECT HYDRAULIC RELIEF PRESSURE SETTING

PROCEDURE OR ACTION:
1. Test secondary relief valve pressure. Refer to the appropriate Main Control Valve SRM .
Is the secondary relief pressure at specifications?
YES: Go to Cause K.
NO: Adjust or replace secondary relief valve.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9070-30-24 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

CAUSE K - INSUFFICIENT OIL FLOW TO CYLINDER

PROCEDURE OR ACTION:
1. Perform Cycle Times. Refer to the appropriate Capacities and Specifications SRM .
Is the sideshift the only hydraulic function that is slow.
YES: Go to Step 2.
NO: Problem is in hydraulic pump circuit. See Hydraulic Pump Flow Test.
2. Check electro-hydraulic control valve calibration. Install Service Tool.
Is valve calibration correct?
YES: Go to Cause L.
NO: Calibrate valve to operator's preference. Refer to the appropriate Calibration Procedures SRM .

CAUSE L - DEFECTIVE FORK POSITIONER CYLINDER

PROCEDURE OR ACTION:

CAUTION
Cylinder orifices are made from soft metal and can be easily damaged. Do not alter cylinder orifice size
while cleaning.

1. Inspect and clean cylinder port orifices. Refer to the appropriate Cylinder Repair SRM .
Are the orifices clean and installed correctly?
YES: Remove and repair cylinder.
NO: Adjust or replace orifices.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-25
Observed Symptoms Front End (Mast) and Chassis

Mast is Loose
POSSIBLE CAUSE
A. MAST DAMAGED
B. LOOSE OR MISSING MAST MOUNTING HARDWARE
C. MAST NOT SHIMMED CORRECTLY
D. DAMAGED LOAD ROLLERS OR WORN STRIP BEARINGS
E. CHANNELS WORN

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - LOOSE OR MISSING MAST MOUNTING HARDWARE

PROCEDURE OR ACTION:
1. Inspect mast mounting hardware.
Is mounting hardware in good condition and torqued correctly?
YES: Go to Cause C.
NO: Replace mast mounting hardware. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE C - MAST NOT SHIMMED CORRECTLY

PROCEDURE OR ACTION:
1. Inspect mast shimming. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Is the mast shimmed correctly?
YES: Go to Cause D.
NO: Shim or adjust as required.

CAUSE D - DAMAGED LOAD ROLLERS OR WORN STRIP BEARINGS

PROCEDURE OR ACTION:
1. Inspect load rollers and strip bearings. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
Are the load rollers and strip bearings in good condition?
YES: Go to Cause E.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9070-30-26 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

NO: Adjust, repair, or replace load rollers and strip bearings as required. Depending on your lift truck see,
Mast Repair (S/N A270, A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665)
4000SRM1405, Mast Repair (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564,
D515, E509, E564) 4000SRM1338, or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE E - CHANNELS WORN

PROCEDURE OR ACTION:
1. Repair or replace mast components. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

END SYMPTOM

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-27
Observed Symptoms Front End (Mast) and Chassis

Mast Lift Chains Are Loose

POSSIBLE CAUSE
A. MAST DAMAGED
B. DAMAGED CHAIN SHEAVES
C. INCORRECT CHAIN ADJUSTMENT

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause C.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - DAMAGED CHAIN SHEAVES

PROCEDURE OR ACTION:
1. Inspect chain sheaves.
Do chain sheaves rotate freely without noise?
YES: Go to Cause C.
NO: Replace chain sheaves. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE C - INCORRECT CHAIN ADJUSTMENT

PROCEDURE OR ACTION:
1. Inspect lift chains. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272) 4000SRM1386,
Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555, A559, B551,
B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Repair (S/N
B551, B555, and B559) 4000SRM1441.
Are the chains in good condition and adjusted correctly?
YES: See Observed Symptoms, Mast or Carriage Binding, Page 9070-30-29.
NO: Adjust or replace chain.

