CODIGOS DE ERROR pdmm-0057

CATERPILLAR® Reach Service Manual Troubleshooting
Introduction
Troubleshooting 6:
Introduction When troubleshooting truck problems it is important to:

• Use a logical, common sense approach
• Begin with the simplest solution and work towards the most
complex
The following procedure can aid in developing a logical and systematic
troubleshooting procedure:
Troubleshooting 1. Verify problems by:

Procedure • Obtaining as much information as you can about the problem
• Determining, if possible, what the truck’s performance was
before the problem began
• Seeing any records which might have been kept about the
truck’s performance
• Operating the truck yourself to verify the problem
2. Locate the truck’s problem area by:
• Opening the various truck compartment doors and visually
inspecting the systems, then consult the hydraulic, electrical
and mechanical maintenance sections for general information
which may save you time
• Determining if the problem is in the control circuit or the
power circuit if there is no obvious physical problem
3. Establish a logical testing sequence by:
• Using the electrical schematic. Begin at the battery and
establish a sequence of testing points to locate the problem.
Use the schematic in conjunction with the appropriate Flow
Diagram
• Establishing test points which indicate that all components
between any new test point and the battery are good
• Avoiding haphazard checking which provides inconclusive
results
4. Use the troubleshooting Flow Diagrams by:
• Consulting the List of Truck problems
• If a Flow Diagram is applicable, then follow the particular
diagram from the beginning to where the probable cause is
isolated
5. Identify the cause of the problem by:
• Checking for improper truck usage
• Bringing the problem to the service manager’s attention to
avoid repetition of the cause
PDMM-0057 6-1
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
6. Correct the problem by:

• Repairing or replacing defective components following
instructions in the maintenance section of this manual
• Complying with appropriate safety procedures
! WARNING
Use extreme care whenever the truck is jacked up for any
reason. Never block the truck between the telescopic and
the floor. Use a suitable hoist to stabilize the mast. Keep
hands and feet clear from beneath vehicle while jacking.
Use jack stands or solid blocks to support truck - Do not
rely on jacks. Refer to"Jacking Truck" on page 5-2.
! CAUTION
Disconnect the battery before checking electrical circuits
with an ohmmeter. Battery current can damage the
ohmmeter.
NOTE: Use the electrical schematic and the hydraulic schematic when
troubleshooting.
NOTE: Check all truck fail-safe and overload circuits:
• Before attempting any troubleshooting procedure
• After making any repairs or adjustments before returning the
truck to operation
6-2 PDMM-0057
Introduction
Electrical
Wiring-General Save time and trouble - look for simple causes first.
1. Visually inspect all wiring in all components for:
• Broken wiring and shorted conditions (especially close to
metal edges or surfaces).
• Loose connections
• Loose or broken terminals
• Damaged terminal blocks or strips
2. Use an ohmmeter to check wiring continuity.
3. Repair or replace the wiring wherever a problem exists.
! CAUTION
Disconnect the battery before checking electrical circuits
with an ohmmeter. Battery current can damage the meter.
If a truck problem cannot be located in the wiring or a short-to-frame

test, troubleshoot in accordance with the following procedure:
1. Determine exactly which operation(s) the truck is failing to
perform.
2. To accomplish this, it is often advisable to jack up and block the
truck so the drive wheel is off the floor. Be sure the mast is
supported by a suitable hoist so the truck does not tip over.
! WARNING
Use jack stands or solid blocks to support truck - Do not
rely on jacks. Refer to"Jacking Truck" on page 5-2.
3. Operate all the truck’s functions slowly, observing during which

sequence the truck malfunctions.
4. Perform the checks in the appropriate Flow Diagram.
PDMM-0057 6-3
Introduction
Shorts to Frame A common cause of truck electrical problems is shorting to the truck
frame which can be caused by:
• Accumulation of dirt
• Breakdown in insulation
• Bare wires
Shorts to frame can occur at numerous locations including:
• Battery
• Motors
• Cables
• Buss Bars
• Heat Sinks
• Solenoids
Check for shorts to frame using the following procedure:
! CAUTION
Unplug the battery; battery current can damage the meter.
1. Use an ohmmeter set to Rx10,000 scale.

2. Connect one lead to the truck frame and the other to different
points in the electrical system - i.e., terminal strips, contactors,
wire connections, etc.
3. If the ohmmeter registers less than two megohms, the short
within the particular circuit must be located.
4. Reverse the leads and repeat steps 3 through 5.
5. Remove the control fuses (FU1, FU2, FU3, FU4, FU5. FU6, FU8,
FU9, FU10, FU11, and sense wires).
6. For each fuse, make a connection between the battery side
terminal and the truck frame with the ohmmeter.
7. Any reading below 200K ohms in the power system (motors)
indicates unacceptable shorts somewhere in the system.
8. For each fuse, make a connection between the control side
terminal and the truck frame with the ohmmeter.
9. A reading registering below two megohms on the meter indicates
unacceptable shorts in the control system.
6-4 PDMM-0057
Introduction
Voltage to Frame Voltage grounds are the most common causes for system intermittent
overloads.
Voltage to frame leakage is a result of dirt accumulation and can
occur at:
• Motors
• Heatsinks
• Battery
• Switches
• Contactor panel
• Cables/Wiring
Check for voltage to frame using the following procedure:
1. Use a voltmeter set to a voltage above the truck system.
2. Connect voltmeter leads as follows:
• Positive lead to PC-1; Negative lead to truck frame
• Positive lead to truck frame; Negative lead to TP4
Voltage readings of 2-3 volts in either test should be eliminated.
3. Eliminating voltage to frame can be accomplished by isolating a
particular area of the truck’s electrical system. Use the following
procedure:
• Connect voltmeter leads as in Step 2 above.
• Remove the battery from the truck. Reconnect the battery
to the receptacle. If the voltage drops, the battery needs
cleaning or resealing.
4. If the battery checks good, reinstall in truck and:
• Remove fuses (one at a time). If voltage drops when a fuse is
removed the defective circuit is isolated.
• Disconnect motor leads (one at a time). If the voltage drops,
the motor needs cleaning or repair.
PDMM-0057 6-5
Introduction
Board and Troubleshooting by following the instructions given in this manual is

Component usually more productive than swapping components until the
problem is corrected.
Swapping
Bear in mind that LEARN must be run after swapping, replacing, or
Precautions adjusting any of the following components:
• Directional/Speed Controller Potentiometer
• Vehicle Manager (VM)
• Pressure Transducer
Every time a new VM is placed into a truck, IT MUST BE LEARNED.
be particularly aware of this when swapping cards between trucks to
isolate a problem. When swapping VM Cards between a working and
non-working truck, BOTH must be re-learned after finishing
troubleshooting. Additionally, verify all DIP switch settings.
When in doubt, it is wise to run LEARN after servicing a truck.
Likelihood of When troubleshooting a problem, some components should be

Component Failure suspected before others. This “suspect order” is based on either:
• The probability of a particular component failing
• The ease of replacing a particular component
All troubleshooting is based on the following “suspect order.”
1. Wiring and terminal connections and coil drivers should be
suspected before circuit cards.
2. Coil drivers should be suspected before circuit cards.
3. Hydraulic fluid contamination.
4. Component mis-adjustment is more likely then component failure
(directional/speed control potentiometer).
5. Mast switches should be suspected before other components.
6. Circuit cards are normally the last item to suspect.
Handling Printed Refer to Electrostatic Discharge Damage (Chapter 5) for complete

Circuit Cards information on handling circuit cards.
6-6 PDMM-0057
Introduction
Major Faults The following pages provide troubleshooting procedures for

catastrophic truck failures. These are a starting point for symptoms
which prevent use of the truck.
Truck Completely Many truck problems result from one or more of three conditions:
Inoperative, • Low battery charge
S1 is ON, • Battery leakage to frame
No 2-digit Display • Shorts to frame (other than battery)
Before you begin troubleshooting:
1. Check the battery charge.
2. Perform the battery leakage to frame test.
3. Perform the shorts to frame test.
4. Perform voltage to frame test.
! WARNING
Whenever troubleshooting requires closing key switch S1,
the truck must be blocked up to avoid unexpected truck
travel.
PDMM-0057 6-7
Introduction
Does a voltmeter between the NO Does recharging NO Check battery and

positive and negative battery bring battery to charger. Repair or re-
terminals or connections proper voltage place faulty battery,
indicate system voltage? reading? cables or charger.
YES
Disconnect battery.
Remove Covers.
Replace line fil-
Is the vehicle equipped with a line YES ter fuse.
filter?
NO
Is FU2 OK? NO Replace FU2.
YES
NO Replace FU4.
Is FU4 OK?
YES
Continued next page.
6-8 PDMM-0057
Introduction
Continued from previous page.
Unplug JPS10. Is Is JPF3

NO Tighten JPF3.
B+ at JPS10-1, 2, loose? YES
and 3?
NO
YES Is JPF1
loose? YES Tighten JPF1.
NO
Is JPN5 YES Tighten JPN5.

loose?
Unplug JPS10. Is NO
B+ at JPS10-1, 2, NO
and 3? Is JPN4 loose? YES Tighten
JPN4.
GO to "A"
YES NO
on page 6-
10.
On power supply Is key switch S2 NO Repair/
in Vehicle Man- OK? Replace
ager, check for NO Replace power
YES
battery voltage supply ribbon
between TP1 and cable. If this Is there continuity
does not correct GO to B on
TP6. OK? between JPN4-1 to NO page 6-11.
the problem, re- JPS10-1, 2, and 3
place the on Vehicle Manager.
YES Vehicle Manag-
er.
Look for +5.3 YES
volts between TP4
and TP6 on power NO Replace the
Power Supply. Is there continuity GO to "C" on
supply. OK? between JPN4-2 and NO page 6-12.
FU4?
YES
If there is still a problem,

replace the Vehicle Manager.
PDMM-0057 6-9
Introduction
“A” from page 6-9.
Is there continuity
between FU2 to JPF 3- NO Replace the Power Panel Driver Assembly.
9, 10, and 11?
YES
Is there continuity be- Replace the cable between Power Panel

NO
tween JPF3-9,10, and Driver Assembly and Vehicle Manager.
11 to JPS10-9,01, and
11?
YES
NO Replace the Vehicle Manager.
Is there continuity
between JPS10-9, 10,
and 11 to JPS11-1?
YES
NO Replace the Power Supply ribbon cable.
Is there continuity
between JPS11-1 to
JPP1-6?
6-10 PDMM-0057
Introduction
“B” from page 6-9.
Is there continuity NO Replace the key switch harness.

between S1-1 to JPN4-
1?
YES
Is there continuity be- NO Replace the Hydraulic Driver Assembly.

tween JPN4-1 to JPN5-
2?
YES
Is there continuity be- Replace cable between the Hydraulic Driver Assembly and
NO
tween JPN5-2 to the Power Panel Driver Assembly.
JPF1-2?
YES
NO Replace the Power Driver Assembly.
Is there continuity be-
tween JPF1-2 to JPF3-
1,2, and 3 (B+)?
YES
Is there continuity be- Replace the cable between the power panel driver assembly
NO
tween JPF3-1,2,and 3 and the Vehicle Manager.
to JPS10-1,2, and 3
(B+)?
YES
Is there continuity be- NO Replace the Vehicle Manager.

tween JPS10-1,2,and
3 to JPS11-6 (B+)?
YES
Is there continuity be- Replace the Power Supply ribbon cable.

NO
tween JPS11-6 to
JPP1-1?
PDMM-0057 6-11
Introduction
“C” from page 6-9.
Is there continuity Replace the key switch harness.

between S1-2 to JPN4- NO
2?
YES
Is there continuity be- Replace the Hydraulic Driver Assembly.

tween JPN4-2 to JPN5- NO
3?
YES
Is there continuity NO Replace cable between the Hydraulic Driver Assembly and
between JPN5-3 to the Power Panel Driver Assembly.
JPF1-3?
YES
Replace the Power Panel Driver Assembly.
Is there continuity NO
between JPF1-3 to
FU4?
6-12 PDMM-0057
Introduction
Truck Completely Inoperative,

2-digit Display Lit, But No Valid Code
Remove covers from power section.

Open Vehicle Manager.
Replace the VFC. OK? NO Replace Distribution

Board.
During Powerup, Operator's

Display Shows - “Deadman?”
Are you standing on

deadman pedal?
YES Release deadman pedal.
NO
Run Test I00 and

troubleshoot accordingly.
Speed Limited with No Code
If the speed of the truck is limited with no speed limit or fault code shown check mast
switches SW1 and/or SW2 and associated wiring.
PDMM-0057 6-13
Introduction
No Lift/Travel OK SelfTest OK
Run Test O02
and trouble-
Does the pump motor run? Is the voltage below lift cutout? shoot
NO NO according to
test.
YES YES
Recharge battery or
adjust cutout point
through CONFIG.
Check for continuity on

switches S20 & S21 at
JPS4 & JPC1.
6-14 PDMM-0057
Introduction
Power Panel Use the information below when removing or replacing components
Service on the Power Panel Assembly.
Information
Coil Drivers
Power Panel
Driver Assy.
PC
1S Contactor
(36-Volt Trucks
Only)
P
Contactor
L1
Transistor (Q1)
Chopper
Control
Module
H-Bridge
Power Panel
Temp. Sensor
(HT)
Field Wiring
Board
When replacing REC1, Apply oxide inhibitor

apply Heatsink compound between Bus Bar and
to threads. Torque to 30 ft- Heatsink. Wipe off any All 1/4-20 screws without lock
lbs (42 N•m). excess. washers to be torqued to 60-
64 in-lbs (6.8-7.2 N•m).
Figure 6-1: Power Panel Assembly
PDMM-0057 6-15
Introduction
Power Panel Heat When replacing the Power Panel Temperature Sensor (HT), apply
Sensor heatsink compound to the threads.
Replacement
Power Transistor Referring to the figure below, connect a DVM to the points to test the
(Q1) Test Power Transistor. The values shown below were measured using a
Fluke 8060 digital voltmeter. If the readings are not as specified,
replace the Power Transistor. See Note.
NOTE: Before testing the Power Transistor, ensure that all leads are
disconnected and clear from the device.
! CAUTION
If the power transistor (Q1) goes bad, it may destroy the
chopper control module (CCM) and if the chopper control
module goes bad, it may destroy the power transistor.
Therefore, if the power transistor is found to be bad, test
the chopper module before installing a new power
transistor; likewise, if the chopper control module is
defective, test the power transistor before installing a new
chopper control module.
Positive Test Negative Test Acceptable Reading

Lead at: Lead at: (Ohms)
E C 10K-100K
E B 20-1000
B C 10K-100K
C B 200K-10M
Both of the resistance readings must be observed for the Power
Transistor to be considered good!
Table 6-1: Power Transistor Test
NOTE: If the Power Transistor test shows that is shorted, replace

REC1. Even if REC1 passes the static test, it may be defective
under dynamic conditions.
If the Power Transistor shows a short between the collector (C) and
base (B), replace the Chopper Control Module (CCM) also.
6-16 PDMM-0057
Introduction
DVM
.3 to .9 volts
OL
- +
E B
- +
C - +
OL
.3 to .9 volts
DVM
Figure 6-2: Voltage Test Points for Power Transistor Q1
Chopper Module Use this test if the Power Transistor has failed or there is doubt in the
Test condition of the Chopper Control Module (CCM).
To test the CCM when the Power Transistor has failed:
1. Replace the Power Transistor with a known good unit, but DO
NOT connect the collector lead to the transistor (the power lead
which goes through the donut). Be sure that the collector lead is
well away from the heatsink block.
2. Connect the voltmeter positive lead to the Base (B) of the Power
Transistor.
3. Connect the negative lead to the emitter (E) of the Power
Transistor.
4. Turn the truck ON.
5. There should be a 0.18 volt drop from the base to the emitter. See
NOTE.
NOTE: A fault Code 23 will occur when the truck is turned ON.
6. Run Output test 014. The voltage from B to E should ramp up
from 0.18 volt to 0.5 volt:
• If this does NOT occur, replace the CCM
• If this DOES occur, the CCM is OK
7. Other related tests for the CCM are:
• A11, I12, I13, O13, O14
8. Test REC1.
PDMM-0057 6-17
Introduction
200K - 10M Ohms

20 - 1,000 Ohms
E B
Figure 6-3: Resistance Test Points for Power Transistor Q1
Figure 6-4: Power Transistor (Q1) Schematic
6-18 PDMM-0057
Introduction
TM1/TM2 Test Use the following procedure to test TM1/TM2 transistors. For this
test, use a Fluke 8060 digital meter (or equivalent) set on the 200K
ohm resistance scale.
! CAUTION
Be sure to correct polarity.
B2
FW - 2
C2E1 E2 C1
B1
B2
C2E1 E2 C1
FW - 1 FW B FW - 1
B1
Figure 6-5: Transistor Module for Field Wiring Assembly
Positive Lead of Meter Negative Lead of Meter

Good if:
to: to:
C2E1 C1 25K-120K
C2E1 B1 100 ohms-1K
E2 C2E1 25K-120K
E2 B2 100 ohms-1K
If any position of this test fails, replace the transistor assembly.
PDMM-0057 6-19
Introduction
Figure 6-6: Field Wiring Module Schematic
6-20 PDMM-0057
Introduction
HCM Test The following test is used to test the HCM assembly. For this test, use
a Fluke 8060 digital meter (or equivalent).
! CAUTION
If the H-bridge control module (HCM) goes bad, it may
destroy the field wiring assembly (FW), and if the field
wiring assembly (FW) goes bad, it may destroy the H-bridge
control module (HCM). Therefore, if the HCM is found to be
bad, test FW before installing a new HCM. Likewise, if FW is
found to be defective, test the HCM before installing a new
field wiring assembly.
Procedure 1. Disconnect the drive motor power lead at MD-S1.

2. Remove wires from the Field Wiring Assembly: T1, T2, T3, T4.
3. Enter Maintenance Mode and select Test 017 (ramp PWM to HCM
and Field Windings).
4. With test OFF, T1, T2, T3, and T4 should all measure 0.2-1.0 volt
with respect to FW-B-.
5. With test ramping, T1-T4 will be as follows:
Test Point
Meter Indication
(wrt FW-B)
Ramp up to battery voltage and remain
T1
constant through cycle.
Ramp up to battery voltage, drop to 0.2-
T2 1.0 volt and remain constant through
cycle.
Hold at battery voltage, then ramp up
T3
from les than 1.0 volt to battery voltage.
Hold at 0.2-1.0 volt, then ramp up to bat-
T4
tery voltage.
Table 6-2: Test Ramping
Let the test repeat several times for each test point to get a valid
reading. One complete cycle will take approximately 10-15 seconds.
Figure 6-7 is a graphic example of the cycles described above.
PDMM-0057 6-21
Introduction
One Cycle
T1
T2
T3
T4
Figure 6-7: HCM Test
Vehicle Manager The following tests the power supply on vehicles with software version
Power Supply Test 4.0 and up.
Meter Connection Reading (VDC)

+ -
TP6 B+
TP4 B+
TP5 TP1 12 (+/-0.2)
TP2 5.3 (+/-0.1)
TP3 5 (+/-0.1)
Table 6-3: Software Version 4.0 and up
The following tests the power supply on vehicles with software below
version 4.0:
Meter Connection Reading (VDC)

+ -
TP1 B+
TP2 B+
TP3 TP6 12 (+/-0.2)
TP4 5.3 (+/-0.1)
TP5 5 (+/-0.1)
Table 6-4: Software Version Below 4.0
6-22 PDMM-0057
Introduction
Coil Driver Test The coil drivers used on this vehicle are all identical. If a coil is
suspected to be bad, swap it for another coil driver in a circuit that
functions properly.
Contactors- Clean and inspect contactors regularly to help ensure their proper
General operation. See the Scheduled Maintenance in this manual for the
suggested service interval.
Cleaning Wear safety glasses.