END SYMPTOM

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9070-30-28 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

Mast or Carriage Binding

POSSIBLE CAUSE
A. MAST OR CARRIAGE DAMAGED
B. MAST CHANNELS LACK LUBRICATION
C. MAST NOT SHIMMED CORRECTLY
D. CHAINS ARE LOOSE OR NOT EQUAL
E. CONTAMINATION IN CHANNELS IS BINDING LOAD ROLLERS
F. DAMAGED OR WORN LOAD ROLLERS OR STRIP BEARINGS
G. LIFT CYLINDER BINDING

CAUSE A - MAST OR CARRIAGE DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast and carriage for damage.
Are components in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - MAST CHANNELS LACK LUBRICATION

PROCEDURE OR ACTION:
1. Inspect grease on mast channels.
Is a thin coat of grease spread evenly on channels?
YES: Go to Cause C.
NO: Apply grease to mast sliding surfaces. Depending on your lift truck see, Periodic Maintenance
8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic
Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.

CAUSE C - MAST NOT SHIMMED CORRECTLY

PROCEDURE OR ACTION:
1. Inspect mast shimming. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Is the mast shimmed correctly?
YES: Go to Cause E.
NO: Shim or adjust as required.

CAUSE D - CHAINS ARE LOOSE OR NOT EQUAL

PROCEDURE OR ACTION:
1. Inspect lift chains. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272) 4000SRM1386,
Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555, A559, B551,
B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Repair (S/N
B551, B555, and B559) 4000SRM1441.
Are chains adjusted correctly and in good condition?

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-29
Observed Symptoms Front End (Mast) and Chassis

YES: Go to Cause E.
NO: Adjust or repair chains. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE E - CONTAMINATION IN CHANNELS IS BINDING LOAD ROLLERS

PROCEDURE OR ACTION:
1. Inspect mast channels. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Do the rollers rotate freely?
YES: Go to Cause F.
NO: Replace load rollers. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE F - DAMAGED OR WORN LOAD ROLLERS OR STRIP BEARINGS

PROCEDURE OR ACTION:
1. Inspect load rollers and strip bearings. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.
Are the load rollers and strip bearings in good condition?
YES: Go to Cause G.
NO: Adjust, repair, or replace load rollers and strip bearings as required. Depending on your lift truck see,
Mast Repair (S/N A270, A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665)
4000SRM1405, Mast Repair (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564,
D515, E509, E564) 4000SRM1338, or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE G - LIFT CYLINDER BINDING

PROCEDURE OR ACTION:
1. Remove cylinder. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515, D562-64, E509,
E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.
2. Manually extend cylinder exterior.
Does cylinder extend freely?
YES: Mast is loose. See Observed Symptoms, Mast is Loose, Page 9070-30-26.
NO: Service or replace cylinder. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72,
A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.

END SYMPTOM

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9070-30-30 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

Mast/Carriage Bounces or is Spongy

POSSIBLE CAUSE
A. MAST DAMAGED
B. AIR IN HYDRAULIC SYSTEM
C. TRAPPED AIR IN LIFT CYLINDER(S)
D. TWO-STAGE FFL MAST MAIN CYLINDERS NOT BLED OF AIR

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - AIR IN HYDRAULIC SYSTEM

PROCEDURE OR ACTION:
1. Inspect oil condition and level in hydraulic tank.
Is the hydraulic oil level in the operating range and in good condition?
YES: Go to Cause C.
NO:
• If oil level is low, add oil.
• If hydraulic oil is aerated, locate source of suction side leak and repair.

CAUSE C - TRAPPED AIR IN LIFT CYLINDER(S)

PROCEDURE OR ACTION:
1. Fully extend and lower the mast several times.
Does the mast raise and lower without hesitation?
YES: Go to Cause D.
NO: Go to Step 2.
2. Open mast, lower valve, and operate all hydraulic functions in both directions.
3. Close mast lower valve.
4. Repeat Step 1 to see if problem has been solved.

CAUSE D - TWO-STAGE FFL MAST MAIN CYLINDERS NOT BLED OF AIR

PROCEDURE OR ACTION:
1. Bleed air from cylinders. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551, A555,
A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515, D562-64,
E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-31
Observed Symptoms Front End (Mast) and Chassis

Misphasing of Full Free-Lift Mast

POSSIBLE CAUSE
A. MAST DAMAGED
B. COLD OPERATING CONDITIONS
C. CARRIAGE IS BINDING
D. HYDRAULIC RESTRICTION TO FREE-LIFT CYLINDER
E. EXCESSIVE OIL ON TOP SIDE OF FREE-LIFT CYLINDER PISTON

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - COLD OPERATING CONDITIONS

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Confirm that oil is at correct operating temperature. See Hydraulic Warm-up Procedure.
Does mast misphase after oil is at operating temperature?
YES: Go to Cause C.
NO: Incorrect hydraulic oil is being used. Consult Operating Manual for correct grade of hydraulic oil for your
operating conditions.

CAUSE C - CARRIAGE IS BINDING

PROCEDURE OR ACTION:
1. Check carriage shimming. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.
Is carriage shimmed correctly?
YES: Go to Cause D.
NO: Adjust or repair carriage. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272)
4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555,
A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Re-
pair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE D - HYDRAULIC RESTRICTION TO FREE-LIFT CYLINDER

PROCEDURE OR ACTION:
1. Visually inspect hoses and fittings for damage
Are hoses and fitting in good condition?
YES: Go to Cause E.

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9070-30-32 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

NO: Replace damaged hoses and fittings. Depending on your lift truck see, Mast Repair (S/N A270, A271,
A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551,
A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or
Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE E - EXCESSIVE OIL ON TOP SIDE OF FREE-LIFT CYLINDER PISTON

PROCEDURE OR ACTION:
1. Raise mast to full lift height without load and hold at relief pressure for 5 seconds.
2. Recheck for misphasing.
Does the mast still misphase?
YES: Remove cylinder, check piston seal, and check valve. Depending on your lift truck see, Cylinder Repair
(Mast S/N A270-72, A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63,
C665, D507-09, D515, D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555,
B559) 2100SRM1440.
NO: Problem solved.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-33
Observed Symptoms Front End (Mast) and Chassis

Overhead Guard Loose or Damaged

POSSIBLE CAUSE
A. OVERHEARD GUARD DAMAGED
B. ATTACHING HARDWARE IS LOOSE
C. OPERATING TOO FAST OVER ROUGH FLOORS

CAUSE A - OVERHEARD GUARD DAMAGED

PROCEDURE OR ACTION:

WARNING
Death or injury can occur from falling objects. Do not operate lift truck with a damaged overhead guard.

1. Inspect overhead guard. Depending on your lift truck see, Periodic Maintenance 8000SRM1364, Periodic
Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic Maintenance
8000SRM1373, or Periodic Maintenance 8000SRM1442.
Is the overhead guard in good condition?
YES: Go to Cause B.
NO: Replace overhead guard. Depending on your lift truck, see Frame 0100SRM1329 or Frame
0100SRM1342.

CAUSE B - ATTACHING HARDWARE IS LOOSE

PROCEDURE OR ACTION:
1. Visually inspect mounting points for damage and loose or missing hardware. Depending on your lift truck see,
Periodic Maintenance 8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance
8000SRM1339, Periodic Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.
Is overhead guard and attaching hardware in good condition?
YES: Go to Cause C.
NO: Repair or replace damaged components. Depending on your lift truck, see Frame 0100SRM1329 or
Frame 0100SRM1342.

CAUSE C - OPERATING TOO FAST OVER ROUGH FLOORS

PROCEDURE OR ACTION:
1. Reduce speed and listen for noise.
Does noise reduce with reduction in ground speed?
YES: Reduce speed or install softer tires.
NO: Depending on your lift truck, see Frame 0100SRM1329 or Frame 0100SRM1342.

END SYMPTOM

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9070-30-34 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

Racking During Lift

POSSIBLE CAUSE
A. MAST DAMAGED
B. MAIN LIFT CYLINDER NOT SHIMMED CORRECTLY
C. MAIN LIFT CYLINDER CHAINS LOOSE OR UNEQUAL
D. UNEQUAL MAIN LIFT CYLINDER ROD STROKE
E. LIFT CYLINDER BINDING

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - MAIN LIFT CYLINDER NOT SHIMMED CORRECTLY

PROCEDURE OR ACTION:
1. Check cylinder shimming. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.
Is cylinder shimmed correctly?
YES: Go to Cause C.
NO: Adjust or repair cylinder.

CAUSE C - MAIN LIFT CYLINDER CHAINS LOOSE OR UNEQUAL

PROCEDURE OR ACTION:
1. Check chains. Depending on your lift truck see, Mast Repair (S/N A270, A271, A272) 4000SRM1386, Mast
Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N A551, A555, A559, B551, B555,
D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338, or Mast Repair (S/N B551,
B555, and B559) 4000SRM1441.
Are the chains adjusted correctly?
YES: Go to Cause D.
NO: Adjust or replace chains.