Remove dust, dirt, and other foreign materials from contactors with
dry, filtered, compressed air [30 psi (206.8 kPa) max.].
Use a cleaning solution on a clean cloth to remove stubborn dirt.
Inspection Visually inspect all parts for:

• Nicks
• Broken or damaged leads
• Broken terminals or springs
• Burned contact tips
• Cracked or deteriorating bushings, insulation or contact
guards
• Stripped threads
• Other obvious damage
NOTE: The only replaceable component of the contactor assembly are
the contactor tips. If any other segment of the contactor is
found to be defective, the entire contactor assembly must be
replaced.
Guidelines When inspecting contactors, remember:

• Darkening of points does not indicate burning.
• Burning means loss of contact point material or droplets of
molted contact material being displaced.
• The contact may be used until the material is almost
completely gone.
• Replace the contact points if, in the opinion of the
Maintenance department, there is not enough contact point
material to last until the next regular inspection.
• The silver alloy part of the point is usable contact material; the
copper backing is not.
• Do not file contact points to remove discoloration or minor
irregularities. This is wasteful and produces a surface more
susceptible to sticking.
• If a cone and crater appear, remove the cone only with a file;
do not use sandpaper or emery cloth.
PDMM-0057 6-23
Introduction
Motor Open An open circuit is one in which the electrical circuit within the motor
Circuit Test has been broken. This can be caused by:
• Bad brushes or brush springs
• Broken wire in the field winding
• Loose or bad connection
Procedure 1. Disconnect the motor from the truck circuit.

2. Connect the leads of an megohmmeter (preferably), or ohmmeter
between the individual circuits. (The drive motor has four external
connections - two armature and two field. See below.
3. There should be continuity within each circuit and the meter
reading should be:
• 0.020-0.030 ohms between A1 and A2
• 0.9-1.1 ohms between S1 and S2
4. There should be no continuity between the armature and the field
terminals. The meter should register more than 100,000 ohms.
NOTE: If the meter indicates an open circuit in the armature, check
conditions of the brushes before rejecting the motor.
5. The auxiliary and lift motors have only two external connections
because the armature and field windings are connected
internally. The above continuity check may be made between the
two external terminals. If an open circuit is found, these motors
must be disassembled to check the field and armature circuits for
continuity.
1(+)
Drive
Motor
MD A2
S2
MD1
MD
MD
S1 A1
Figure 6-8: Drive Motor Terminals and Circuits
6-24 PDMM-0057
Introduction
Motor Short A short-circuited motor is one in which the insulation on the field or
Circuit Test armature windings has broken down at two or more points. The
breakdown creates a low resistance current path, allowing current to
flow from one turn of the coil to another adjacent coil turn, without
actually flowing through the coil wire. The result is a decrease in total
resistance of the motor winding and an increase in the current flow.
The location of the short determines its severity.
A shorted motor may be indicated by:
• Slow or sluggish operation
• Running faster than normal
• Overheating
• Blowing a power fuse
Short Circuit Test 1. Refer to the inspection report showing the motor current when the
motor was new.
2. Duplicate the same truck conditions (loaded or unloaded) and
measure the present current.
3. If the present current reading is 25% more than the original
current value, a short circuit probably exists.
Armature Shorts A short circuit in the armature will cause heating which will probably
result in burning of:
• Armature coil
• Banding wires
• Commutator segments
A visual inspection should show this condition.
Motor Grounds In a grounded motor, an electrical circuit exists between the current-
Test carrying conductors and the motor housing. This can be caused either
by direct contact or through conductive foreign material.
The ground may be caused by:
• Insulation breakdown
• Brush leads touching the motor housing
• Build-up of carbon dust or other materials
1. Isolate the motor from the truck circuit.
2. Attach one lead of a megohmmeter (preferably), or an ohmmeter
set to the highest resistance scale, to a motor terminal and the
other lead to the motor housing. Be sure paint does not interfere
with connections.
3. If the ohmmeter indicates a resistance of less than 100,000 ohms,
the motor is grounded. Clean, repair or replace the motor as
necessary.
PDMM-0057 6-25
Introduction
Motor Most motor overheating can be prevented by understanding the

Overheating causes and preventions listed below:
Cause Prevention
Insufficient ventilation due to Clean the ventilation holes
ventilating hole blockage by compressed air.
Dirty Motor See motor cleaning in Chap-
ter 5.
Defective bearings If the bearings are replace-
able as a unit, replace them.
If not, replace the motor.
Lifting excessive loads and stall- Make sure the operator
ing the motor knows the truck limitations.
Low battery voltage Replace or recharge the bat-
teries.
Open or short-circuited arma- Follow the test procedures in
ture or field windings this manual.
Table 6-5: Motor Overheating
! WARNING
If an electrical failure or an extreme overload occurs,
especially in a totally enclosed motor, personnel should not
breathe the fumes which have been generated inside the
machine. The heat of the failure arc or overload may
generate noxious fumes by pyrolysis of the insulation
materials. All power should be disconnected from the motor
before any investigation of the failure is attempted. The
area around the motor should be well ventilated. Personnel
should not breathe the toxic fumes produced by the failure.
If possible, time should be allowed for the motor to cool and
for dilution of the fumes with air.
6-26 PDMM-0057
Hydraulics
Hydraulics General topics covered in this section are:

• Leakage (external and internal)
• Hydraulic Pump Problems
• Lift/Lower System
• General hydraulic “tips”
NOTE: It is important to keep accurate records of all hydraulic
inspections and work performed on the trucks. Such records
are helpful in determining:
• Repair and maintenance costs
• Reliability of components
• Durability of hydraulic fluid
• Scheduling of maintenance
Hydraulic Leakage Hydraulic leakage can cause load drop, load drift, bouncing carriage
and noisy pumps.
Wipe all connections clean when checking for leaks. Remember.
leaking fluid is likely to run down the underside of pipes and drip at
low spots. Many situations cause hydraulic leakage. Any leakage
inspection should include operating units as well as connections.
! WARNING
Use extreme caution while looking for high pressure
hydraulic leaks. Personal injury may result if struck by a
high pressure stream of hydraulic fluid.
Faulty Flexible When installing a flexible connector, avoid twisting it which creates a
Connectors strain on the joint.
Fitting Do not spring a tube into place before tightening a fitting. The
resultant stress may cause a leak.
Cracked or Bad Tubing Inspect all tubing before installation. Make sure when making the
Flare flare that it is the right size.
Foreign Material in the Make sure the flare is clean before installation.
Flare
Defective Threads Check for leakage around the threads when installing new tubing.
Dirt Around O-Rings Thoroughly clean and lubricate any O-rings before installation.
Wrinkled or Flattened Use a known-to-be-good tube bender and carefully bend the tube.
Tube
PDMM-0057 6-27
Hydraulics
Worn Packings Examine packings for wear and leakage around the cylinder pistons.
If the packing is too tight, abnormal friction and wear will occur. See
that cylinders are securely anchored and that pistons are in
alignment. Misalignment is a cause of heavy wear of both pistons and
packings. Worn packings should be replaced since they, many times,
cause internal leakage. If truck operation is sluggish, check the
packing inside the cylinder.
Bad Connections When checking connections to pumps, cylinders, manifold valves,

etc., be sure to observe both pressure and suction sides. Pressure side
leaks can be found by wiping connections and observing the
accumulations of oil after brief truck operation. Brushing soap
solution on joints can be helpful. Air leaks on the suction side of
various components can cause considerable trouble; listen for these
leaks; they may lead to air bubbles in hydraulic oil. Suction leaks are
always difficult to find, but they rate high in importance.
Drive Coupling Check the alignment of the drive coupling between the motor and
Alignment pump. Also, make sure the usual motor checks suggested in the
electrical maintenance section. Be sure hydraulic fluid from a leak is
not seeping onto the field windings and armature.
System Contamination System contamination can cause erratic or sluggish operation of lift or
auxiliary functions, load drift, load drop, clogging, leaking, and
damage to the valve/pump parts.
Packing Disintegration Examine rod surfaces which contact the packing. If these are nicked
or scratched, they should be resurfaced or replaced.
Cylinder and Piston If a hydraulic cylinder is disassembled, inspect the inside of the
Packing Wear cylinder housing. If the inside cylinder surface is scored, packing grit
is probably in the hydraulic fluid.
Hydraulic System Oxidation can cause internal rusting and sludge. Use a top grade oil
Oxidation with additives. See the Lubrication Equivalency Chart in the
Appendix.
Opening Hydraulic Whenever a hydraulic system is opened, all hoses should be capped or
System plugged to keep out dirt and moisture-laden air. Examine pipe fittings
and hoses to be certain there are no seal particles, nicks, burrs or dirt
present when reassembling the parts. Wipe all fittings before
reconnecting them.
Clogged Filter If the filter becomes clogged in less than the recommended change
interval, the bypass valve will allow contaminants into the system.
Inspect, clean and/or replace the element whenever contamination is
evident.
NOTE: If severe contamination occurs, drain the system, flush all
components and replace the oil and filter.
6-28 PDMM-0057
Hydraulics
Hydraulic
Problems
Pump Problems
Trouble Probable Cause Remedy

Pump Not Fluid intake pipe in reservoir restricted. Check all strainers and filters
Delivering for dirt and sludge. Clean if
Fluid necessary.
Air leaks at the intake. Pump not priming. Check the inlet connections to
determine where air is being
drawn in. Tighten any loose
connections. See that the fluid
in the reservoir is at the
proper level.
Fluid viscosity incorrect. Completely drain the system.
Add new filtered fluid of the
proper viscosity.
Coupling or shaft sheared or disengaged. Repair/replace pump.
Insuffi- System relief valve set too low. use a pressure gauge to cor-
cient Pres- rectly adjust the relief valve.
sure Build-
Up
Complete broken relief inlet or pressure line. Replace/repair as required.
loss of flow
from
pump.
Noisy Oil supply low. Fill reservoir.
pump Oil too heavy. Change to proper viscosity.
caused by
cavitation. Oil filter plugged. Clean filters.
Suction line plugged or too small. Clean line and check for size.
Oil over- Oil supply low. Fill reservoir.
heating Contaminated oil. Drain reservoir and refill with
clean oil.
Setting of relief valve too high or too low. Set to correct pressure.
Oil viscosity incorrect. Drain reservoir and refill with
proper viscosity oil.
Shaft seal Worn shaft seal. Replace shaft seal. If replacing
leakage Broken diaphragm seal or back-up gasket. shaft seal does not stop leak-
Bearings out of position. age, the pump should be dis-
Excessive internal wear. assembled and checked or
replaced.
Air leaking into suction line. Tighten fittings.
Wrong kind of oil. Drain and fill reservoir with
non-foaming oil.
Table 6-6: Pump Problems
PDMM-0057 6-29
Hydraulics
Trouble Probable Cause Remedy

Pump Pump intake partially blocked. Check the fluid condition and
making if necessary, drain and flush
Noise the system. Refill with clean
fluid of the correct viscosity.
Air leaks at the intake or shaft seal. (Oil in Check the inlet connections
reservoir would probably be foamy). and seal to determine where
air is being drawn in. Tighten
any loose connections and
replace the seal if necessary.
See that the fluid in the reser-
voir is at the proper level.
Coupling misalignment. Check if the shaft seal bearing
or other parts have been dam-
aged. Replace any damaged
parts. Realign the coupled
shafts.
Table 6-6: Pump Problems
Lift/Lower/ Reach The following table is designed to refer service personnel to

System Hydraulic diagnostics and/or procedures which should aid in pinpointing and
eliminating problems in the lift/lower/reach hydraulic systems.
Troubleshooting
The procedures referred to by number (1-5) will be found below. When
they are indicated, follow them in the order suggested.
If... Then...
The load drifts Lift relief valve may be faulty or malad-
excessively (more justed. (#’s 4,1,2,3,5)
than 3 inches in Load holding check valve may be faulty. (#’s
10 minutes with 1,2,3,5)
a 3000 lb load) Emergency lowering valve may be faulty or
maladjusted. (#’s 4,1,2,3,5)
L/L SOL may be faulty. (#’s 1,2,3,5)
The forks begin to Lift relief valve may be faulty. (#’s 4,1,2,3,5)
drop while LIFT is
actuated
Table 6-7: Hydraulic Troubleshooting
Suggested Procedures - These checks and procedures are designed to aid in locating the cause
Lift/Lower/Reach of trouble in lift/lower/reach systems.
1. Check the operation of the indicated component:
• Solenoids: Remove, energize, watch for spool or poppet motion,
listen for click of plunger
• Relief Valves: Check poppet for sticking; back off adjustment
(counterclockwise) if necessary
6-30 PDMM-0057
Hydraulics
2. Check the indicated component for contamination:

• Visually inspect for metal chips, grit, teflon tape bits
• Remove foreign material
• Inspect sealing surfaces for damage
3. Check O-rings and backup rings; Replace seals if:
• Nicked
• Extruded
• Deformed
• Any doubt exists
4. Readjust relief valves to factory specification.
5. Replace the indicated component. If any doubt exists about the
operation or condition of a component, we recommend
replacement.
Hydraulic
Maintenance Tips Cleaning Hydraulic Dip in clean kerosene or equivalent light
Components solvent.
Wash them off.
Blow dry using dry, compressed air.
Replacing or Rein- Dip cartridge in hydraulic oil. Ensure that
stalling Hydraulic the O-ring is well lubricated. Screw in by
Cartridge Valves hand until the outer O-ring touches the
manifold.
Use a wrench to tighten them. Tighten
cartridge 1/2 turn then back off 1/4 turn.
Continue this process until cartridge is
tight. Tightening O-ring components in
this manner will prevent damage to the
O-ring seal.
Replacing or Rein- Immerse components with spring cham-
stalling Hydraulic bers in hydraulic oil and activate the
Seals spring to remove any air.
Table 6-8: Hydraulic Maintenance Tips
NOTE: After locating and repairing any leak or other problem, fill the
reservoir and bleed the system.
! CAUTION
When clamping lift/lower manifold in vise, ensure valve
body is not damaged which might void warranty.
Follow these procedures to avoid future hydraulic problems:
PDMM-0057 6-31
Hydraulics
Hydraulic Check regularly for the correct level and

Oil for the presence of contaminants or bub-
bles.
Reservoir Change semi-annually.
Oil
Reservoir Clean semi-annually.
Strainer
New Oil Use only clean containers. Pass all oil
added to the reservoir thru a 25 micron-
rated filter.
Filling cap Check for possible clogging.
Air Vent
Return Fil- Replace semi-annually.
ter
Table 6-9: Prevention Procedures
! CAUTION
Do not use brake fluid in the hydraulic system.
6-32 PDMM-0057
Hydraulics
Troubleshooting MicroCommandNA incorporates a number of features to help facilitate

Micro debugging.
CommandNA These features fall into two groups:

• Status Codes
• Test Mode diagnostic procedures
Troubleshooting normally begins with a Status Code, which leads into
one or more Test Mode procedures.
Based on the status, the service technician should read the
corresponding Status Code explanation. The Status Code pages will
explain how the code is caused, and what troubleshooting is
necessary to isolate the problem. Often the reader is directed to run
one or two more Test Mode tests. If a particular test fails, then
appropriate troubleshooting which is listed in that test’s section
should also be performed.
Generally as long as the Vehicle Manager is functioning enough to
display a status code, then it can also run Maintenance Mode.
Learn Mode and Some Status or Fault Code conditions may be corrected by running
Troubleshooting Learn. For example, a worn spring may cause the Lift Potentiometer to
stop at a different neutral setting than previously learned. The
troubleshooting section for the particular code will indicate if Learn
should be run.
Test mode does not depend on any of the learned constants. Therefore
running Learn will never affect the results of any test.
It is generally unproductive to indiscriminately run Learn mode as a
response to every problem. However, as long as the Learn procedure is
performed properly, there is no harm in running Learn mode, even
when it was not required.
Maintenance Maintenance Mode allows the service technician a means of testing

Mode and individual circuits within the MicroCommandNA system. Maintenance
mode is accessed through Program mode after the SUPERWRD is
Troubleshooting entered. Refer to Chapter 3 for information on procedures for
accessing Maintenance Mode.
PDMM-0057 6-33
Hydraulics
! WARNING
By entering Maintenance Mode, you have disabled the
safety circuits associated with the Vehicle Manager.
Therefore, you must take extra precautions while in
Maintenance mode. Follow all instructions contained in
this manual for each test. If you are unsure how to conduct
a test while in Maintenance mode, STOP - Do not proceed
with the test. Contact a certified technician.
Please review the following comments and suggestions before doing

any tests.
Using If you go into and out of Maint several times to resolve a problem, it
Maintenance may save time if the SUPERWRD is temporarily changed to all spaces.
The Operator’s Display would appear as shown below:
Mode
[ __ __ __ __ __ __ __ __ ]
That way, when Program Mode is entered, the password is
automatically on the Operator’s Display. Remember to re-enter the
correct SUPERWRD when you are done.
! CAUTION
If the power transistor (Q1) goes bad, it may destroy the
chopper control module (CCM) and if the chopper control
module goes bad, it may destroy the power transistor.
Therefore, if the power transistor is found to be bad, test
the chopper module before installing a new power
transistor; likewise, if the chopper control module is
defective, test the power transistor before installing a new
chopper control module.
! CAUTION
If the H-Bridge control module (HCM) goes bad, it may
destroy the field wiring assembly (FW) and if the field
wiring assembly (FW) goes bad it may destroy the H-Bridge
control module (HCM). Therefore, if the HCM is found to be
bad, test FW before installing a new HCM. If the FW is found
to be defective, test the HCM before installing a new field
wiring assembly.
6-34 PDMM-0057
Hydraulics
! CAUTION
For any of the tests where you are instructed to disconnect
JPT1, JPH1, or JPD1, turn power OFF before disconnecting
either connector, then re-enter the test. This is very
important as failure of the chopper module field wiring
assembly, H-Bridge control module or power transistor is
possible if the connector is removed and power is still
applied.
! CAUTION
Disconnecting wires or connectors to integrated circuits
with power ON can result in premature failure of those or
other components. Always turn power OFF before making
or breaking any connections.
! CAUTION
When removing a connector, do not pull on the wires to
separate the connection.
! WARNING
While in Maintenance Mode:
• The drive tire must be elevated off the floor

• Ensure that the controls are in neutral
• The vehicle is blocked to prevent movement
• The carriage is lowered completely to the floor
PDMM-0057 6-35
Status Codes
Status Codes The following pages contain all truck status codes and related tests,
arranged by category and in sequence, including:
• Informational Codes
• Fault Codes
• Analog Tests
• Digital Input Tests
• Digital Output Tests
The analog and digital input/output test pages are preceeded by

tabular summaries which list and describe the tests contained
therein.
Additionally, an expanded alphanumeric listing of all status codes,
messages, test conditions, effects, and clearance procedures is
provided at the end of this chapter. This listing will serve as a quick
finder for specific troubleshooting information as related to each given
code.
6-36 PDMM-0057
Informational Codes
Informational
Codes
Code 00 - All
Systems
Functioning
Code Title All Systems Functioning

Reason This is not an error condition; it is merely an indication of
the mode of the traction motor's controller. Coast mode is
the default mode when the motor is not being driven. All
systems are OK and the truck is ready for operation.
System 1. Alarm sounds: No
Response 2. Operator's Display: Battery State-of-Charge...
3. PC Contactor: Energized
4. VFC Display: 00
How to Clear This is a status indication only; there is no need to clear
this code.
Corrective Actions and None required.

Checks
Code 10 - Power Up
Self Test
Code Title Power-Up SelfTest

Reason This is not a fault with the system. This code will appear
whenever the vehicle is performing SelfTest during power
up.
System 1. Contactors cycle
Response 2. Horn sounds
3. Operator's Display: SelfTest Passed...
4. PC Contactor: Not energized until SelfTest passes
5. VFC Display: 10
6. Speed Limit: 0.0 mph
How to Clear This is a status indication only; there is no need to clear.
Corrective Actions and None required.

Checks
PDMM-0057 6-37
Informational Codes
Code 11 - Drive
Motor
Temperature HOT
Code Title Drive Motor Temperature HOT

Reason Operation of the vehicle has caused drive motor to over-
heat.
Response 2. Operator’s Display: Travel speed limited due to traction
motor temperature
4. VFC Display: 11
5. Speed Limit: As the temperature increases, the speed will
continue to be restricted.
How to Clear Allow the motor to cool.
Possible causes:
1. Traction motor may be overheated…let cool.
2. DT sensor may be bad.
3. Cable between DT and Hydraulic Driver Assembly may be loose or
defective.
4. Cable between Hydraulic Driver Assembly and Vehicle Manager
may be loose or defective.
5. Hydraulic Driver Assembly may be bad.
6. Vehicle Manager may be bad.
Corrective Actions and 1. Check that the connector at JPN10 is connected properly.
Checks
2. There may be a problem with the traction temperature sensing
circuit.
• Run test A08 - Traction Motor Temperature Voltage
6-38 PDMM-0057
Informational Codes
Code 12 - Lift Motor

Temperature HOT
Code Title Lift Motor Temperature HOT

Reason Operation of the vehicle has caused drive motor to over-
heat.
Response 2. Operator’s Display: Lift Motor Overheating...
4. VFC Display: 12
How to Clear Allow the motor to cool.
Possible causes:
1. Lift motor may be overheated…let cool.
2. PT sensor may be bad.
3. Cable between PT and Hydraulic Driver Assembly may be loose or
defective.
may be loose or defective.
Corrective Actions and 1. Check that connector at JPN11 is connected properly.

Checks 2. There may be a problem with the lift motor temperature sensing
system.
• Run test A09 - Lift Pump Motor Temp/Voltage
PDMM-0057 6-39
Informational Codes
Code 13 - Power
Panel Temperature
HOT
Code Title Power Panel Temperature HOT

Reason The temperature of the power panel has risen enough to
cause the Vehicle Manager to restrict vehicle speed.
Response 2. Operator’s Display: Travel speed limited due to power
panel temperature...
4. VFC Display: 13
How to Clear Allow the power panel to cool.
Possible causes:
1. Power panel may be overheated…let cool.
2. HT sensor may be bad.
3. Cable between HT and Power Panel Driver Assembly may be loose
or defective.
4. Cable between Power Panel Driver Assembly and CCM may be
loose or defective.
5. Cable between CCM and Vehicle Manager may be loose or
damaged.
6. Power Panel Driver Assembly may be bad.
7. CCM may be bad.
Corrective Actions and 1. Check that connectors JPT1 are connected properly.
Checks
2. The power panel temperature sensing circuit may be defective:
• Run test A10 - Panel Temperature Sensor Voltage
6-40 PDMM-0057
Fault Codes
Fault Codes
Code 20 -
Temperature
Sensor Circuits
Not Responding
Code Title Temperature Sensor Circuits Not Responding

Reason The signal from Power Panel temperature sensor (HT) is not
correct
System 1. Alarm sounds: Yes
Response 2. Operator's Display: CODE 20…Inform Service Personnel
4. VFC Display: 20
5. Speed Limit: 1 mph
How to Clear The key switch must be cycled OFF/ON to clear this fault.
Possible causes:
1. Check the cables between:
• HT sensor and CCM
• CCM and Vehicle Manager
2. The HT sensor may be bad.
3. The CCM may be bad.
4. The Power Panel Driver Assembly may be bad.
5. The sensor cable may be running close to the power cables.
6. The Vehicle Manager may be bad.
Corrective Actions and Ensure the following cables are properly connected:
Checks
• JPT1 on CCM
• JPT1, JPT2 on CCM
• JPS1 on Vehicle Manager
Run Tests:
• A10 to verify the analog temperature reading
• I12 to verify the digital temperature limit signal
PDMM-0057 6-41
Fault Codes
Code 21 - Short
Detected In Armature
Circuit
Code Title Short Detected In Armature Circuit

Reason During the start-up SelfTest, either:
The analog current signal indicated current flowing while
the CCM was disabled.
OR
The analog current signal indicated current flowing while
no PWM was being generated.
During operation, either:

Voltage across Power Transistor is less than 2 volts
OR
There was no drive request (i.e., no PWM) and there was at
least 70 amps for at least 3 seconds.
3. PC Contactor: De-energized
4. VFC Display: 21
Possible causes:
1. Q1 may be shorted. See Power Transistor (Q1) Test and
3. The cable between the CCM and the Vehicle Manager may be bad.
4. The motor or motor cable may be bad.
Corrective Actions and If this error occurred while operating the truck, try turning the key off
Checks and back on, to see if SelfTest will detect the code.
Run tests:
• A11 - Armature Current Sensor Voltage
• O14 - Chopper Control Module PWM Test
• O13 - CCM Enable Signal
• I13 - Armature Current Limit Signal
6-42 PDMM-0057
Fault Codes
Code 22 - Power
Panel Overheated
Code Title Power Panel Overheated

Reason The temperature signal from the HT exceeded maximum
value.
Response 2. Operator's Display: Power Panel Overheated, allow time
to cool...
4. VFC Display: 22
Possible causes:
1. The Power Panel may be overheated…allow to cool.
2. The HT sensor may be bad or disconnected from the CCM.
3. The battery may be discharged or have a bad cell.
Corrective Actions and Run tests:

Checks
• A10 - Panel Temperature Sensor Voltage
• I12 - Power Panel Temperature Limit Signal
1. Check the cables between:
• HT sensor and CCM
• CCM and Vehicle Manager
PDMM-0057 6-43
Fault Codes
Code 23 - Open
Detected In Armature
Circuit
Code Title Open Detected In Armature Circuit

Reason During SelfTest, proper current levels were not sensed in
the Power Transistor (Q1)
4. VFC Display: 23
Possible causes:
1. FU5 may be blown.
2. There may be an open circuit in the drive motor.
3. There may be an open circuit in power wiring for armature in
drive motor.
4. Power Transistor (Q1) may be bad. See Power Transistor (Q1)
Test.
Corrective Actions and Run Tests:

Checks
• O14 - Chopper Control Module PWM Test
• O13 - CCM Enable Signal
6-44 PDMM-0057
Fault Codes
Code 24 - Armature
Current Sensor
Circuit Not
Responding
Code Title Armature Current Sensor Circuit not Responding

Reason During operation, maximum current was exceeded and
current limit signal was not activated or…
Current limit active with low current

4. VFC Display: 24
Possible causes:
1. Check the cables from:
• Q1 to CCM
• CCM to Vehicle Manager


Checks
• I13 - Armature Current Limit Signal
PDMM-0057 6-45
Fault Codes
Code 25 - Short
Detected In Field
Circuit
Code Title Short Detected in Field Circuit

Reason During operation, maximum field current was exceeded
and current limit signal was activated.
4. VFC Display: 25
Possible causes:
• Field Windings to Field Wiring Assembly
• Field Wiring Assembly to H-Bridge Control Module (HCM)
• HCM to Vehicle Manager
• Field Wiring Assembly T1 - T4 (base leads for TM1 and TM2)
2. The Field Wiring Assembly (TM1 or TM2) may be bad.
3. The HCM may be bad.
5. The motor may have an internal short.

Checks
• O17 - HCM PWM Ramp
• A12 - Field Current Sensor Voltage
• I14 - Field Current Limit Signal
• O15 - HCM Forward Enable Test
• O16 - HCM Reverse Enable Test
6-46 PDMM-0057
Fault Codes
Code 26 - Open
Detected In Field
Circuit
Code Title Open Detected in Field Circuit

Reason During operation, current was not detected in the field cir-
cuit when it should be.
4. VFC Display: 26
Possible causes:
1. FU8 may be open.
• Field Windings to Field Wiring Assembly
• Field Wiring Assembly T1 - T4 (base leads for TM1 and TM2)
3. The Field Wiring Assembly may be bad.
4. TM1 or TM2 may be bad.
7. The drive motor may have an open circuit in the windings.

Checks
• O17 - HCM PWM Ramp
• O16 - HCM Reverse Enable Test
• O15 - HCM Forward Enable Test
PDMM-0057 6-47
Fault Codes
Code 27 - Field
Current Sensor
Circuits Not
Responding
Code Title Field Current Sensor Circuits not Responding

Reason During operation, maximum current was exceeded and
current limit signal was not activated or…
Current limit active with low current.

4. VFC Display: 27
Possible causes:

Checks
6-48 PDMM-0057
Fault Codes
Code 30 - Excessive
Acceleration
Code Title Excessive Acceleration

Reason The output signal from the drive motor encoder (DE)
exceeded the maximum allowable limit.
Response 2. Operator's Display: CODE 30...Inform Service Personnel
4. VFC Display: 30
Possible causes:
1. The mechanical mounting or coupling of the encoder may be bad.
Check for a loose hardware, defective belt, etc.
2. Check cable between DE and the Vehicle Manager.
3. The drive motor encoder may be bad.
5. The traction wheel may be spinning on a wet surface.
Corrective Actions and The encoder may not be generating pulses correctly.
Checks
• Run Test I16 - Encoder Count
PDMM-0057 6-49
Fault Codes
Code 32 - No
Movement Detected
When Travel Is
Requested
Code Title No Movement Detected When Travel is Requested

Reason This code is detected if all four of the following conditions
occur at the same time for more than two seconds:
1. Speed request from throttle is not zero.
2. Velocity from the encoder is zero.
3. The PWM command to the CCM & transistor is greater
than 20%.
4. No current limit.
4. VFC Display: 32
Possible causes:
1. If the brake is mis-adjusted so that it is too tight, the drive motor
will not turn freely. This may cause this code. See section
“Adjusting the brake.”
2. The encoder cable may not be plugged securely into the Vehicle
Manager at JPS12.
3. The mechanical mounting or drive belt for the encoder may be
bad. Check for a loose coupling, etc. If the hardware is loose,
Corrective Actions and The encoder may not be generating pulses correctly.
Checks
6-50 PDMM-0057
Fault Codes
Code 34 - Drive
Motor Overheated
Code Title Drive Motor Overheated

Reason The temperature of the drive motor is hot enough for the
Vehicle Manager to prevent travel.
System Response 1. Alarm sounds: Yes
2. Operator's Display: CODE 34...Drive motor overheated,
allow time to cool
4. VFC Display: 34
Possible causes:
1. The drive motor may be overheated…allow to cool.
2. Check cables between:
• DT sensor and Hydraulic Driver Assembly (HDA)
• HDA and VFC
3. The DT sensor may be bad.
4. If the brake is mis-adjusted so that it is too tight, the drive motor
will not turn freely. This may cause this code. See section
"Adjusting the brake".
5. The drive motor may be excessively dirty, clean using dry,
compressed air, 30 psi (206.8 kPa) max.
6. The DT sensor may be bad.
Corrective Actions and The drive motor temperature circuit may not be functioning correctly:
Checks
• Run Test A08 - Traction Motor Temperature Voltage
PDMM-0057 6-51
Fault Codes
Code 38 - Lift Motor

Overheated
Code Title Lift Motor Overheated

Reason The temperature of the lift motor is hot enough for the Vehi-
cle Manager to prevent lift.
Response 2. Operator's Display: CODE 38...Lift motor overheated,
allow time to cool…
4. VFC Display: 38
5. Lift speed Limit: 0.0 fpm
Possible causes:
1. Check cables between:
• PT sensor and Hydraulic Driver Assembly (HDA)
• HDA and Vehicle Manager
2. The PT sensor may be bad.
3. Check for malfunction in hydraulic circuit which would cause
system to labor.
4. The lift motor may be excessively dirty; clean using dry,
compressed air, 30 psi (206.8 kPa) max.
Corrective Actions and The lift motor temperature circuit may not be functioning correctly:
Checks
• Run Test A09 - Lift Pump Motor Temp/Voltage
6-52 PDMM-0057
Fault Codes
Code 40 - B
Contactor Detected
Closed When
Commanded Open
Code Title B Contactor Detected Closed When Commanded Open

Reason The B contactor tips are closed when they should be open.
See Corrective Actions and Checks below
below.
System 1. Alarm sounds: Yes.
4. VFC Display: 40
Corrective Actions and A down-level Vehicle Manager software version exists in the truck.
Checks Contact Material Handling Associates for the current software version.
PDMM-0057 6-53
Fault Codes
Code 41 - B
Contactor Detected
Open When
Commanded Closed
Code Title B Contactor Detected Open When Commanded Closed

Reason The B contactor was found to be open when it should be
closed. See Corrective Actions and Checks below.
System 1. Alarm sounds: Yes.
4. VFC Display: 41
Corrective Actions and A down-level Vehicle Manager software version exists in the truck.
Checks Contact Material Handling Associates for the current software version.
6-54 PDMM-0057
Fault Codes
Code 42 - P
Contactor Detected
Closed When
Commanded Open
Code Title P Contactor Detected Closed When Commanded Open

Reason The P contactor is closed when it should be open.
4. VFC Display: 42
Possible causes:
1. Welded P contactor tips.
2. Defective P contactor coil.
3. Defective P contactor spring.
4. Defective P coil driver.
5. Bad contactor panel harness.
7. The pump sense circuit may be defective.
8. The Pump Sense line (JPF2-7) may be shorted to B+.
Corrective Actions and 1. The P contactor or its wiring may be defective.

Checks • Run Test O02 - Toggle the P Contactor
2. The Pump sense circuit may be defective.
• Run Test A02 - Lift Pump (P) Contactor Sense Voltage
PDMM-0057 6-55
Fault Codes
Code 43 - P
Contactor Detected
Open When
Commanded Closed
Code Title P Contactor Detected Open When Commanded Closed

Reason The P contactor is open when it should be closed.
4. VFC Display: 43
5. Lift Speed: 0.0 fpm
Possible causes:
1. Defective P coil driver.
2. Binding P contactor plunger.
3. Defective P contactor coil.
4. Defective P contactor tips.
5. Bad contactor panel harness. The wiring which controls the coil
may be bad.
7. The Pump sense circuit may be defective.
8. The power wiring to the lift motor may be open.
9. The pump sense line (JPF2-7) may be open or shorted to B-.
Corrective Actions and 1. Check for a possible blown fuse. Check:

Checks
• FU6
• Defective P coil driver
2. The P contactor or its related wiring may not be functioning
correctly.
• Run Test O02 - Toggle the P Contactor
• Run Test A02 - Lift Pump (P) Contactor Sense Voltage
6-56 PDMM-0057
Fault Codes
Code 44 - PC
Contactor Detected
Closed When
Commanded Open
Code Title PC Contactor Detected Closed When Commanded Open

Reason The PC contactor is detected closed when it should be open.
4. VFC Display: 44
5. Speed Limit: 0.0
Possible causes:
1. Defective PC coil driver.
2. Welded PC contactor tips.
3. Binding contactor plunger.
4. Defective return spring.
7. The PC Sense circuit may be defective.
8. The PC Sense line (JPF2-9) may be shorted to B+.
9. Circuitry related to the PC Sense line on either the Power Panel
Driver Assembly, distribution board, or the VFC may be bad.
Corrective Actions and The PC contactor or its related wiring may not be functioning
Checks correctly.
• Run Test O00 - Toggle the PC Contactor
• Run Test A00 - PC Contactor Sense Voltage
PDMM-0057 6-57
Fault Codes
Code 45 - PC
Contactor Detected
Open When
Commanded Closed
Code Title PC Contactor Detected Open When Commanded Closed

Reason PC contactor is open when it should be closed
System 1. Alarm sounds: YES
Response 2. Operator's Display: CODE 45...Inform Service personnel
4. VFC Display: 45
5. Speed Limit: 0.0
Possible causes:
1. Defective PC coil driver.
2. Defective PC contactor tips.
3. Binding contactor plunger.
4. Bad contactor coil.
5. Bad contactor panel harness. The wiring which controls the coil
may be bad.
6. The PC sense circuit may be defective.
7. FU8 may be bad.
8. The PC Sense line (JPF2-9) may be open or shorted to B-.
9. Circuitry related to the PC Sense line on the Power Panel Driver
Assembly may be bad,
Corrective Actions and The PC contactor or its related wiring may not be functioning
Checks correctly.
• Run Test O00 - Toggle the PC Contactor
• Run Test A00 - PC Contactor Sense Voltage
6-58 PDMM-0057
Fault Codes
Code 49 - IS
Contactor Detected
Closed When
Commanded Open
Code Title 1S Contactor Detected Closed When Commanded Open

Reason The 1S contactor is closed when it should be open.
Response 2. Operator's Display: CODE 49...Inform Service personnel
4. VFC Display: 49
5. Speed Limit: 1.0
Possible causes:
1. Defective 1S coil driver.
2. Welded 1S contactor tips.
3. Defective 1S contactor coil.
4. Defective 1S contactor spring.
6. The 1S contactor sense circuit may be defective.
7. The 1S Sense line (JPF2-6) may be shorted to B+.
8. Circuitry related to the 1S Sense line on the Power Panel Driver
Assembly may be bad.
Corrective Actions and The IS contactor or its related wiring may not be functioning correctly.
Checks
• Run Test O01 - Toggle the 1S Contactor
• Run Test A01 - 1S Contactor Sense Voltage.
PDMM-0057 6-59
Fault Codes
Code 4A - IS
Contactor Is Detected
Open When
Commanded Closed
Code Title 1S Contactor Is Detected Open When Commanded Closed

Reason The 1S contactor is open when it should be closed.
Response 2. Operator's Display: CODE 4A...Inform Service personnel
4. VFC Display: 4A
5. Speed Limit: 0.0
Possible causes:
1. Defective 1S contactor tips.
2. Binding 1S contactor plunger.
3. Bad 1S contactor coil.
4. Defective 1S coil driver.
5. Bad contactor panel harness. The wiring which controls the 1S
coil may be bad.
6. Circuitry related to the 1S contactor on either the Power Panel
Driver Assembly, Distribution Board, or the VFC may be bad.
7. The 1S Sense circuit may be defective.
8. The power wiring to the Auxiliary motor may be open.
9. The 1S Sense line (JPF2-6) may be open or shorted to B-.
10. Circuitry related to the 1S Sense line on either the Power Panel
Driver Assembly, Distribution Board, or the VFC may be bad.
Corrective Actions and 1. Check for a possible blown fuse. Check:

Checks
• FU7
• IS coil driver
2. The 1S contactor or its related wiring may not be functioning
correctly.
• Run Test O01 - Toggle the 1S Contactor
• Run Test A01 - 1S Contactor Sense Voltage.
6-60 PDMM-0057
Fault Codes
Code 6C - Main Lift

Pressure Out Of
Range
Code Title Main Lift Pressure Out of Range

Reason The Vehicle Manager has sensed hydraulic pressure
exceeding programmed limits.
Response 2. Operator's Display: CODE 6C...Inform Service Personnel
4. VFC Display: 6C
5. Lift Speed Limit: 0.0 fpm
Possible causes:
1. Check pressure sensor cable JPN9.
may be bad.
3. Pressure sensor may be defective.
5. The +12-volt power supply may be bad.
Corrective Actions and Check the pressure sensor.