CAUSE D - UNEQUAL MAIN LIFT CYLINDER ROD STROKE

PROCEDURE OR ACTION:
1. Operate lift and compare each cylinder rod stroke.
Are the cylinder rod strokes equal?
YES: Go to Cause E.
NO: Replace cylinder or cylinders spacers (if equipped). Depending on your lift truck see, Cylinder Repair
(Mast S/N A270-72, A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63,
C665, D507-09, D515, D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555,
B559) 2100SRM1440.

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-35
Observed Symptoms Front End (Mast) and Chassis

CAUSE E - LIFT CYLINDER BINDING

PROCEDURE OR ACTION:
1. Remove cylinder. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515, D562-64, E509,
E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.
2. Manually extend cylinder.
Does cylinder extend freely?
YES: Cylinder is OK. See Observed Symptoms, Mast is Loose, Page 9070-30-26.
NO: Repair or replace cylinder. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.

END SYMPTOM

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9070-30-36 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

Racking During Tilt

POSSIBLE CAUSE
A. MAST DAMAGED
B. TILT ROD OUT OF ADJUSTMENT
C. UNEQUAL LENGTH OF BACK TILT SPACERS

CAUSE A - MAST DAMAGED

NOTE: See Operating Manual.

PROCEDURE OR ACTION:
1. Visually inspect mast for damage.
Is the mast in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair (S/N A270,
A271, A272) 4000SRM1386, Mast Repair (S/N C661, C662, C663, C665) 4000SRM1405, Mast Repair (S/N
A551, A555, A559, B551, B555, D507, D562, D508, D563, D509, D564, D515, E509, E564) 4000SRM1338,
or Mast Repair (S/N B551, B555, and B559) 4000SRM1441.

CAUSE B - TILT ROD OUT OF ADJUSTMENT

PROCEDURE OR ACTION:
1. Inspect tilt rod. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515, D562-64, E509,
E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.
Is tilt rod adjusted correctly?
YES: Go to Cause C.
NO: Adjust tilt rod.

CAUSE C - UNEQUAL LENGTH OF BACK TILT SPACERS

PROCEDURE OR ACTION:
1. Inspect length of spacers. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.
Are back tilt spacers equal?
YES: Mast is too loose. See Observed Symptoms, Mast is Loose, Page 9070-30-26.
NO: Adjust or replace spacers. Depending on your lift truck see, Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 or Cylinder Repair (Mast S/N B551, B555, B559) 2100SRM1440.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-37
Observed Symptoms Front End (Mast) and Chassis

Truck Feels Unstable

POSSIBLE CAUSE
A. OPERATING WITH TOO LARGE A LOAD
B. LOW PNEUMATIC TIRE INFLATION
C. LOAD IS BEING CARRIED TOO HIGH
D. OPERATING AT TOO HIGH A SPEED
E. OPERATING OFF HARD SURFACES
F. MAST IS TOO LOOSE

CAUSE A - OPERATING WITH TOO LARGE A LOAD

NOTE: See Serial Number plate or Operating Manual for lift capacity.

PROCEDURE OR ACTION:

NOTE: Carrying a load that exceeds truck capacity will cause the steer axle wheels to loose contact with ground
and negatively affect control of truck.

1. Check load weight and compare to truck capacity rating.

CAUSE B - LOW PNEUMATIC TIRE INFLATION

PROCEDURE OR ACTION:
1. Check and adjust tire inflation. See Operating Manual.

CAUSE C - LOAD IS BEING CARRIED TOO HIGH

PROCEDURE OR ACTION:
1. Carry load as low as possible to lower center of gravity and improve stability.

CAUSE D - OPERATING AT TOO HIGH A SPEED

PROCEDURE OR ACTION:
1. See Operating Manual for correct operating speeds.

CAUSE E - OPERATING OFF HARD SURFACES

PROCEDURE OR ACTION:
1. Operate truck only on hard surfaces.

CAUSE F - MAST IS TOO LOOSE

PROCEDURE OR ACTION:
1. See Observed Symptoms, Mast is Loose, Page 9070-30-26.