Checks
• Run Test A13 - Pressure Sensor Voltage
• Run Test A14 - Power Supply +12 Voltage
PDMM-0057 6-61
Fault Codes
Code 73 - Armature
Current Sensor Out
Of Range
Code Title Armature Current Sensor Out of Range

Reason The Armature Current Sensor analog input was detected
out of range.
4. VFC Display: 73
Possible causes:
1. The cable between the CCM and Vehicle Manager may be
defective.
2. The Chopper Control Module (CCM) may be bad.
Corrective Actions and The Armature Current Sensor or its related wiring and circuitry may
Checks not be functioning correctly.
• Run Test A11 - Armature Current Sensor Voltage
6-62 PDMM-0057
Fault Codes
Code 74 - Power
Panel Temperature
Sensor Out Of Range
Code Title Power Panel Temperature Sensor Out of Range

Reason The power panel temperature sensor analog input was
detected out of range.
Response 2. Operator's Display: CODE 74...Check Battery
4. VFC Display: 74
Possible causes:
The following components could be defective:
1. Cable between the CCM and Vehicle Manager.
2. Chopper Control Module (CCM).
3. Temperature sensor (HT).
4. HT harness.
5. Power Panel Driver Assembly.
Corrective Actions and The Armature Current Sensor or its related wiring and circuitry may
• Run Test A10 - Panel Temperature Sensor Voltage
• Run Test I12 - Power Panel Temperature Limit Signal
PDMM-0057 6-63
Fault Codes
Code 75 - Diag
Sense Line Out Of
Range
Code Title Diag Sense Line Out of Range

Reason The Diag Sense line is used during manufacturing test pro-
cedures. This code should NEVER occur. If it does, contact
Material Handling Associates.
4. VFC Display: 75
Possible causes:
1. Pendant connections in Vehicle Manager may be shorted together.
Corrective Actions and The Diag Sense line (JS6-3) or its related wiring and related circuits
Checks may not be functioning properly.
• Run Test A16 - Diag Sense Voltage
6-64 PDMM-0057
Fault Codes
Code 77 - Battery
Voltage Reading Out
Of Range
Code Title Battery Voltage Reading Out of Range

Reason The battery voltage sense analog input was detected out of
range.
Response 2. Operator's Display: CODE 77...Check Battery
4. VFC Display: 77
Possible causes:
1. The battery may have just been removed from the charger. Wait a
few minutes and try again.
2. Electrolyte level in battery may be low.
4. The battery may be the wrong voltage.
Corrective Actions and The battery voltage sense line or its related wiring and circuitry may
• Run Test A15 - Battery Voltage
PDMM-0057 6-65
Fault Codes
Code 79 - +12-Volt
Sense Reading Out
Of Range
Code Title +12-Volt Sense Reading Out of Range

Reason The +12-volt sense analog input was detected out of range.
4. VFC Display: 79
Possible causes:
1. The Power Supply may be bad.
2. A 12-volt device may be shorted.
6-66 PDMM-0057
Fault Codes
Code 7B - Traction
Motor Temperature
Sensor Out Of Range
Code Title Traction Motor Temperature Sensor Out of Range

Reason The traction motor analog signal is not within programmed
limits.
Response 2. Operator's Display: CODE 7B...Inform Service Personnel
4. VFC Display: 7B
Possible Causes:
1. Check sensor cable (JPN10) and JPM.
2. Check cable from Hydraulic Driver Assembly to Vehicle Manager.
3. The temperature sensor may be bad.
4. The Hydraulic Driver Assembly may be bad.
5. The pressure transducer may be shorted (36 volt only)
Corrective Actions and The traction motor temperature sensor or its related wiring and
Checks circuitry may not be functioning correctly.
• Run Test A08 - Traction Motor Temperature Voltage
NOTE: If the Vehicle Manager is found to be bad, check the wire
harness and pressure transducer for a short circuit (36 volt
only). Failure to do so may cause the new Vehicle Manager to
go bad.
PDMM-0057 6-67
Fault Codes
Code 7C - Lift Motor

Temperature Out Of
Range
Code Title Lift Motor Temperature Out of Range

Reason The lift motor analog signal is not within programmed lim-
its.
Response 2. Operator's Display: CODE 7C...Inform Service Personnel
4. VFC Display: 7C
5. Lift Speed Limit: 0.0 fpm
Possible Causes:
1. Check sensor cable (JPN11) and JPZ.
2. Check cable from Hydraulic Driver Assembly to Vehicle Manager.
3. The temperature sensor may be bad.
4. The Hydraulic Driver Assembly may be bad.
6-68 PDMM-0057
Fault Codes
Code 7E - Field
Current Reading Out
Of Range
Code Title Field Current Reading Out of Range

Reason The analog signal from the H-Bridge Assembly is not cor-
rect.
Response 2. Operator's Display: CODE 7E...Inform Service Personnel
4. VFC Display: 7E
5. Speed Limit: 0.0 fpm
Possible Causes:
1. Check cable from Vehicle Manager to H-Bridge Module (JPS2 to
JPH2).
2. Check cable from H-Bridge Module to Field Wiring Assembly
(JPH1 to JPD1).
3. The Field Wiring Assembly may be bad.
4. The H-Bridge Module may be bad.
Corrective Actions and The field current sense line or its related circuitry may not be
Checks functioning correctly.
Run Test:
PDMM-0057 6-69
Fault Codes
Code 80 - Throttle
Controller Reading
Out Of Range
Code Title Throttle Controller Reading Out of Range

Reason The throttle pot analog input was detected below 0.156 volts
or above 4.844 volts.
4. VFC Display: 80
How to The key switch must be cycled OFF/ON to clear this fault.
Clear
Possible Causes:
1. Learn Mode may need to be run.
2. Potentiometer VR1 may be bad.
3. Check cable JPS4, JPC1.
Corrective Actions and The throttle pot sense line or its related wiring and circuitry may not
Checks be functioning correctly.
Run Test:
• A04 - Throttle Pot Voltage
• A14 - Power Supply +12 Voltage
6-70 PDMM-0057
Fault Codes
Code 84 - Brake
Inoperable Or Not
Properly Adjusted
Code Title Brake Inoperable or Not Properly Adjusted. See Warning Below.
Reason The restraining ability of the brake is checked every time the
truck is powered up. The encoder reading is recorded, Q1 is
briefly pulsed, and the encoder is read again. If the motor
rotates more than 1.5 degrees, this code is displayed.
4. VFC Display: 84
Clear
Possible Causes:
1. Ensure that the deadman pedal is released during SelfTest.
2. The brake may be loose. Adjust brake per Chapter 5.
3. The encoder mounting or coupling may be loose. Inspect and
4. Loss of deadman switch signal while traveling. Check switch
adjustment and harness connections.
! WARNING
Operators should test brakes as part of their daily
inspection of the truck, (refer to Chapter 5). Do not rely
solely upon brake testing feature of selftest. Complete all
items on the operator's checklist at the start of each shift.
! WARNING
Brakes require periodic maintenance (refer to Chapter 5).
Do not rely upon this selftest of the brakes as a substitute
for proper periodic maintenance.
Corrective Actions and There may be a problem in drive motor encoder circuit.
Checks
PDMM-0057 6-71
Fault Codes
Code 85 - Remote NOTE: This code should only apply to vehicles with remote lift/lower
Lower Reading Out Of option.
Range
Code Title Remote Lower Reading Out of Range

Reason During remote lower, the voltage levels were not within pro-
grammed limits.
4. VFC Display: 85
Clear
Possible Causes:
1. Resistor R2 may be bad.
2. Check cable between Hydraulic Driver Assembly and Vehicle
Manager.
4. Reach solenoid may be bad.
Corrective Actions and There may be a problem in drive motor encoder circuit.
Checks
• Run Test A07 -Display Remote Lower Sense Voltage
6-72 PDMM-0057
Fault Codes
Code 86 - Remote This code should only apply to vehicles with remote lift/lower option.
Lift Reading Out Of
Range
Code Title Remote Lift Reading Out of Range

Reason During remote lift, the voltage levels were not within pro-
grammed limits.
4. VFC Display: 86
Clear
Possible Causes:
1. Resistor R3 may be bad.
2. Check cable between Hydraulic Driver Assembly and Vehicle
Manager.
4. Sideshift solenoid may be bad.
Corrective Actions and There may be a problem in the remote lift circuit.
Checks
• Run Test A06 - Display Remote Lift Sense Voltage
PDMM-0057 6-73
Fault Codes
Code 87 - Release
Throttle To Resume
Operation
Code Title Release Throttle To Resume Operation

Reason Travel control out of neutral before deadman depressed.
Response 2. Operator's Display: CODE 87...Release throttle to
resume operation
4. VFC Display: 87
How to Clear Depress deadman pedal before moving the throttle.
Corrective Actions and None.

Checks
NOTE: Excessive play in the handle could prevent the vehicle from
returning to its learned neutral position.
Code 88 - Lift Bypass Switch Activated
Code Title Lift Bypass Switch Activated

Reason Optional lift cutout switch has been activated
Response 2. Operator's Display: CODE 88...Press lift bypass switch to
continue lifting
4. VFC Display: 88
5. Lift Speed Limit: 0.0 mph
How to Clear Press lift bypass switch to continue lifting.
Corrective Actions and None.

Checks
6-74 PDMM-0057
Fault Codes
Code A0 - Software
Does Not Match
Vehicle Setup
Code Title Software Does Not Match Vehicle Setup

Reason The model number stored in the VFC's EPROM is not the
same as the model number stored in the Operator's Display
EPROM.
Response 2. Operator's Display: CODE A0...Inform Service Personnel
3. VFC Display: A0
Corrective Actions and 1. Wrong EPROM is installed in the VFC (i.e., ORDERPICKER
Checks firmware installed in REACH vehicle).
2. The Operator's Display memory is bad. See NOTES.
NOTE: Requires special procedures; contact Material Handling
Associates.
NOTE: None of the program modes (Maintenance, Learn, or Config)
can be entered until this code is cleared.
PDMM-0057 6-75
Fault Codes
Code A1 -
Uninitialized
Operator's Display
Code Title Uninitialized Operator's Display

Reason When an ODI is built, a location in its memory is set to
indicate that it is brand new. When the ODI is installed in
the vehicle at the factory, it is configured to reflect the
options purchased. When the ODI is configured, the new
memory location is cleared.
During power-up, this code is reported if the ODI's new

location is set.
3. VFC Display: A1
Corrective Actions and 1. The static strap may be bad.

Checks
2. The factory configuration program has not been run.
3. A field-installed option was not installed properly.
4. The Operator's Display is bad. See NOTES.
NOTE: Requires special procedures, contact Material Handling
Associates.
6-76 PDMM-0057
Fault Codes
Code A2 - New VFC

Installed
Code Title New VFC Installed

Reason This code indicates that the start-up procedure detected a
VFC which was never calibrated. This code should never be
detected in normal operation.

3. VFC Display: A2
Corrective Actions and 1. Install a replacement VFC. The VFC must be sent back to Material
Checks Handling Associates for re-calibration before it can be re-used.
See NOTE.
PDMM-0057 6-77
Fault Codes
Code A3 - EPROM
Failure Or Computer
Not Enabled
Code Title EPROM Failure or Computer Not Enabled

Reason This code indicates that the start-up procedure detected a
EPROM failure or the VFC which did not have the Com-
puter is not operating properly. This check is run before
the contactor test is started.
This code should never be detected in normal operation.

3. VFC Display: A3
5. Brake Activated: Yes
Corrective Actions and 1. Install a replacement EPROM. If this does not correct the problem
Checks then replace the VFC. The VFC must be sent back to Material
Handling Associates for refurbishing before it can be re-used.
6-78 PDMM-0057
Fault Codes
Code A4 - COP
Timeout
Code Title COP Timeout

Reason This code indicates that the COP on the VFC has timed out.
This code should never be detected in normal operation.
3. VFC Display: A4
5. Brake Activated: Yes
Corrective Actions and 1. Check vehicle static straps and circuitry.

Checks 2. Use D-cat, version 2.8 or above to resolve code. See “Supplement -
Dealer/Technician Configuration Program: User Instructions” on
page 7-3.
PDMM-0057 6-79
Fault Codes
Code EC - Operating
System Error
Code Title Operating System Error

Reason EPROM/Software failed/EPROM or RAM has bad locations.
Response 2. VFC Display: EC

Corrective Actions and 1. Install a replacement EPROM. If this does not correct the problem
Checks then replace the VFC. The VFC must be sent back to the Material
Handling Associates for refurbishing before it can be re-used.
Code ED - ODI Communications Failed
Code Title ODI Communications Failed

Reason The VFC communicates with the ODI to store information
such as Time On Deadman, etc. This occurs during power-
up, and once for every hour on the deadman after that.
Response 2. VFC Display: ED

Corrective Actions and 1. The cable from the Operator's Display may not be properly
Checks connected to the Vehicle Manager at JPS8.
2. The cable to the Operator's Display may not be properly
connected to the ODI at JPI.
3. The cable between the Operator's Display and Vehicle Manager
may be damaged.
4. The Operator's Display is bad. See NOTE.
NOTE: Requires special procedures; contact Material Handling
Associates.
6-80 PDMM-0057
Fault Codes
Code EF - Bad ODI

Checksum
Code Title Bad ODI Checksum

Reason The integrity of the information stored in the ODI is verified
using a checksum.
Response 2. Operator's Display: CODE EF...Inform Service Personnel
3. VFC Display: EF

Corrective Actions and 1. Noise on the communication line to the Operator's Display. The
Checks probability of this happening is very low. Restart the vehicle and
see if that clears the code.
2. The Operator's Display is bad, and must be replaced. See NOTE.
NOTE: Requires special procedures, contact Material Handling
Associates.
3. A field retro-fitted option was not installed properly.
PDMM-0057 6-81
Analog Test Summary
Analog Test The following pages contain a summary of the analog input tests.
Summary NOTE: These tests were performed on a 36-volt truck.
Test Setup and Result (What will be on

Test Description of Test
Conditions the Operator’s Display)
A00 PC Contactor Sense Volt- PC Contactor Open 0.0 - 0.5 V
age PC Contactor Approx. System Volt-
Closed (Manually) age (Aux pump runs)
A01 1S Contactor Sense Volt- PC Contactor Open 0.0 - 0.5 V
age PC Contactor Approx. System Volt-
Closed (Manually) age (Aux pump runs)
A02 Lift Pump (P) Contactor P Contactor Open 0.0 - 0.5 V
Sense Voltage P Contactor Approx. System Volt-
(Hold PC Contactor in) Closed (Manually) age (Lift Pump Runs)
(See WARNING below)
! WARNING
When performing test A02, forks may elevate. Keep clear of forks!
A04 Throttle Pot Voltage (VR1) Throttle Position:
Full Forks First 2.75 - 4.50 V
Neutral 2.0 - 3.0 V
Full Tractor First 0.5 - 1.75 V
A06 Display Remote Lift Sense Lift Buttons Not Battery Voltage
Voltage Depressed
Both Buttons Battery Voltage
Depressed minus 4.5
A07 Display Remote Lower Lower Buttons Not Battery Voltage
Sense Voltage Depressed
Both Buttons Battery Voltage
Depressed minus 4.5
A08 Traction Motor Tempera- Traction Motor
ture Voltage Case Temp.: 3.0 - 4.0 V
Room Tempera-
ture 4.0 - 4.5 V
Normal Opera-
tion 4.5- 4.62 V
Hot (Speed Lim-
ited) 4.62 - 5.2 V
Overheated
(or JPN10 Dis-
connected)
6-82 PDMM-0057
Analog Test Summary
A09 Lift Motor Temperature Lift Motor Case

Temp.:
Room Tempera- 3.5 - 4.0 V
ture
Normal Opera- 4.0 - 5.65 V
tion
Overheated 5.65 - 5.05 V
(or JPN-11 Discon-
nected)
A10 Power Panel Temperature Heat Sink Temp.:
Sensor Voltage Room Tempera- 3.5 - 4.0 V
ture
Normal Opera- 4.0 - 4.7 V
tion
Hot (Speed Lim- 4.85 - 5.7 V
ited) or…
JPT1 Discon- 5.65 - 6.05 V
nected
A11 Armature Current Sensor All Cables Con- 5.5 - 6.5 V
Voltage nected
JPS1 Disconnected 0.0 - 0.5 V
A12 Field Current Sensor Volt- All Cables Con- 5.5 - 6.5 V
age nected
JPS2 Disconnected 0.0 - 0.5 V
A13 Pressure Sensor Voltage All Connected 0.7 - 1.5 V
JPN9 Disconnected 0.0 - 05 V
A14 Power Supply +12 Voltage Vehicle at Rest 11.5 - 12.5 V
A15 Battery Voltage Vehicle at Rest Battery voltage
A16 Diagnostic Sense Voltage Vehicle at Rest 9.0 - 11.0V
No Pendant Con-
nected
A18 Remote Lift/Lower Key switch not in 0.0 - 1.0V
Remote
Key switch in Battery voltage
Remote
PDMM-0057 6-83
Analog Tests
Analog Tests The following tests check all analog signal functions.
! CAUTION
Connect test meter properly before testing.
Test: A00 - PC
Contactor Sense
Voltage
Related Codes and Tests Code 44 - PC Contactor Detected Closed When Commanded Open
Code 45 - PC Contactor Detected Open When Commanded Closed
Test O00 - Toggle the PC Contactor
For information on how to use maintenance mode, refer to Chapter 3.
Expected Results The PC sense line monitors the voltage on the B+ side of the Field
Wiring Assembly.
1. Manually press and hold the PC contactor tips closed.
2. The Operator's Display will display voltage which the Vehicle
Manager reads from the Armature sense line. The auxiliary pump
should run.
3. The test is a success if the voltage displayed is within these limits:
PC Contactor Voltage Displayed

Approximately
Closed
system voltage
Open 0.0 - 0.5
• If the reading is outside of these limits, then the test is a

failure.
• If the reading fluctuates by more than 0.5 volts in 10 seconds,
then the test is a failure.
Possible causes of test failure:
1. FU8 may be blown.
2. PC contactor tips may be bad.
3. The battery may be the wrong voltage, or it may be discharged or
defective. Check each cell using a voltmeter and hydrometer.
4. The wiring for the PC sense circuit may be bad. Check wires from
TP7 to JPF2-9, JPF3-15 to JPS10-15.
5. The Power Panel Driver Assembly may be bad. Check for
continuity between JF2-9 and JF3-15.
NOTE: After replacing boards, be sure to run Learn Mode before
re-running the test.
6-84 PDMM-0057
Analog Tests
Test: A01 - 1S This test displays the voltage that the Vehicle Manager is reading from
Contactor Sense the PC contactor sense line.
Voltage ! CAUTION
Related Codes and Tests Code 49 - 1S Contactor Detected Closed When Commanded Open
Code 4A - 1S Contactor Is Detected Open When Commanded Closed
Test O01 - Toggle the 1S contactor
NOTE: The 1S sense line monitors the voltage across R1. It is used as
a double check on the correct operation of the 1S contactor.
Expected Results The Operator's Display will display the voltage which the Vehicle
Manager reads from the 1S sense line.
1. Manually press and hold the 1S contactor tips closed (if not
already closed).
NOTE: Make sure the PC contactor is engaged.
1S Contactor Voltage Displayed

Closed Approximately
system voltage
Open 0.0 - 0.5

failure.
1. Fuse FU5 may be blown.
2. PC contactor tips may be bad.
4. The wiring for the 1S sense circuit may be bad. Check wires from
1S-1 to JPF2-6, JPF3-12 to JPS10-12.
continuity between JPF2-6 and JPF3-12.
NOTE: After replacing the Vehicle Manager, be sure to run Learn Mode
before re-running the test.
PDMM-0057 6-85
Analog Tests
Test: A02 - Lift This test displays the voltage that the Vehicle Manager is reading from
Pump (P) the pump sense line.
Contactor Sense
! CAUTION
Voltage Connect test meter properly before testing.
Related Codes and Tests Code 42 - P Contactor Detected Closed When Commanded Open
Code 43 - P Contactor Detected Open When Commanded Closed
Test O02 - Toggle the P Contactor
Expected Results The pump sense line monitors the voltage between the pump
contactor and the pump motor. It is used to verify correct operation of
the P contactor, and to determine when the pump motor stops
spinning by measuring its EMF.
1. Manually press and hold the lift pump contactor and PC
contactor tips closed. See WARNING.
! WARNING
Keep clear, the mast might elevate as soon as the contactor
tips are closed!
2. The Operator's Display will display the voltage which the Vehicle
Manager reads from the pump sense line.
Lift Pump Contactor Voltage Displayed

Approximately
Closed
system voltage
Open 0.0 - 0.5

failure.
1. Fuse FU6 may be blown.
2. P contactor tips may be bad.
4. The wiring for the P sense circuit may be bad. Check wires from
TP3 to JPF2-7, JPF3-13 to JPS10-13.
6-86 PDMM-0057
Analog Tests

continuity between JPF2-7 and JPF3-13.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
PDMM-0057 6-87
Analog Tests
Test: A04 - Throttle This test displays the voltage that the Vehicle Manager reads from the
Pot Voltage throttle pot (VR1).
! CAUTION
Related Codes and Tests Code 80 - Throttle Controller Reading Out of Range
NOTE: Learn mode should be run whenever the throttle assembly is
replaced, repaired or adjusted.
Expected Results The Operator's Display will show the voltage which the Vehicle
Manager reads from the throttle pot (VR1).
Throttle Position Voltage Displayed

Full Forks First 2.75 - 4.75
Neutral 2.0 - 3.0
Full Tractor First 0.5 - 1.75
• If the voltage is outside of these limits, then the test is a

failure.
• While using this test, move the control handle slowly. Observe
the reading on the Operator’s Display. The numbers should
increase/decrease in a smooth, progressive manner. If the
reading jumps out of sequence, this would indicate a defective
potentiometer.
• It is possible to have a defective potentiometer that passes this
test. The reason is that during “run” mode, the pot is
“sampled” at a rate faster than the values are displayed for this
test. If the potentiometer is still thought to be defective,
disconnect from the circuit and check with an ohmmeter.
1. The throttle pot (VR1) or wiring between the pot and the
Distribution Board may be defective.
2. The cable between VR1 and the Vehicle Manager (JPS4) may be
defective or loose. Trace and verify wiring continuity.
3. The mechanical portion of the controller may be defective,
allowing the potentiometer to move further than its design
parameter.
6-88 PDMM-0057
Analog Tests
Test A06 - Display This test displays the voltage that the Vehicle Manager is reading
Remote Lift Sense when both remote lift switches (S16/S17) are pressed. A successful
test proves that the Vehicle Manager is properly reading the remote lift
Voltage inputs.
! CAUTION
Related Codes and Tests Code 86 - Remote Lift Reading Out of Range
Expected Results The ODI will display the voltage which the Vehicle Manager reads from
TS19-2.
1. Press and hold in the PC contactor tips. The test is a success if
voltage displayed is as shown in the table below:
Remote
Voltage Displayed (With Voltage Displayed (Without
Lower S16/
Sideshift) Sideshift)
S17
Approx. 9.0 volts less
Open Battery Voltage
than battery voltage
Both Closed Approx. 4.0 volts less
Less than 5 volts
(Pressed) than battery voltage
• If the reading fluctuates by more than 0.25 volts in 10

seconds, then the test is a failure.
1. Check the wiring over the mast for continuity.
2. This test will fail if the sideshift solenoid is open or shorted. Test
sideshift solenoid coil.
3. Resistor R3 may be defective. The resistance of resistor R3 should
be approximately 150 ohms.
4. Diode assembly DA1 may be defective. Replace DA1 and test
again.
PDMM-0057 6-89
Analog Tests
Test A07 - Display This test displays the voltage that the Vehicle Manager is reading
Remote Lower when both remote lower switches (S14/S15) are pressed. A successful
test proves that the Vehicle Manager is properly reading the remote
Sense Voltage lower inputs.
! CAUTION
Related Codes and Tests Code 85 - Remote Lower Reading Out Of Range
TS19-3.
1. Press and hold in the PC contactor tips. The test is a success if
voltage displayed is as shown in the table below:
Voltage Displayed Voltage Displayed

Remote Lower S14/S15
(With Sideshift) (Without Sideshift)
Approx. 9.0 volts
Open Battery Voltage less than battery
voltage
Approx. 4.0 volts
Both Closed (Pressed) less than battery Less than 5 volts
voltage
• If the reading fluctuates by more than 0.25 volts in 10

seconds, then the test is a failure.
1. Check the wiring over the mast for continuity.
2. This test will fail if the reach solenoid is open or shorted. Test
reach solenoid coil.
3. Resistor R2 may be defective. The resistance of resistor R2 should
be approximately 150 ohms.
running the test.
6-90 PDMM-0057
Analog Tests
Test: A08 - This test displays the voltage that the Vehicle Manager is reading from
Traction Motor the drive motor temperature sensor (DT) that is threaded into the
drive motor housing.
Temperature
Voltage ! CAUTION
Related Codes and Tests Code 11 - Drive motor temperature HOT

Code 34 - Drive Motor Overheated
Code 7B - Traction Motor Temperature Sensor Out Of Range
NOTE: While operating, the Vehicle Manager continually monitors the
temperature of the drive motor. If the temperature gets too
high, the maximum speed limit will be reduced until the motor
cools down.
NOTE: In order to see a range of voltage (temperature) values, heat the
truck up by driving it hard for 30 minutes, and then run this
test. The heat sink cools quite rapidly, and a significant change
will be seen within 5 minutes.
Manager reads from the drive motor temperature sensor.
Heat Sink Block Voltage Displayed

Cold; Room temperature 3.0 - 4.0
Normal operation 4.0 - 4.5
Hot; Speed Limited 4.5 - 4.62
Overheated 4.62 - 5.2
JPN10 Disconnected 0.00
• A successful test proves that the Vehicle Manager is properly

reading the drive motor temperature sensor.
failure.
then the test is a failure. If the truck had just been operated
aggressively just prior to this test, the reading will drop fairly
quickly before leveling off.
PDMM-0057 6-91
Analog Tests
Test: A08 - Possible causes of test failure:

Traction Motor 1. The drive motor temperature sensor may be defective, or the
Temperature wiring between the sensor (DT) and the Hydraulic Driver
Assembly (JPHD5) may be bad. The sensor can be checked as
(cont’d) follows:
a. Unplug JPN10 from the Hydraulic Driver Assembly.
b. Using a digital meter, measure the resistance between the
leads from the JPN10-3 to JPN10-2, (Polarity does not matter).
The resistance should be approximately 2000 ohms at 68o F
(20° C).
c. The sensor can be further checked by removing it from the
heat sink. While watching the digital meter, cup your hands
around the sensor and breathe directly on it with a steady, hot
breath. The resistance should increase by about 20 ohms.
! CAUTION
Do not use a heat gun, lighter, or other source of strong
heat for this test, as this may damage the sensor.
2. The cable between the Vehicle Manager and the Hydraulic Driver
Assembly may be defective.
a. Check for continuity between JPS9-24 on the VFC to JPN14-
24 on the Hydraulic Driver Assembly.
3. The Hydraulic Driver Assembly may not be functioning correctly.
Replace with a known good unit, and re-run the test.
NOTE: After replacing boards, be sure to run Learn Mode BEFORE re-
running the test.
6-92 PDMM-0057
Analog Tests
Test: A09 - Lift This test displays the voltage that the Vehicle Manager is reading from
Pump Motor the temperature sensor (PT) that is threaded into the lift pump motor
housing.
Temp/Voltage
NOTE: No temperature sensor on 24-volt trucks.
! CAUTION
Related Codes and Tests Code 12 - Lift Motor Temperature HOT

Code 38 - Lift Motor Overheated
Code 7C - Lift Motor Temperature Out of Range
temperature of the lift pump motor. If the temperature gets too
high, maximum lift speed limit will be reduced until the motor
cools down.
truck up by lifting maximum loads for 30 minutes, and then
run this test. The heat sink cools quite rapidly, and a
significant change will be seen within five minutes.
Manager reads from the temperature sensor on the lift pump motor.
Motor Temperature Voltage Displayed

Cold; Room tempera-
3.0 - 4.0
ture
Hot; Speed Limited 4.5 - 4.62
Overheated 4.62 - 5.2
JPN11 Disconnected 0.00

reading the lift pump motor temperature sensor.
failure.
PDMM-0057 6-93
Analog Tests
Test: A09 - Lift Possible causes of test failure:

Pump Motor 1. The sensor may be defective, or the wiring between the sensor (PT)
Temp/Voltage and the Hydraulic Driver Assembly (JPN11) may be bad. The
sensor can be checked as follows:
(Cont’d)
a. Unplug JPN11 from the Hydraulic Driver Assembly.
leads from the sensor at JPN11-2 and JPN11-3, (Polarity does
not matter). The resistance should be approximately 2000
ohms at 68o F (20° C).
c. The sensor can be further checked by removing it from the
heat sink. While watching the digital meter, cup your hands
around the sensor and breathe directly on it with a steady, hot
breath. The resistance should increase by about 20 ohms.
! CAUTION
heat for this test, as this may damage the sensor.
2. The cable between the Hydraulic Driver Assembly and the VFC
may be defective.
a. Check for continuity between JPS9-23 on the VFC to JPN14-
23 on the Hydraulic Driver Assembly.
3. The Hydraulic Driver Assembly may be not be functioning
correctly. Replace with a known good unit, and re-run the test.
running the test.
6-94 PDMM-0057
Analog Tests
Test: A10 - Panel This test displays the voltage that the Vehicle Manager is reading from
Temperature the temperature sensor (HT) located on the Power Transistor heat
sink.
Sensor Voltage
! CAUTION
Related Codes and Tests Code 13 - Power Panel Temperature HOT

Code 22 - Power Panel Overheated
Code 74 - Power Panel Temperature Sensor Out of Range
temperature of the heatsink. If the temperature gets too high,
the maximum speed limit will be reduced until the heatsink
cools down.
truck up by driving it hard for 30 minutes, and then run this
test. The heat sink cools quite rapidly, and a significant change
will be seen within 5 minutes.
Manager reads from the Power Panel temperature sensor (HT).
Power Panel Temperature Voltage Displayed

Room temperature 3.5 - 4.0
Hot (Speed Limited) 4.85 - 5.7
Overheated
9 -12
(JPT1 disconnected)
• Turn power off before disconnecting JPT1.

reading the temperature sensor.
failure.
PDMM-0057 6-95
Analog Tests
Test: A10 - Panel Possible causes of test failure:

Temperature 1. The sensor may be defective, or the wiring between HT and the
Sensor Voltage Chopper Module at JPT1 may be bad. The PTC can be checked
as follows:
(Cont’d)
a. Unplug JPT1 from the Chopper Module.
leads of HT from at JPT1-7 and JPT1-10, (Polarity does not
matter). The resistance should be approximately 2000 ohms at
68° F (20° C).
c. HT can be further checked by removing it from the heat sink.
While watching the digital meter, cup your hands around the
sensor and breathe directly on it with a steady, hot breath. The
resistance should increase by about 20 ohms.
! CAUTION
heat for this test, as this may damage the PTC.
2. The cable between the CCM and the Vehicle Manager (JPT2-9/
JPS1-9) may be defective or loose. Check for continuity.
3. The CCM may be not be functioning correctly. Replace with a
known good CCM, and re-run the test.
running the test.
6-96 PDMM-0057
Analog Tests
Test: A11 - This test displays the voltage which is read from the current sensor
Armature Current “donut” on the CCM.
Sensor Voltage ! CAUTION

Related Codes and Tests Code 23 - Open Detected In Armature Circuit

Code 24 - Armature Current Sensor Circuit Not Responding
Code 73 - Armature Current Sensor Out of Range
NOTE: The current sensor continually monitors the current flowing
through the Power Transistor (Q1). The Vehicle Manager
constantly monitors this current, and adjusts its performance
accordingly.
NOTE: The current sensor is dynamically tested for proper operation
by SELF TEST every time the key switch is turned ON. While
monitoring the current sensor, the Vehicle Manager sends a
brief pulse of current through the Power Transistor (Q1).
NOTE: The CCM will automatically limit the maximum current
through the Power Transistor. Whenever the CCM is in current
limit, the green LED will be on. It is normal for the CCM to go
into current limit, particularly when accelerating. The CCM's
current limit threshold is preset at the factory and is not
adjustable.
Manager reads from the current sensor.
System Condition Voltage Displayed

All cables connected 5.5 - 6.5
JPS1 disconnected 0.0 - 0.5
• The test is a success if the voltage is between 5.5 and 6.5 volts.
The reading should remain steady, and should not fluctuate
by more than 0.02 volts. If this is not observed, then the test
is a failure.
1. The cable between the CCM and the Vehicle Manager may be
loose or defective. Check for continuity.
2. The CCM may be bad. Replace with a known good CCM and re-
run this test.
running the test.
PDMM-0057 6-97
Analog Tests
Test A12 - Field This test displays the voltage which is read from the current sensor
Current Sensor “donut” on the HCM.
Voltage ! CAUTION
Related Codes and Tests Code 25 - Short Detected In Field Circuit

Code 26 - Open Detected In Field Circuit
Code 27 - Field Current Sensor Circuits Not Responding Properly
NOTE: The current sensor continually monitors the current flowing
through Power Transistors TM1 and TM2 in the Field Wiring
Assembly (FW). The Vehicle Manager constantly monitors this
current, and adjusts its performance accordingly.
NOTE: The current sensor is dynamically tested for proper operation
by SelfTest every time the key is turned on. While monitoring
the current sensor, the Vehicle Manager sends a brief pulse of
current through transistors TM1 and TM2.
NOTE: The HCM will automatically limit the maximum current
through TM1 and TM2. Whenever the HCM is in current limit,
the green LED will be on. It is normal for the HCM to go into
current limit, particularly when accelerating. The HCM's
current limit threshold is preset at the factory and is not
adjustable.
Manager reads from the current sensor.

All cables connected 5.5 - 6.5
JPS2 disconnected 0.0 - 0.5
• The test is a success if the voltage is between 5.5 and 6.5 volts.
The reading should remain steady, and should not fluctuate
by more than 0.02 volts. If this is not observed, then the test is
a failure.
1. The cable between the HCM and the Vehicle Manager may be
loose or defective. Check for continuity.
2. The HCM may be bad. Replace with a known good HCM and re-
run this test.
running the test.
6-98 PDMM-0057
Analog Tests
Test A13 - Pressure This test displays the voltage which the Vehicle Manager is reading
Sensor Voltage from the pressure sensor on the hydraulic lift control manifold. A
successful test proves that the VFC is properly reading the input from
the pressure sensor.
NOTE: No pressure sensor on 24-volt trucks.
! CAUTION
Connect test meter before testing.
! CAUTION
Before starting this test, ensure that there is not a load on
the forks. Elevate the forks approximately one foot off the
floor.
Related Codes and Tests Code 6C - Main Lift Pressure Out Of Range
Expected Results The ODI will show the voltage which the Vehicle Manager reads from
the pressure sensor.
1. With the carriage empty, the reading on the Operator's Display
should be 1.0 - 1.5 volts.

Carriage empty Cables con-
2.0 - 3.5
nected
JPN9 disconnected 0.0 - 0.5
NOTE: The voltage displayed will depend on the position of the forks. If
the forks are resting on the floor and pressure is relieved, the
voltage displayed will be lower. If the forks are elevated off the
floor the voltage will be higher. Deep-reach carriages will
display slightly higher voltages.
2. While still in test A13, use another lift truck to place a load (1000
lbs min.) on the forks. If another truck is not available, record the
voltage displayed, exit test, place load on forks (one foot off floor),
and run test again.
3. The voltage on the Operator's Display should increase with a load
on the forks.
4. The test is a success if the voltage increases as weight is added to
the forks.
5. If the voltage does not increase, this test is a failure.
PDMM-0057 6-99
Analog Tests
1. If the voltage does not increase as weight is added to the forks

then the pressure transducer is probably defective.
2. If a voltage is not displayed, then check the following:
3. Check for continuity between Hydraulic Driver Assembly (JPN9)
and the pressure transducer.
4. Check for continuity between Hydraulic Driver Assembly (JPN14-
25) and Vehicle Manager (JPS9-25).
5. The Hydraulic Driver Assembly may be defective. Replace with a
known good unit and run test again.
running the test.
6-100 PDMM-0057
Analog Tests
Test A14 - Power This test displays the voltage that the Vehicle Manager is reading from
Supply +12 the +12 volt power supply. A successful test proves that the power
supply and Vehicle Manager are working properly.
Voltage
! CAUTION
Related Codes and Tests Code 79 - +12-Volt Sense Reading Out Of Range
Expected Results The ODI will show the voltage which the Vehicle Manager reads +12
volt power supply.