END SYMPTOM

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9070-30-38 Confidential/Proprietary - Do Not Copy or Duplicate
Front End (Mast) and Chassis Observed Symptoms

Truck Wanders, Does Not Track Straight or Steer Well

POSSIBLE CAUSE
A. EXCESSIVE LOADS
B. LOW PNEUMATIC TIRE INFLATION
C. HIGH PNEUMATIC TIRE INFLATION
D. DAMAGED UPPER AXLE MOUNTING EAR
E. STEERING VALVE PROBLEM

CAUSE A - EXCESSIVE LOADS

NOTE: See Serial Number plate or Operating Manual for lift capacity.

PROCEDURE OR ACTION:

NOTE: Carrying a load that exceeds truck capacity will cause the steer axle wheels to loose contact with ground
and negatively affect control of truck.

1. Check load weight and compare to truck capacity rating.

CAUSE B - LOW PNEUMATIC TIRE INFLATION

PROCEDURE OR ACTION:
1. Check and adjust tire inflation. See Operating Manual.

CAUSE C - HIGH PNEUMATIC TIRE INFLATION

PROCEDURE OR ACTION:
1. Check and adjust tire inflation. See Operating Manual.

CAUSE D - DAMAGED UPPER AXLE MOUNTING EAR

PROCEDURE OR ACTION:

NOTE: The upper axle ear can be bent if lift truck suddenly drops its load while rear steer axle wheels are off the
ground.

1. Inspect axle pinion bearings vertical movement.

Does pinion bearings have excessive endplay?
YES: Replace axle. Depending on your lift truck, see Transaxle 1300SRM1330 or Steering Axle
1600SRM1360.
NO: Go to Cause E.

CAUSE E - STEERING VALVE PROBLEM

PROCEDURE OR ACTION:
1. Check steering hydraulics. Perform Steering Control Unit LS Pressure Test.

END SYMPTOM

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Confidential/Proprietary - Do Not Copy or Duplicate 9070-30-39
Observed Symptoms Front End (Mast) and Chassis

Wheel Studs Breaking

POSSIBLE CAUSE
A. ATTACHING HARDWARE IS LOOSE
B. WHEEL STUDS ARE OVER TORQUED

CAUSE A - ATTACHING HARDWARE IS LOOSE

PROCEDURE OR ACTION:
1. Visually inspect wheel studs for damage and loose or missing hardware. Depending on your lift truck see,
Periodic Maintenance 8000SRM1364, Periodic Maintenance 8000SRM1372, Periodic Maintenance
8000SRM1339, Periodic Maintenance 8000SRM1373, or Periodic Maintenance 8000SRM1442.
Do wheels and attaching hardware appear to be in good condition?
YES: Go to Cause B.
NO: Repair or replace damaged components. Depending on your lift truck, see Transaxle 1300SRM1330,
Transaxle 1300SRM1370, Steering Axle 1600SRM1360, or Drive Axle, Speed Reducer, and Differential
1300SRM1366.

CAUSE B - WHEEL STUDS ARE OVER TORQUED

PROCEDURE OR ACTION:
1. Check wheel stud torque. Depending on your lift truck see, Periodic Maintenance 8000SRM1364, Periodic
Maintenance 8000SRM1372, Periodic Maintenance 8000SRM1339, Periodic Maintenance
8000SRM1373, or Periodic Maintenance 8000SRM1442.
Are the wheels studs at correct torque?
YES: Check maintenance records to see what repairs were made that may have caused problem.
NO: Replace all studs and torque correctly. Depending on your lift truck, see Transaxle 1300SRM1330,
Transaxle 1300SRM1370, Steering Axle 1600SRM1360, or Drive Axle, Speed Reducer, and Differential
1300SRM1366.