Vehicle at rest 11.5 - 12.5


1. The power supply may be defective
running the test.
PDMM-0057 6-101
Analog Tests
Test A15 - Battery This test displays the voltage that the Vehicle Manager is reading from
Voltage the battery sense line. A successful test proves that the Vehicle
Manager is properly reading the battery sense line.
! CAUTION
Related Codes and Tests Code 77 - Battery Voltage Reading Out Of Range
NOTE: This voltage is the voltage which the VM uses when calculating
the battery state of charge.
the Battery sense line.
NOTE: If the reading fluctuates by more than 0.8 volts in 10 seconds,

1. If the displayed voltage is steady but out of range, then check the
battery voltage using a voltmeter.
2. The wiring between the Power Panel Driver Assembly and the
Vehicle Manager may be loose or intermittent.
running the test.
6-102 PDMM-0057
Analog Tests
Test A16 - Diag This test displays the voltage that the Vehicle Manager is reading from
Sense Voltage the Diag Sense line. A successful test proves that the Vehicle Manager
is properly reading the JPS6-3 line.
NOTE: JPS6-3 is used for manufacturing test procedures. This test
allows the voltage on the line to be displayed.
! CAUTION
Related Codes and Tests None.

Expected Results With no remote device attached to the vehicle the voltage on the
Operator's Display should be greater than 10 volts. If the reading
fluctuates by more than 0.25 volts in 10 seconds, then the test is a
failure.
PDMM-0057 6-103
Analog Tests
Test A18 - Remote For trucks with remote lift/lower, this test displays the position of key
Lift/Lower switch S1, as seen by the Vehicle Manager.
Related Codes and Tests None

Expected Results The display will show the position of key switch (S1):
Key Switch Position Operator’s Display

Remote Battery Voltage
Normal 0.0 - 1.0 volt
• If this is not observed, then the test is a failure.

1. The “Remote” segment of key switch (S1) may be defective.
2. The wiring between S1 and the Power Panel Driver Assembly may
be defective.
6-104 PDMM-0057
Analog Tests
Digital Input Test Summary
Result (What will be on

Test Description of Test Test Setup and Conditions the Operator’s
Display?)
Digital Input Tests
I00 Deadman switch (S2) Deadman pedal raised. (Switch Up
open) Down (Beep...Beep)
Deadman pedal depressed. (Switch
closed)
I01 Remote EPO (S18) or Button raised, (Switch closed) Up
Unnested Switch (S19) Button pressed (Switch open) Down (Beep...Beep)
I02 Mast Switch #1 (S10) Mast above activation point. (Switch In
open) Out (Beep...Beep)
Mast below activation point (Switch
closed)
I03 Mast Switch #2 (S11) Mast above activation point. (Switch In
open) Out (Beep...Beep)
Mast below activation point. (Switch
closed)
I04 Lift inhibit bypass Switch open Off
switch (S12) Switch closed On (Beep...Beep)
I05 Lift inhibit mast switch Mast above activation point. (Switch In
(S13) open) Out (Beep...Beep)
Mast below activation point. (Switch
closed)
I06 Reach Switch (S4) Button not pressed. (Switch open) Out
Button pressed. (Switch closed) In (Beep...Beep)
I07 Retract Switch (S5) Button not pressed. (Switch open) Out
Button pressed. (Switch closed) In (Beep...Beep)
I08 Tilt Up Switch (S6) Disk not pressed. (Switch open) Up
Bottom edge of disk pressed. Down (Beep...Beep)
(Switch closed)
I09 Tilt Down Switch (S7) Disk not pressed. (Switch open) Up
Top edge of disk pressed). (Switch Down (Beep...Beep)
closed)
I10 Sideshift right switch Disk not pressed. (Switch open) Up
(S9) Right edge of disk pressed. (Switch Down (Beep...Beep)
closed)
I11 Sideshift left switch Disk not pressed. (Switch open) Up
Left edge of disk pressed. (Switch Down (Beep...Beep)
closed)
PDMM-0057 6-105
Analog Tests
Result (What will be on

Test Description of Test Test Setup and Conditions the Operator’s
Display?)
I12 Power panel temp. limit Truck operational, (Non-limited con- No (Red CCM LED
signal dition). Off)
Limit activated. (Limited condition - Yes (Red CCM LED
activate by disconnecting JPT1 from ON Beep...Beep)
CCM)
I13 Armature current limit Truck operational, (Non-limited con- No
signal dition). Yes (Beep...Beep)
JPT2 disconnected from CCM;
jumper JPT2-2 to JPT2-7. (Limited
condition)
I14 Field current limit sig- Truck operational, (Non-limited con- No
nal dition) Yes (Beep...Beep)
JPH2 disconnected from HCM;
jumper
JPH2-2 tp JPH2-7. (Limited condi-
tion)
I15 Horn Button (S3) Button not pressed. (Switch open) Off
Button pressed. (Switch closed) On (Beep...Beep)
I16 Encoder Count Remove drive belt from encoder. NNN (Where NNN
is 000 to 255)
Turn Encoder by hand CW (Viewed Count decreases,
from top) starts over every
1/4 turn.
Count increases,
Turn Encoder CCW (Viewed from starts over every
top) 1/4 turn.
I17 Lift Switch (S20) & Control in neutral Blank
Lower Switch (S21) Sta-
tus Control moved to lift UP (Beep...Beep)
Control moved to lower DOWN(Beep...Beep

)
The table above contains a summary of all digital input tests.
! CAUTION
6-106 PDMM-0057
Digital Input Tests
Digital Input The following tests check all digital input signal functions.
Tests
Test I00 - Using this test, the state of the deadman switch can be monitored.
Deadman Switch This test will show what the Vehicle Manager is reading from the
switch. A successful test proves that the Vehicle Manager is correctly
reading the deadman switch.
The deadman switch is closed (activated) when the deadman pedal is
depressed. The deadman signal is routed to the Vehicle Manager at
JPN14 on the Hydraulic Driver Assembly. No travel can occur unless
the deadman is activated.
! CAUTION

Expected Results The display will show the state of the switch:
Deadman Pedal
Audible Alarm Operator’s Display
Position
Depressed Sounding Down
Extended Off Up
If this is not observed, then the test is a failure.

1. The harness from the switch may not be properly plugged into the
Hydraulic Driver Assembly at JPN6. Inspect and verify the
connection.
2. The switch may not be operating correctly electrically. Disconnect
JPN6 from the Hydraulic Driver Assembly. Connect an ohmmeter
to the harness side of JPN6-2 between JPN6-3. The following
should be observed:
PDMM-0057 6-107
Digital Input Tests
Deadman
Switch Resistance
Switch
Down Depressed Less than one ohm
Up Extended More than two megohms
If this is not observed, troubleshoot the switch and cable.

3. The switch may not be properly adjusted. See “Brake Assembly
and Pedal Adjustment” on page 5-60.
known good unit and retest.
running the test.
6-108 PDMM-0057
Digital Input Tests
Test I01 - Remote This applies only to vehicles with remote lift and/or unnested switch
EPO and/or option. Using this test, the state of the remote EPO switch (S18) can
be monitored. This test will show what the Vehicle Manager is reading
Unnested Switch from the switch.
! CAUTION
The E-stop switch electrically removes power so that motion of the

vehicle is stopped. The E-stop switch does not, however, remove power
from the Vehicle Manager. The Vehicle Manager monitors the state of
the E-stop switch. This test displays what the Vehicle Manager reads
from the E-stop switch.
When the E-stop button is up, the switch contacts are closed. When
the E-stop button is pushed down, the switch contacts are opened.
Related Codes and Tests Code 83 - Emergency Power Off Switch Detected Down
Remote EPO Audible Operator’s

Unnested Switch
(S18) Alarm Display
Raised Raised Off Up
Pressed Pressed Sounding Down
Open Raised Sounding Down
Open Pressed Sounding Down

1. Remote EPO switch (S18) or nested switch (S19) may be defective
or wired incorrectly. Check operation of switch and verify wiring
connections.
2. Verify wiring between S18-1 to TS19-6 and S18-2 to TS19-4 (B-).
3. Check the wiring between Hydraulic Driver Assembly (JPN14-16)
and the VFC (JPS9-16).
known good assembly and retest.
running the test.
PDMM-0057 6-109
Digital Input Tests
Test I02 - Mast This test applies only to vehicle which have the single-mast switch
Switch #1 option (S10).
Using this test, the state of mast switch #1 (S10) can be monitored.
This test will show what the Vehicle Manager is reading from the
switch.

Audible Operator’s
Fork Position Mast Switch #1
Alarm Display
Raised Open Sounding Out
Lowered Closed Off In
To test the other state of the switch, exit maintenance mode, elevate
the mast above switch #1 and run this test again.
1. Mast switch #1 (S10) may be defective or wired incorrectly. Check
operation of switch and verify wiring connections.
2. The wiring from S10 to JPN7 on the Hydraulic Driver Assembly
may be defective.
3. The wiring from the Hydraulic Driver Assembly JPN14-1 to the
Vehicle Manager JPS9-1 may be defective. Repair/replace as
required.
running the test.
6-110 PDMM-0057
Digital Input Tests
Test I03 - Mast This test applies only to vehicle which have the two-mast switch
Switch #2 option (S10/S11).
Using this test, the state of mast switch #2 (S11) can be monitored.
This test will show what the Vehicle Manager is reading from the
switch.

Operator’s
Fork Position Mast Switch #2 Audible Alarm
Display
Raised Open Sounding Out
Lowered Closed Off In

• To test the other state of the switch, exit maintenance mode,
elevate the mast above switch #2 (S11) and run this test again.

1. Mast switch #2 (S11) may be defective or wired incorrectly. Check
operation of switch and verify wiring connections.
may be defective.
required.
running the test.
PDMM-0057 6-111
Digital Input Tests
Test I04 - Lift This test applies only to vehicles equipped with lift inhibit bypass
Bypass Switch option.
For trucks with lift bypass, this test displays the position of S12 as
seen by the Vehicle Manager.
Related Codes and Tests Test I05 - Lift Inhibit Mast Switch
Expected Results The display will show position of lift bypass switch S12:
Switch S12
Alarm Display
Open Off Off
Closed Sounding On

1. Switch S12 may be defective or wired incorrectly. Check operation
of switch and verify wiring connections.
may be defective.
required.
running the test.
6-112 PDMM-0057
Digital Input Tests
Test I05 - Lift This test applies only to vehicles equipped with lift inhibit bypass
Inhibit Mast option. Using this test, the position of switch S13 as seen by the
Vehicle Manager is displayed.
Switch
Related Codes and Tests Test I04 - Lift Bypass Switch

Operator’s
Switch S13 Audible Alarm
Display
Open Sounding Out
Closed Off In

1. Switch S13 may be defective or wired incorrectly. Check operation
of switch and verify wiring connections.
may be defective.
required.
running the test.
PDMM-0057 6-113
Digital Input Tests
Test I06 - Reach Using this test, the state of the reach switch (S4) can be monitored.
Switch This test will show what the Vehicle Manager is reading from the
switch.
! CAUTION

Reach Button
Alarm Display
Pressed Sounding In
Not Pressed Off Out

Vehicle Manager at JPS4. Inspect and verify the connection.
JPS4 from the Vehicle Manager. Connect an ohmmeter to the
harness side of JPS4 between JPS4-8 and JPS4-10. The following
should be observed:
Reach Button Resistance

Extended More than two Megohms
Depressed Less than one ohm
• If this is not observed, troubleshoot the switch and harness.
running the test.
6-114 PDMM-0057
Digital Input Tests
Test I07 - Retract Using this test, the state of the retract switch (S5) can be monitored.
switch.
! CAUTION
Connect test meter properly before testing

Operator’s
Retract Button Audible Alarm
Display
Depressed Sounding In
Not Depressed Off Out

should be observed:
Retract Button Resistance

running the test.
PDMM-0057 6-115
Digital Input Tests
Test I08 - Tilt-Up Using this test, the state of the tilt-up switch (S6) can be monitored.
switch.
! CAUTION

Enter test with horn button.
Operator’s
Tilt-Up Button Audible Alarm
Display
Not Pressed Off Up
Pressed Sounding Down

should be observed:
Tilt-Up Button Resistance

Pressed Less than one ohm
running the test.
6-116 PDMM-0057
Digital Input Tests
Test I09 - Tilt- Using this test, the state of the tilt-down switch (S7) can be
Down Switch monitored. This test will show what the Vehicle Manager is reading
from the switch.
! CAUTION

Operator’s
Tilt-Down Button Audible Alarm
Display
Not Pressed Off Up

should be observed:
Tilt-Down Button Resistance

Pressed Less than one ohm
• If this is not observed, troubleshoot the switch and

harness.
running the test.
PDMM-0057 6-117
Digital Input Tests
Test I10 - Sideshift- Using this test, the state of the sideshift-right switch (S9) can be
Right Switch monitored. This test will show what the Vehicle Manager is reading
from the switch.
! CAUTION

Sideshift-Right Button
Alarm Display
Not Pressed Off Up

should be observed:
Sideshift-Right Button Resistance

running the test.
6-118 PDMM-0057
Digital Input Tests
Test I11- Sideshift- Using this test, the state of the sideshift-left switch (S8) can be
Left Switch monitored. This test will show what the Vehicle Manager is reading
from the switch.
! CAUTION

Operator’s
Sideshift-Left Button Audible Alarm
Display
Not Depressed Off Up
Depressed Sounding Down

should be observed:
Sideshift-Left
Resistance
Button
More than two Mego-
Extended
hms
running the test.
PDMM-0057 6-119
Digital Input Tests
Test I12 - Power Using this test, the temperature limit signal from the CCM can be
Panel Temperature monitored. A successful test proves that the Vehicle Manager is
correctly reading the temperature limit signal.
Limit Signal
! CAUTION
Related Codes and Tests Code 22 - Power Panel Overheated

Test A10 - Panel Temperature Sensor Voltage
NOTE: The CCM sends two indications of power panel temperature to
the Vehicle Manager: an analog “temperature sense” signal,
and a digital “temperature limit” signal.
This test allows the temperature limit signal to be checked.
See Test A10 - Panel Temperature Sensor Voltage to check the
temperature sense signal.
The temperature limit signal is activated by the CCM whenever the
power panel is overheated. When this happens, the CCM will light the
red LED to indicate overheating, and Code 22 - Power Panel
Overheated, will be displayed.
Expected Results With the system operational, the display should show “NO.” If “YES” is
displayed, the test is a failure.
NOTE: Turn power OFF before disconnecting JPT1.
The temperature limit signal can be activated by unplugging
JPT1 (i.e., by causing an open in the HT circuit).
• The display should now show “YES.” If this is not observed,
• The red LED on the CCM should also be on. If this is not
observed, then the CCM may be bad.
• Reconnect JPT1.
1. Ensure cables are properly connected at:
• CCM (JPT2)
• Vehicle Manager (JPS1)
• CCM (JPT1)
2. Using an ohmmeter, verify continuity between:
• JPT2 and JPS1
• HT and JPT1
3. The CCM may be bad. Replace with a known good unit, and re-
run this test.
4. After running test again, if the display shows “YES.” the HT
sensor may be bad. Replace the HT and run test again.
6-120 PDMM-0057
Digital Input Tests
running the test.
PDMM-0057 6-121
Digital Input Tests
Test I13 - Using this test, the current limit signal from the CCM can be
Armature Current monitored. A successful test proves that the Vehicle Manager is
correctly reading the armature current limit signal.
Limit Signal
! CAUTION
Related Codes and Tests Code 24 - Armature Current Sensor Circuit Not Responding.
Test A11 - Armature Current Sensor Voltage
NOTE: The CCM sends two indications of transistor current to the
Vehicle Manager:
• Analog “current sense” signal
• Digital “current limit” signal
This test allows the current limit signal to be checked.
• See Test A11 - Armature Current Sensor Voltage to check
the current sense signal.
The current limit signal is activated by the CCM whenever the
transistor current is exceeded. The green LED on the CCM will
be illuminated whenever the current limit signal is active.
Expected Results The display should show “NO.” If “YES” is displayed, the test is a
failure.
NOTE: Turn power OFF before disconnecting JPT2.
Grounding the signal will activate it. To test:
a. Unplug JPT2 from the CCM.
b. Carefully connect a jumper between JPT2-2 and JPT2-7.
c. The display should now show “YES.” If this is not observed,
d. Reconnect cable at JPT2.
Pin 2
Pin 7
Figure 6-9: Pinout for JPT2
6-122 PDMM-0057
Digital Input Tests

1. The cable from the CCM may not be properly plugged into the
Vehicle Manager at JPS1, or the cable may be bad. Using an
ohmmeter, verify continuity of all conductors between JPT2 and
JPS1.
2. If the green LED is on when running this test, then the CCM is
bad. Replace with a known good unit, and re-run this test.
3. The CCM may be bad. Replace with a known good unit, and re-
run this test.
running the test.
PDMM-0057 6-123
Digital Input Tests
Test I14 - Field Using this test, the current limit signal from the HCM can be
Current Limit monitored. A successful test proves that the Vehicle Manager is
correctly reading the field current limit signal.
Signal
! CAUTION
Related Codes and Tests Code 27 - Field Current Sensor Circuits Not Responding.
Test A12 - Field Current Sensor Voltage
NOTE: The HCM sends two indications of transistor current to the
Vehicle Manager:
• Analog “current sense” signal
• Digital “current limit” signal
This test allows the current limit signal to be checked.
• See Test A12 - Field Current Sensor Voltage to check the
current sense signal.
The current limit signal is activated by the HCM whenever the
transistor current is exceeded. The green LED on the HCM will
be illuminated whenever the current limit signal is active
(exceeded).
Expected Results The display should show “NO.” If “YES” is displayed, the test is a
failure.
NOTE: Turn power OFF before disconnecting JPH2.
Grounding the signal will activate it. To test:
a. Unplug JPH2 from the HCM.
b. Carefully connect a jumper between JPH2-2 and JPH2-7.
Looking at the end of the cable:
c. The display should now show “YES.” If this is not observed,
d. Reconnect cable at JPH2.
Pin 2
Pin 7
Figure 6-10: Pinout for JPH2
6-124 PDMM-0057
Digital Input Tests

1. The cable from the HCM may not be properly plugged into the
Vehicle Manager at JPS2, or the cable may be bad. Using an
ohmmeter, verify continuity of all conductors between JPH2 and
JPS2.
2. If the green LED is on when running this test, then the HCM is
bad. Replace with a known good unit, and re-run this test.
3. The HCM may be bad. Replace with a known good unit, and re-
run this test.
running the test.
PDMM-0057 6-125
Digital Input Tests
Test I15 - Horn This test verifies that the horn button and input to the Vehicle
Button Manager works correctly.
Related Codes and Tests None

Expected Results
Horn Switch Operator's Display

Not Pressed Out
Pressed In
• If this is not observed, the test is a failure.

1. The cable between the horn switch (S3) and the Vehicle Manager
may be disconnected or defective.
2. The horn switch (S3) may be defective.
6-126 PDMM-0057
Digital Input Tests
Test I16 - Encoder Using this test, the encoder, driven by the traction motor, can be
Count monitored. A successful test proves that the Vehicle Manager is
reading the encoder correctly.
! CAUTION
Related Codes and Tests Code 30 - Excessive Acceleration

Code 32 - No Movement Detected When Travel is Requested
Code 84 - Brake Inoperable Or Not Properly Adjusted
NOTE: The Drive Motor Encoder (DE) provides speed and direction
input to the Vehicle Manager. While traveling, the Vehicle
Manager uses this information to decide how to pulse the
Power Transistor (Q1).
This test shows the value read from the encoder. The displayed
value will range between 0 - 255.
Turning the encoder by hand counterclockwise (when viewed
from above) will cause the count to increase. This indicates a
tractor first direction. Turning the encoder clockwise will cause
the count to decrease.
In order to freely turn the encoder during this test, remove the
drive belt.
Expected Results 1. The display will show the encoder count.

2. Remove the drive belt which turns the encoder.
3. Manually turning the encoder clockwise should cause the count
shown on the display to decrease; counter-clockwise should
increase the count. If this is not observed, then the test is a
failure. If the display counts down to 0, it resets to 255 and
continues counting down. Likewise, if the display counts up to
255, it resets to 0 and continues to count up.
4. When finished, reattach drive belt.
1. The cable from the encoder may not be properly plugged into the
Vehicle Manager at JPS12.
2. The drive belt for the encoder may be loose or defective. Inspect
and troubleshoot accordingly.
3. The encoder may be bad. Replace with a known good encoder, and
re-run the test.
PDMM-0057 6-127
Digital Input Tests
4. The 5.0-volt section of the power supply may be bad. Open the
Vehicle Manager and connect a voltmeter to these test points on
the power supply:
• Positive lead to TP5 (+5V).
• Negative lead to TP6 (B-).
If the voltmeter does not read between 4.90 - 5.10 volts, replace the
power supply.
running the test.
6-128 PDMM-0057
Digital Input Tests
Test I17- Lift This test displays the state of the lift switch (S20) and lower switch
Switch & Lower (S21).
Switch Status
! CAUTION
Related Codes and Tests Code 42 - P Contactor Detected Closed When Commanded Open
Expected Results 1. The display will show the state of S20/S21:

• With the control in neutral the display will be blank and no
alarm will sound.
• When the control is moved to lift, the display will show “UP”
and the alarm will beep.
• When the control is moved to lower, the display will show
“DOWN” and the alarm will beep.
If this is not observed, the test is a failure.
Possible Causes of Test Failure:
1. Wiring between S20/S21 and Vehicle Manager may be
disconnected or defective.
2. S20/S21 may be misadjusted or defective.
3. The encoder may be bad. Replace with a known good encoder, and
re-run the test.
4. The 5.0-volt section of the power supply may be bad. Open the
Vehicle Manager and connect a voltmeter to these test points on
the power supply:
• positive lead to TP5 (+5V)
• negative lead to TP6 (B-)
If the voltmeter does not read between 4.90 - 5.10 volts, replace the
power supply.
running the test.
PDMM-0057 6-129
Digital Output Test Summary
Digital The following table contains a summary of all digital output tests.
Output Test
Summary
Result
Test Setup and Conditions
Test Description of Test (What
hat will be on the
(if required)
Operator's Display)
O00 Toggle the PC Contactor PC closed (Pump starts) On
PC open Off
O01 Toggle the IS Contactor 1S closed On
1S open Off
O02 Toggle the P Contactor P closed On
P open Off
O04 Toggle DIRA Solenoid Ammeter in series with DIRA. On (0.5 to 1.0 amp)
(+) to DIRA-1; (-) to wire removed from DIRA-1 Off (0.0 to 0.02 amp)
O05 Toggle DIRB Solenoid Ammeter in series with DIRB. On (0.5 to 1.0 amp)
(+) to DIRB-1; (-) to wire removed from DIRB-1 Off (0.0 to 0.02 amp)
O06 Toggle Reach Solenoid Ammeter in series with TS19-3 on HDA. On ( 0.25 to 0.75 amp)
(+) to wire removed from TS21-3. (-) to terminal TS21- Off (0.0 to 0.02 amp)
3.
O07 Toggle Tilt Solenoid Ammeter in series with TS19-1 on HDA. On (0.25 to 0.75 amp)
(+) to wire removed from TS21-1. (-) to terminal TS21- Off (0.0 to 0.02 amp)
1.
O08 Toggle Sideshift Ammeter in series with TS19-2 on HDA. On ( 0.25 to 0.75 amp)
Solenoid (+) to wire removed from TS21-2. (-) to terminal TS21- Off (0.0 to 0.02 amp)
2.
O09 Toggle Equalizing Ammeter in series with EQ. On (0.5 to 1.0 amp)
Solenoid (+) to EQ-1; (-) to wire removed from EQ-1 Off (0.0 to 0.02 amp)
O10 Toggle 2nd Stage Ammeter in series with 2ND. On (0.5 to 1.0 amp)
Solenoid (+) to 2ND-1; (-) to wire removed from 2ND-1 Off (0.0 to 0.02 amp)
O11 Toggle Load-Holding Ammeter in series with L/H. On (0.5 to 1.0 amp)
Solenoid (+) to L/H-1; (-) to wire removed from L/H-1 Off (0.0 to 0.02 amp)
O13 CCM Enable Signal Voltmeter connected to cable end: On (10.5 to 12.5 volts
JPT2-6 (+), JPT2-1 (-) Off (0.0 to 0.5 volts)
O14 Ramp PWM to CCM and Voltmeter connected across Q1 with all wires Ramp (Voltage ramps from B+
Q1 connected. (+) to Q1-c, (-) to TP4. to B+ minus 6.0 volts)
Off (B+)
O15 HCM Forward Enable Voltmeter connected to cable end. JPH2-6 (+), JPH2- On (10.5 to 12.5 volts)
Test 1 (-) Off (0.0 to 0.5 volts)
O16 HCM Reverse Enable Voltmeter connected to cable end. JPH2-6 (+), JPH2- On (10.5 to 12.5 volts)
Test 5 (-) Off (0.0 to 0.5 volts)
O17 Ramp PWM to HCM and Voltmeter connected across motor terminals with all Ramp (Voltage ramps from 0.0
field windings cables connected. (+) MD-S1, (-) MD-S2 to approx. +/- 31 volts
Off (0.0 to approx. +/- 1 volt)
O18 Toggle Horn Voltmeter connected across H1 On (battery voltage, horn
sounds) Off (0.00 volts)
O19 Audible Alarm Test None Ramp (Pitch ramps up)
Off (No sound)
O20 Forward Relay Test None On (Relay energized - Closed)
Off (Relay de-energized - Open)
O21 Reverse Relay Test None On (Relay energized - Closed)
Off (Relay de-energized - Open)
6-130 PDMM-0057
Digital Output Test Summary
! CAUTION
PDMM-0057 6-131
Digital Output Tests
Digital NOTE: For all output tests:

Output Tests • Enter the test using the horn button
• Perform the test using the tilt switch
The following tests check all digital output signal functions.
Test O00 - Toggle Using this test, the PC contactor can be turned off and on, verifying
the PC Contactor its correct operation. A successful test proves that the wiring and
related circuitry in the Vehicle Manager, Power Panel Driver Assembly,
and PC coil driver are all functioning correctly. A successful test also
proves that the PC contactor's coil is functioning.
! CAUTION
Related Codes Code 44 - PC Contactor Detected Closed When Commanded Open

and Tests
Code 45 - PC Contactor Detected Open When Commanded Closed
Test A00 - PC Contactor Sense Voltage
NOTE: The PC contactor is usually closed during SelfTest, and is
opened only when an error occurs, or when one of the special
programming modes (Learn Mode, Configure Mode, or
Maintenance Mode) is entered. The PC provides a secondary
means to turn off the traction and lift systems.
Expected Results
PC Contactor Operator's Display

Closed On
Open Off
• The test is a success if the PC contactor tracks the On/Off

shown on the display. If this is not observed, then the test
is a failure.

1. The coil driver may be bad. Replace it with a known good coil
driver and re-run the test. If the test passes, replace the bad coil
driver.
2. The plunger in the PC contactor may be binding or not operating
correctly. Visually inspect for proper operation:
a. Check the contactor tips for signs of welding.
6-132 PDMM-0057
b. Check that the return spring is functioning correctly.
3. The PC contactor's coil circuit may be open. Check as follows:

a. Turn off power.
b. Unplug JPF2 from the Power Panel Driver Assembly.
c. Using an ohmmeter, measure across harness between JPF2-3
and JPF2-5.
d. If the resistance is less than 10 ohms or more than 75 ohms,
then there is a problem in the contactor coil circuit.
Troubleshoot the contactor coil and its associated wiring.
4. The Power Panel Driver Assembly may be defective. Replace with a
known good unit and rerun this test.
running the test.
PDMM-0057 6-133
Test O01 - Toggle NOTE: Enter and exit test with horn button.
the 1S Contactor Using this test, the 1S contactor can be turned off and on, verifying its
correct operation. A successful test proves that the wiring and related
circuitry in the VFC, Vehicle Manager, Power Panel Driver Assembly,
and 1S coil driver are all functioning correctly. A successful test also
proves that the 1S contactor's coil is functioning.
! CAUTION
Related Codes Test A01 -1S Contactor Sense Voltage

and Tests Code 49 -1S Contactor Detected Closed When Commanded Open
Code 4A - 1S Contactor Is Detected Open When Commanded Closed
Expected Results
1S Contactor Operator's Display

Closed On
Open Off
The test is a success if the 1S contactor tracks the On/Off shown on

the display. If this is not observed, then the test is a failure.

1. The coil driver may be bad. Replace it with a known good coil
driver.
2. The plunger in the 1S contactor may be binding or not operating
3. There may be an open in the 1S contactor's coil circuit. Check as
follows:
a. Turn off power.
and JPF2-5.
e. Troubleshoot the contactor coil and associated wiring.
6-134 PDMM-0057

running the test.
PDMM-0057 6-135
Test O02 - Toggle Using this test, the P contactor can be turned off and on, verifying its
the P Contactor correct operation.
A successful test proves that the wiring and related circuitry in the
Vehicle Manager, Power Panel Driver Assembly, and P coil driver are
all functioning correctly. A successful test also proves that the P
contactor's coil is functioning, that the Pump Sense circuit is working
correctly, and that the SOL1 circuit is operational.
! CAUTION
Related Codes Test A02 - Lift Pump (P) Contactor Sense Voltage
and Tests Code 42 - P Contactor Detected Closed When Commanded Open
! CAUTION
Turning the P contactor on will start the lift pump. The
carriage should not raise because this test also opens the
proportional solenoid SOL1. If, however, there is a fault in
SOL1, the carriage may elevate. To safeguard against
unexpected carriage motion, ensure nobody is near the load
handler before entering this test.
Expected Results
P Contactor Operator's Display

Closed On
Open Off
The test is a success if the P contactor tracks the On/Off shown on

the display. If this is not observed, then the test is a failure.
NOTE: The PC contactor will open before the P contactor closes. If the
PC sense line is open, the P contactor will not close and this
test will hang. The only way out is to turn the key switch OFF.
Repair the PC sense line and run this test again.
6-136 PDMM-0057
1. The P coil driver may be bad. Replace it with a known good coil
driver.
2. The plunger in the P contactor may be binding or not operating
3. There may be an open in the P contactor's coil circuit. Check as
follows:
a. Turn off power.
and JPF2-5.
Troubleshoot the contactor coil and
associated wiring.
running the test.
PDMM-0057 6-137
Test O04 - Toggle Using this test, DIRA solenoid can be turned off and on, verifying its
Solenoid DIRA correct operation.
VFC, Vehicle Manager, Hydraulic Driver Assembly, and DIRA coil
driver are all functioning correctly. It also proves that DIRA and its
harness are electrically functional.
! CAUTION
Related Codes None

and Tests
Procedure Connect an ammeter in series with DIRA as follows:

• Positive (+) to DIRA-1 terminal
• Negative (-) to wire remove from DIRA-1
Expected Results
DIRA Operator's
Ammeter Reading
Solenoid Display
Open 0.5 - 1.0 amp On
Closed 0.0 - 0.02 amp Off
If this is not observed, then the test is a failure. Otherwise the test is a
failure.
• Reconnect wire at DIRA-1.
1. There may be an open or short in DIRA's coil or associated wiring.
Check as follows:
a. Turn off power.
b. Unplug JPN1 from the Hydraulic Driver Assembly.
c. Using an ohmmeter, measure across harness between JPN1-1
and JPN1-8.
then there is a problem in the DIRA coil circuit. Troubleshoot
the solenoid coil and its associated wiring.
e. Reconnect JPN1.
f. Check for continuity between JPS9-21 on the Vehicle Manager
and JPN14-21 on the Hydraulic Driver Assembly.
6-138 PDMM-0057
2. The DIRA coil driver may be bad. Replace it with a known good
coil driver and re-run the test. If the test passes, replace the bad
coil driver.
known good unit and test again.
running the test.
4. There may be a hydraulic problem in the valve portion of DIRA
which is preventing it from operating properly. Investigate and
PDMM-0057 6-139
Solenoid DIRB Using this test, DIRB solenoid can be turned off and on, verifying its
correct operation.
Vehicle Manager, Hydraulic Driver Assembly, and DIRB coil driver are
all functioning correctly. It also proves that DIRB and its harness are
electrically functional.
! CAUTION
Related Codes Test O00 - Toggle the PC Contactor

and Tests
Procedure 1. Disconnect wire form DIRB.

2. Connect an ammeter in series with DIRB as follows:
• Positive (+) to DIRB-1 terminal
• Negative (-) to wire removed from DIRB-1
Expected Results
DIRB Ammeter
Operator's Display
Solenoid Reading
0.0 - 0.02
Closed Off
amp
If this is not observed, then the test is a failure. Reconnect wire at

DIRB-1.

1. There may be an open or short in DIRB's coil or associated wiring.
Check as follows:
a. Turn off power.
and JPN1-9.
then there is a problem in the DIRB coil circuit. Troubleshoot
e. Reconnect JPN1.
6-140 PDMM-0057
f. Check for continuity between JPS9-7 on the Vehicle Manager

2. The DIRB coil driver may be bad. Replace it with a known good
coil driver.
running the test.
4. There may be a hydraulic problem in the valve portion of DIRB
PDMM-0057 6-141
Reach Solenoid Using this test, the Reach solenoid can be turned off and on, verifying
its correct operation.
Vehicle Manager, Hydraulic Driver Assembly, and reach coil driver are
all functioning correctly. It also proves that the reach solenoid and its
! CAUTION
Related Codes None

and Tests
Procedure 1. Disconnect wire from TS19-3 on the Hydraulic Driver Assembly.

2. Connect an ammeter in series with Reach solenoid as follows:
• Positive (+) to wire removed from TS19-3
• Negative (-) to terminal TS19-3
Expected Results
Reach Ammeter
Operator's Display
Solenoid Reading
0.25 - 0.75
Open On
amp
0.0 - 0.02
Closed Off
amp
failure.
• Reconnect wire to TS19-3.
1. There may be an open or short in the Reach coil or associated
wiring. Check as follows:
a. Turn off power.
b. Using an ohmmeter, measure across harness between TS19-5
and TS19-3.
c. If the resistance is less than 10 ohms or more than 75 ohms,
then there is a problem in the Reach coil circuit. Troubleshoot
d. Check for continuity between JPS9-17 on the Vehicle Manager
6-142 PDMM-0057
2. The reach coil driver may be bad. Replace it with a known good
coil driver.
running the test.
4. There may be a hydraulic problem in the valve portion of the
reach solenoid which is preventing it from operating properly.
Investigate and troubleshoot accordingly.
PDMM-0057 6-143
Tilt Solenoid Using this test, the tilt solenoid can be turned off and on, verifying its
correct operation.
Vehicle Manager, Hydraulic Driver Assembly, and tilt coil driver are all
functioning correctly. It also proves that the tilt solenoid and its
! CAUTION
Related Codes None

and Tests

2. Connect an ammeter in series with tilt solenoid as follows:
Expected Results
Tilt Operator's
Ammeter Reading
Solenoid Display
Open 0.25 - 0.75 amp On
failure.

1. There may be an open or short in the tilt coil or associated wiring.
Check as follows:
a. Turn off power.
and TS19-1.
then there is a problem in the tilt coil circuit. Troubleshoot the
solenoid coil and its associated wiring.
6-144 PDMM-0057

2. The tilt coil driver may be bad. Replace it with a known good coil
driver.
running the test.
PDMM-0057 6-145
Sideshift Solenoid Using this test, the sideshift solenoid can be turned off and on,
verifying its correct operation.
Vehicle Manager, Hydraulic Driver Assembly, and sideshift coil driver
are all functioning correctly. It also proves that the reach solenoid and
its harness are electrically functional.
! CAUTION
Related Codes None

and Tests

2. Connect an ammeter in series with tilt solenoid as follows:
Expected Results
Sideshift Operator's
Ammeter Reading
Solenoid Display
Open 0.25 - 0.75 amp On
failure.

1. There may be an open or short in the sideshift coil or associated
wiring. Check as follows:
a. Turn off power.
and TS19-2.
then there is a problem in the Tilt coil circuit. Troubleshoot
6-146 PDMM-0057
2. The sideshift coil driver may be bad. Replace it with a known good
coil driver.
NOTE: After replacing boards, be sure to run Learn Mode
before re-running the test.
PDMM-0057 6-147
Equalizing Using this test, the equalizing solenoid (E/Q) can be turned off and
Solenoid (E/Q) on, verifying its correct operation.
Vehicle Manager, Hydraulic Driver Assembly, and E/Q coil driver are
all functioning correctly. It also proves that E/Q and its harness are
electrically functional.
! CAUTION
Related Codes None

and Tests
Procedure 1. Disconnect wire from equalizing solenoid EQ-1.

2. Connect an ammeter in series with EQ solenoid as follows:
• Positive (+) to terminal of EQ-1
• Negative (-) to wire removed from EQ-1
Expected Results
Equalizing Operator's
Ammeter Reading
Solenoid Display
failure.
• Reconnect wire to EQ-1.

1. There may be an open or short in the E/Q coil. Check as follows:
a. Turn off power.
and JPN1-7.
then there is a problem in the E/Q coil circuit. Troubleshoot
e. Reconnect JPN1.
6-148 PDMM-0057
2. The E/Q coil driver may be bad. Replace it with a known good
coil driver.
running the test.
4. There may be a hydraulic problem in the valve portion of E/Q
PDMM-0057 6-149
2ND-Stage Using this test, the 2ND-stage solenoid can be turned off and on,
Solenoid verifying its correct operation.
Vehicle Manager, Hydraulic Driver Assembly, and 2ND solenoid coil
driver are all functioning correctly. It also proves that 2ND solenoid
and its harness are electrically functional.
! CAUTION
Related Codes Test O00 - Toggle the PC Contactor

and Tests
Procedure 1. Disconnect wire from second stage solenoid 2ND-1.