END SYMPTOM

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9070-30-40 Confidential/Proprietary - Do Not Copy or Duplicate
 SECTION 9080

SUPPLEMENTARY DATA

TABLE OF CONTENTS

Group 50 - Abbreviations and Acronyms

Abbreviations and Acronyms.............................................................................................................. 9080-50-1

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Confidential/Proprietary - Do Not Copy or Duplicate 9080-1
9080-2
Supplementary Data Abbreviations and Acronyms

Group 50

Abbreviations and Acronyms

ABBREVIATIONS AND ACRONYMS

Table 9080-50-1. Abbreviations and Acronyms

Term Definition or Description

AC Alternating Current
ACC Accessory
A/D Analog to Digital
AUX Auxiliary
BAT Battery
Baud A line’s signaling rate, the switching speed, or number of voltage or frequency changes
made per second
BIT Smallest element of binary data storage
BDI Battery Discharge Indicator
bit Smallest element of binary data storage
°C Celsius Temperature
Calbr Adjustment to accommodate truck-to-truck variations. Typical usage in system
specifications applies to software processes to “learn” and store sensor baseline or
extreme values. Calibration procedures may require repeating when controllers are
replaced or if a specific sensor or mounting mechanism is replaced.
CANbus Controller Area Network bus
CBDC Counter Balanced Development Center
CD or CD-ROM Compact Disc Read-Only Memory - a compact disc format used to hold text, graphics and
hi-fi stereo sound in excess of 650MB of data, which is equivalent to about 250,000 pages
of text
CDF Configuration Data File (previously known as Cal Data) - factory-created file defining truck
configuration details, dependent on truck model and option permutations (considered
unique for a given truck). Not modified by service technicians, but a replacement file (with
alternate options) may be factory-generated and loaded into a truck’s controller by a
service technician
CO Carbon Monoxide
COP Computer Operating Properly
CMP Cam Position Sensor
CPS Connector Plug Socket
CPU Central Processing Unit

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Abbreviations and Acronyms Supplementary Data

Table 9080-50-1. Abbreviations and Acronyms (Continued)

Term Definition or Description

CRC Cyclic Redundancy Checksum
CRP Connector Receptacle Pin
CRS Connector Receptacle Socket
DC Direct Current
DCS Direction Control Selector
Deactivated A feature which is not currently Activated
Defaults The set of factory values for all truck parameters. A setup menu function can restore the
default values of all parameters.
Disabled A Software Enabled Feature which is NOT present on a given truck
DM Diagnostic Message
DMM Digital Multi-Meter
DP Display Panel – equipped with 10 numeric keys, two arrow keys (left and right arrows) and
two symbol keys (the Star (*) key and the pound (#) key).
DSC Display Switch Cluster
DTC Diagnostic Troubleshooting Code
DTM Diagnostic Troubleshooting Manual
EDBP Extended Drawbar Pull
EEPROM Electronically Erasable Programmable Read Only Memory
EF Excess Flow
EFI Electronic Fuel Injection
EGI Electronic Gasoline Injection
EGO Exhaust Gas Oxygen
EHP Electro-Hydraulic Pilot
EHPV Electro-Hydraulic Poppet Valve
E-Hyd Electro-Hydraulic - hydraulic option utilizing electronic inputs and electrically-driven valves
to actuate hydraulic functions, as opposed to manual hydraulics using mechanical levers
Embedded Software that is installed on Lift Truck control system
EMI Electro-Magnetic Interference
Enabled A Software Enabled Feature which is present on a given truck, but not necessarily
Activated (i.e., purchased but not necessarily in use)
EPA Environmental Protection Agency
EPR Electronic Pressure Regulator
EST Electronic Spark Timing
ETC Electronic Throttle Control
FFL Full-Free Lift
FIFO First In, First Out

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Supplementary Data Abbreviations and Acronyms

Table 9080-50-1. Abbreviations and Acronyms (Continued)

Term Definition or Description

FOSI Format Output Specification Instances - an instance of the Output Specification (OS) that
assigns values to the style characteristics for a particular document type declaration. The
FOSI uses the syntax of an SGML/XML document instance and is designed to format
documents for paper delivery.
FWD Forward travel direction command signal to system
GB Gigabyte - equal to 1024 Megabytes
H Henry - Unit of measurement of electrical inductance
HYDR Hydraulic
Hz Basic unit of frequency measurement, 1 Hz = 1 periodic interval in one second
IAC Idle Air Control
IAT Intake Air Temperature
IBPP Inching/Brake Pedal Position
ISR Interrupt Service Routine
kBps KiloBytes per second
kHz KiloHertz - common frequency measurement of Hertz X 1000
kilobit 1,000 bits
kilobyte A standard quantity measurement for disk and diskette storage. One kilobyte of memory
equals 1024 bytes (8-bit characters) of computer memory.
kg Kilogram, equal to 1000 grams
kPa Kilo-Paschals, metric unit of pressure measurement X 1000
kph Kilometers per Hour
L Liter
LAN Local Area Network
lbf ft Foot Pounds
lbf in Inch Pounds
LCD Liquid Crystal Display
LED Light Emitting Diode
LFL Limited Free Lift
MB Megabyte - 1,048,576 bytes, equal to 1,024 kilobytes. The basic unit of measurement of
mass storage
MDU Master Drive Unit
MHz Megahertz - a unit of frequency equal to 1024 kilohertz. A common method for describing
the speed of a computer CPU
MIL Malfunction Indicator Lamp

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Abbreviations and Acronyms Supplementary Data

Table 9080-50-1. Abbreviations and Acronyms (Continued)

Term Definition or Description

MLCV Mast Lowering Control Valve
MLM Mini Lever Module
mH Milli-Henry, 1 one thousandth of a Henry
Modem Modulator-Demodulator - a device that adapts a terminal or computer to a telephone line
converting the computer’s digital pulses into audio frequencies (analog) for the telephone
system and converts the frequencies back into digital pulses at the receiving side
MPH Miles Per Hour
MRV Main Relief Valve
ms Milli-second, 1 one thousandth of a second
MSB Most Significant Bit
NEU Neutral travel direction command signal to system
N•m Newton Meters
NOR Normal
OBD On Board Diagnostics
OC Open Circuit - indicates an open connection or break in an electrical path
OORH Out-Of-Range High
OORL Out-Of-Range Low
OPS Operator Presence System
OS Operating System - the embedded system of instructions and applications that control the
operation of the processor
Parameter A system characteristic which may be adjusted by a technician, e.g., Auto-Deceleration,
which may be set on a scale of from 1 to 10. Each parameter will also have a default value.
PC Personal Computer
PC Tool Any software that is installed on a PC that is used to service the lift truck control system
PCB Printed Circuit Board
PGN Parameter Group Number
PPRV Proportional Pressure Reducing Valve
PTC Positive Temperature Coefficient Resistor
RAM Random Access Memory - the computer's primary workspace where the contents of each
byte can be accessed directly without regard to the bytes before or after it
REV Reverse travel direction command signal to system
Rev. Revision - the issue control or version number of an item
RL Relay
ROM Read Only Memory
RPM Revolutions Per Minute
RTST Return to Set Tilt
SAE Society of Automotive Engineers

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Supplementary Data Abbreviations and Acronyms

Table 9080-50-1. Abbreviations and Acronyms (Continued)

Term Definition or Description

Scroll Repeat The repeating, incrementing, or decrementing of a displayed value when continuously
pressing the scroll buttons
Scroll Wrap-around In the setup menu, if wrap-around is specified, when extreme-adjustment values are
reached while scrolling, the value shall change to the other extreme of adjustment. I.e.,
scrolling down to lowest point on menu shall jump back to the top of the menu.
SCU Steering Control Unit
SEF Software Enabled Function - options which are Enabled by software (either entirely or in
combination with additional hardware). For all SEFs, enabling the function requires a new
CDF. An SEF may be Selectable, allowing it to be Activated or Deactivated by the
technician once it has been enabled, or it may be non-selectable, such that it cannot be
deactivated after being enabled.
Selectable See Software Enabled Function (SEF)
Service Pack Software update provided by a software manufacturer to fix an error and/or improve quality
SPED Special Products Engineering Department - responsible for options not in the standard
price book, but available by special order
SPI Serial Peripheral Interface
SPN Suspect Parameter Number
SRM Service Reference Manual
SRV Secondary Relief Valve
STB Short-To-Battery - indicates a short to a battery level voltage source
STG Short-To-Ground - indicates a short to a ground or frame connection
STS Short-To-Supply - indicates a short to a supply voltage source other than battery level
TBC To Be Continued
TBD To Be Determined
Truck Settings The specific adjustments of the various parameters on a given truck. They may be saved
to a data file through the Service PC software and copied to additional similar trucks.
TSP Troubleshooting Procedure
USB Universal Serial Bus - serial 4-wire connection that has advanced features over a serial
port. Normally found on computers as a slotted connector configuration

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 NOTES

9080-50-6
 TECHNICAL PUBLICATIONS

9000 SRM 1377 3/16 (2/16)(11/15)(10/14)(8/13)(12/12)