2. Connect an ammeter in series with 2ND solenoid as follows:
• Positive (+) to terminal of 2ND-1
• Negative (-) to wire removed from 2ND-1
Expected Results
Equalizing Operator's
Ammeter Reading
Solenoid Display
failure.
• Reconnect wire to 2ND-1.
1. There may be an open or short in the 2ND solenoid coil. Check as
follows:
a. Turn off power.
and JPN1-6.
then there is a problem in the E/Q coil circuit. Troubleshoot
e. Reconnect JPN1.
6-150 PDMM-0057
2. The 2ND coil driver may be bad. Replace it with a known good
coil driver.
running the test.
4. There may be a hydraulic problem in the valve portion of 2ND
solenoid which is preventing it from operating properly.
PDMM-0057 6-151
Load-Holding Using this test, load-holding solenoid (L/H) can be turned off and on,
Solenoid verifying its correct operation.
Vehicle Manager, Hydraulic Driver Assembly, and L/H coil driver are
all functioning correctly. It also proves that L/H solenoid and its
! CAUTION
Related Codes Test O12 - Proportional Solenoid PWM Ramp.

and Tests Test O02 - Toggle the P Contactor
Test O00 - Toggle the PC Contactor
NOTE: L/H is the load-holding solenoid in the lift/lower manifold. It is

energized to open and allow hydraulic fluid to flow out of the
lift cylinders. See Chapter 4 for more information about the
hydraulic theory of operation.
NOTE: Turning L/H ON should not cause the carriage to lower since
the proportional lift/lower valve should be closed. If, however,
there is a fault in the lift/lower circuit or a fault in the
proportional solenoid itself, the carriage may lower. To guard
against unexpected motion of the carriage, fully lower the
carriage before entering this test.
Procedure 1. Disconnect wire from load-holding solenoid L/H-1.

2. Connect an ammeter in series with L/H solenoid as follows:
• Positive (+) to terminal of L/H-1
• Negative (-) to wire removed from L/H-1
Expected Results
L/H Operator's
Ammeter Reading
Solenoid Display
failure
• Reconnect wire to L/H-1
6-152 PDMM-0057

1. There may be an open or short in the L/H coil. Check as follows:
a. Turn off power.
and JPN1-5.
then there is a problem in the L/H coil circuit. Troubleshoot
e. Reconnect JPN1.
2. The L/H coil driver may be bad. Replace it with a known good coil
driver.
running the test.
4. There may be a hydraulic problem in the valve portion of L/H
PDMM-0057 6-153
Test O13 - Using this test, proper operation of the Chopper Control Module
Chopper Control (CCM) enable signal can be verified.
Module Enable A successful test proves that the wiring and related circuitry in the
Vehicle Manager and distribution board are all functioning properly.
Signal
Related Codes Test O14 - Chopper Control Module PWM Test

and Tests
NOTE: Turn off power before unplugging connectors.
NOTE: This test will toggle the enable signal from the Vehicle Manager
on and off. The enable signal “enables” the CCM to pulse the
Power Transistor (Q1). If the CCM is not enabled, it can’t pass
pulses from the Vehicle Manager on to the transistor.
During normal operation, the enable signal is activated
whenever the Vehicle Manager is pulsing the Power Transistor
(Q1).
This test only checks the enable signal from the Vehicle
Manager is actually arriving at the input to the CCM. Test O14
- Chopper Control Module PWM must be run in order to verify
that the CCM is correctly enabling its output.
JPT2-1 (-)
JPT2-6 (+)
Figure 6-11: Pinout for JPT2
Procedure 1. Disconnect the cable from JPT2, and connect a voltmeter to the
cable between JPT2-6 (+ lead) and JPT2-1 (- lead).
The voltmeter should display the following:
On 10.5 - 12.5 volts
Off 0.0 - 0.5 volts
If this is not observed, then the test is a failure.

Possible causes of failure:
Check for continuity on all lines.
6-154 PDMM-0057
running the test.
JPH2-5 (-)
JPH2-6 (+)
Figure 6-12: Pinout for JPH2 - Reverse HCM Enable
PDMM-0057 6-155
Test O14 - Using this test, proper operation of the Pulse Width Modulation (PWM)
Chopper Control to the Power Transistor (Q1) can be verified.
Module PWM Test NOTE: For information on how to use maintenance mode, refer to
Chapter 3.
VFC, distribution board, and CCM are all functioning properly.
Related Codes Test O13 - CCM Enable Signal

and Tests
NOTE: This test will ramp a signal to the Chopper Control Module
(CCM). A voltmeter is used to measure the resulting signal.
During this test, the field is not powered up, so the truck
should not move. If, however, there is a fault in the traction
motor circuit, the traction motor may start. To guard against
unexpected movement of the truck, elevate the drive tire off the
floor before entering this test.
NOTE: The CCM enable signal is also activated during this test, so
that the CCM can pulse the base of Q1.
Procedure 1. Elevate the drive tire off the floor. See WARNING.
! WARNING
Use jack stands or solid blocks to support truck - do not
rely on jacks.
Procedure 1. Connect a voltmeter across power transistor Q1 as follows:

• Positive (+) to Q1-C
• Negative (-) to TP4
2. If system voltage is not present, check drive fuse (FU5) and
related connections.
Expected Results
Voltmeter Reading Operator's Display

B+ to B+ minus 6.0 Ramp
B+ Off
The meter will ramp from B+ to B+ minus 6.0 volts. Example: If the
battery voltage is 36 volts, B+ minus 6.0 would equal 30 volts.
6-156 PDMM-0057
Therefore, in this example, the voltage will ramp between 30.0 and
36.0 volts.
failure.
Remove meter.
! CAUTION
Do not run this test for an extended period of time as it
may damage Q1 and/or the CCM due to overheating.

1. The Power Transistor (Q1) may be shorted, grounding the base.
a. Turn the key switch OFF.
b. Disconnect:
• Wire from Q1-B on the Power Transistor (Q1) and connect it
directly to the voltmeter's + lead.
• The power cable from the collector (C) of the Power
Transistor (Q1)
c. Connect the voltmeter's negative lead to TP4, and set the
voltmeter to read nominal battery voltage. The meter should
read less than one volt.
d. Turn the key switch ON then re-run the test. The voltage
should be at about three volts.
3. The CCM may be bad. Replace it with a known good unit, and
rerun the test.
running the test.
PDMM-0057 6-157
Test O15 - HCM Using this test, proper operation of the H-Bridge Control Module
Forward Enable (HCM) forward enable signal can be verified.
Test A successful test proves that the wiring and related circuitry in the
Vehicle Manager and Distribution Board are all functioning properly.
Related Codes Test O17 - HCM PWM Ramp

and Tests
NOTE: This test will toggle the HCM forward enable signal on and off
from the Vehicle Manager. The enable signal “enables” the HCM
to pulse the Power Transistors (TM1, TM2). If the HCM is not
enabled, it can't pass pulses from the Vehicle Manager on to
the H-Bridge transistors (TM1, TM2).
whenever the Vehicle Manager is pulsing the Power Transistors
(TM1, TM2).
NOTE: This test only checks that the forward enable signal from the
Vehicle Manager is actually arriving at the input to the HCM.
Test O17 - HCM PWM Ramp must be run in order to verify that
the HCM is correctly enabling its output.
Procedure 1. Disconnect the cable from JPH2, and connect a voltmeter to the
cable between JPH2-6 (+ lead) and JPH2-1 (- lead).
JPH2-1 (-)
JPH2-6 (+)
Figure 6-13: Pinout for JPH2 - Forward HCM Enable
On 10.5 - 12.5 volts

Off 0.0 - 0.5 volts

1. The cable between the HCM and the Vehicle Manager may be bad.
running the test.
6-158 PDMM-0057
Test O16 - HCM Using this test, proper operation of the H-Bridge Control Module
Reverse Enable (HCM) reverse enable signal can be verified.
Test A successful test proves that the wiring and related circuitry in the
Vehicle Manager and Distribution Board are all functioning properly.
Related Codes Test O17 - HCM PWM Ramp

and Tests
NOTE: This test will toggle the HCM reverse enable signal on and off
from the Vehicle Manager. The enable signal “enables” the HCM
to pulse the Power Transistors (TM1, TM2). If the HCM is not
enabled, it can't pass pulses from the Vehicle Manager on to
the H-Bridge transistors (TM1, TM2).
whenever the Vehicle Manager is pulsing the Power Transistors
(TM1, TM2).
NOTE: This test only checks that the reverse enable signal from the
Vehicle Manager is actually arriving at the input to the HCM.
Test O17 - HCM PWM Ramp must be run in order to verify that
the HCM is correctly enabling its output.
Procedure 1. Disconnect the cable from JPH2, and connect a voltmeter to the
cable between JPH2-6 (+ lead) and JPH2-5 (- lead).
JPH2-5 (-)
JPH2-6 (+)
Figure 6-14: Pinout for JPH2 - “Reverse HCM Enable”

On 10.5 - 12.5 volts

Off 0.0 - 0.5 volts

NOTE: After replacing boards, be sure to run Learn Mode before-
running the test.
PDMM-0057 6-159
Test O17 - HCM Using this test, proper operation of the PWM (Pulse Width Modulation)
PWM Ramp to the H-Bridge (HCM) can be verified.
Vehicle Manager, distribution board, and HCM are all functioning
properly.
Related Codes To perform this test, refer to HCM Test on page 6- 21.
and Tests
Procedure • Elevate the drive tire off the floor. See WARNING.
! WARNING
Use jack stands or solid blocks to support truck - do not
rely on jacks.
! CAUTION
Do not run this test for an extended period of time as it
may damage the HCM or field wiring assembly.

1. TM1 or TM2 may be shorted, grounding the base.
3. The HCM may be bad. Replace it with a known good unit, and
rerun the test.
running the test..
6-160 PDMM-0057
Test O18 - Toggle Using this test, proper operation of the horn can be verified.
Horn A successful test proves that the horn and its related wiring and
circuitry in the Vehicle Manager, Power Panel Driver Assembly, and
distribution board are functional.
Related Codes None.

and Tests
NOTE: Every time that SelfTest is run during power up, the horn is
briefly beeped to indicate that SelfTest completed successfully.
Procedure 1. Connect a voltmeter across H1 at the horn.
Expected Results
Voltmeter
Horn Operator's Display
Reading
Sounding B+ On
Off 0.0 Off
• If this is not observed, then the test is a failure. Remove meter.

1. There may be an open in the horn circuit, or the horn may be
defective. Check as follows:
a. Turn the key switch OFF. Leave the battery connected.
c. Attach a ground jumper from TP4 to JPN6-4.
d. Attach one end another jumper from JPN6-5 . Briefly touch
the other end of the jumper to FU5. The horn should sound.
If the horn does not sound, then troubleshoot the horn and its
associated wiring.
e. Reconnect JPN6.
2. The horn switch may be defective.
3. Check for continuity between JPS9-8 and JPN14-8.
known good unit a perform test again.
running the test
PDMM-0057 6-161
Test O19 - Audible Using this test, the operation of the audible alarm in the Operator's
Alarm Test Display can be verified.
Vehicle Manager, distribution board, and Operator's Display are all
functioning, and that the audible alarm is functioning.
Related Codes None.

and Tests
Expected Results
Alarm Operator's Display

Sounding Ramp
Off Off
• This test will generate a sound on the audible alarm in the

Operator's Display. The sound begins at a low pitch and
ramps up to a high pitch, then repeats.

1. The Operator's Display is defective and must be replaced.
NOTE: Replacing the Operator's Display requires assistance from
Material Handling Associates; be sure that the problem is in
the Operator's Display before attempting to replace it.
6-162 PDMM-0057
Test O20 - Forward This test verifies the operation of the forward relay. The forward relay
Relay Test is used to turn optional equipment (i.e., travel alarm) on/off in
relation to the travel direction.
Vehicle Manager, distribution board, and Hydraulic Driver Assembly
are all functioning.
Related Codes None.

and Tests
Expected Results
Forward Relay Operator's Display

De-energized Off
Energized On
• When the display shows on, the optional device should be

activated.

1. The optional device may be defective.
2. Diode assembly DA1 may be bad.
3. The relay may be defective.
4. Wiring between TS19-5 or JPS3-6 may be defective.
5. The Hydraulic Driver Assembly may be bad. Replace with a
known good assembly and re-run the test.
PDMM-0057 6-163
Test O21 - Reverse This test verifies the operation of the reverse relay. The reverse relay is
Relay Test used to turn optional equipment (i.e., travel alarm) on/off in relation
to the travel direction.
Vehicle Manager, distribution board, and Hydraulic Driver Assembly
are all functioning.
Related Codes None.

and Tests
Expected Results
Reverse Relay Operator's Display

De-energized Off
Energized On
• When the display shows on, the optional device should be

activated.

1. The optional device may be defective.
2. Diode assembly DA1 may be bad.
3. The relay may be defective.
4. Wiring between TS19-5 or JPS3-7 may be defective.
5. The Hydraulic Driver Assembly may be bad. Replace with a
known good assembly and re-run the test.
running the test.
6-164 PDMM-0057
Status Code Summary
Status Code This summary comprises a complete listing of all status codes and
related troubleshooting data. It contains references to all maintenance
Summary tests contained in this chapter.
PDMM-0057 6-165
Status Code Summary
This page intentionally left blank.
6-166 PDMM-0057
Status Code Summary Chart
6: Troubleshooting

Code Operator’s Display Message: Code Title: Effect: Cleared By: Related Tests
Traction System Status

00 Battery State-Of-Charge All systems functioning 1 NA (Not Applicble) None
Performance Limiting
10 SelfTest Passed Power on SelfTest 0 SelfTest Passing None
(P.O.S.T.)
11 Travel speed limited due to Drive motor temperature D,1 Drive motor cools A08
traction motor temperature HOT
12 Lift motor overheating Lift motor temperature N Lift motor cools A09
HOT
13 Travel speed limited due to Power Panel temperature D Power panel cools A10
power panel temperature HOT
Power Panel
20 Code 20, Inform Service Per- Temperature sensor cir- 1 Fix & cycle key A10, I12
sonnel cuits not responding switch OFF/ON
21 Code 21, Inform Service Per- Short detected in arma- X Fix & cycle key A11, O13, O14,
sonnel ture circuit switch OFF/ON I13
22 Code 22, Power Panel Over- Power panel overheated X Let cool & key A10, I12
heated, allow time to cool switch
23 Code 23, Inform Service Per- Open detected in arma- X Fix & cycle key A11, O13, O14
sonnel ture circuit switch OFF/ON
24 Code 24, Inform Service Per- Armature current sensor X Fix & cycle key A11, I13
sonnel circuit not responding switch OFF/ON
25 Code 25, Inform Service Per- Short detected in field cir- X Fix & cycle key- A12, I14, O15,
sonnel cuit switch OFF/ON O16, O17
26 Code 26, Inform Service Per- Open detected in field cir- X Fix & cycle key A12, I14, O15,
sonnel cuit switch OFF/ON O16, O17
27 Code 27, Inform Service Per- Field current sensor cir- X Fix & cycle key A12, I14
sonnel cuits not responding switch OFF/ON
Motor & Encoder

30 Code 30, Inform Service Per- Excessive acceleration 1 Fix & cycle key I16
sonnel switch OFF/ON
32 Code 32, Inform Service Per- No movement detected 1 Fix & cycle key I16
sonnel when travel is requested switch OFF/ON
34 Code 34, Drive Motor Over- Traction motor over- X Let cool & key A08
heated, Allow Time To Cool heated switch
38 Code 38, Lift Motor Over- Lift motor overheated L Let cool & key A09
heated, Allow Time To Cool switch
Contactors
42 Code 42, Inform Service Per- P (Lift) contactor detected X Fix & cycle key O02, A02
sonnel closed when commanded switch OFF/ON
open
43 Code 43, Inform Service Per- P (Lift) contactor detected L Fix & cycle key O02, A02
sonnel open when commanded switch OFF/ON
closed
PDMM-0057 6-167
44 Code 44, Inform Service Per- PC contactor detected X Fix & cycle key O00, A00
open
45 Code 45, Inform Service Per- PC contactor detected X Fix & cycle key O00, A00
closed
49 Code 49, Inform Service Per- 1S contactor detected 1 Fix & cycle key O01, A01
open
4A Code 4A, Inform Service Per- 1S contactor detected X Fix & cycle key O01, A01
closed
Height & Weight

6C Code 6C, Inform Service Main lift pressure out-of- L Fix & cycle key A13, A14
Personnel range switch OFF/ON
Analog Sense
73 Code 73, Inform Service Per- Armature current sensor X Fix & cycle key A11
sonnel out-of-range switch OFF/ON
74 Code 74, Inform Service Per- Power panel temperature 1 Fix & cycle key A10, I12
sonnel sensor out-of-range switch OFF/ON
75 Code 75, Power Panel Over- Diagnostic sense line out- 1 Let cool & key A16
heated, Allow Time To Cool of-range switch
77 Code 77, Check Battery Battery voltage out-of- A15
range
79 Code 79, Inform Service Per- +12 volt sense reading X Fix & cycle key A14
7B Code 7B, Inform Service Traction motor tempera- 1 Fix & cycle key A08
Personnel ture sensor out-of-range switch OFF/ON
7C Code 7C, Inform Service Lift motor temperature L Fix & cycle key A15
Personnel out-of-range switch OFF/ON
7E Code 7E, Inform Service Field current reading out- X Fix & cycle key A12, I14
Personnel of-range switch OFF/ON
Operator’s Controls
80 Code 80, Inform Service Per- Throttle controller read- T Fix & cycle key A04, A14
sonnel ing out-of-range switch OFF/ON
83 Code 83, Inform Service Per- Emergency power off X Fix & cycle key A04. A14
sonnel switch detected down switch OFF/ON
84 Code 84, Inform Service Per- Brake inoperable or not X Fix & cycle key I16
sonnel properly adjusted switch OFF/ON
85 Code 85, Inform Service Per- Remote lower reading X Fix & cycle key A07
86 Code 86, Inform Service Per- Remote lift reading out-of- X Fix & cycle key A06
sonnel range switch OFF/ON
87 Code 87, Inform Service Per- Release throttle to resume O Return travel con- None
sonnel operation trol to neutral
88 Code 88, Inform Service Per- Press lift bypass to con- L Press lift bypass None
sonnel tinue lifting switch to continue
lifting
6-168 PDMM-0057
System
A0 Code A0, Inform Service Per- Incorrect S/W for proper X Fix & cycle key None
sonnel vehicle operation switch OFF/ON
A1 Code A1, Inform Service Per- Operator’s display not X Fix & cycle key None
sonnel installed switch OFF/ON
A2 Code A2, Inform Service Per- Uncalibrated VFC X Fix & cycle key None
A3 Code A3, Inform Service Per- Not published (COP not X Fix & cycle key None
sonnel established) switch OFF/ON
A4 Code A4, Inform Service Per- COP Timeout X Fix & cycle key None
EC Code EC, Inform Service Operating system error X Fix & cycle key None
Personnel switch OFF/ON
ED Code ED, Inform Service Communications to Oper- X Fix & cycle key None
Personnel ator’s Display failed switch OFF/ON
EF Code EF, Inform Service Bad Operator’s Display X Fix & cycle key None
Personnel checksum switch OFF/ON
Effect Designations
O 0 mph speed limit
1 1 mph speed limit
D Traction system derating
I Informational
L Lift System Shutdown
N 2nd stage lift pump
inhibited
X Total shutdown
PDMM-0057 6-169
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6-170 PDMM-0057

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CATERPILLAR® Reach Service Manual Troubleshooting

Introduction When troubleshooting truck problems it is important to:

Troubleshooting 1. Verify problems by:

6. Correct the problem by:

If a truck problem cannot be located in the wiring or a short-to-frame

3. Operate all the truck’s functions slowly, observing during which

1. Use an ohmmeter set to Rx10,000 scale.

Board and Troubleshooting by following the instructions given in this manual is

Likelihood of When troubleshooting a problem, some components should be

Handling Printed Refer to Electrostatic Discharge Damage (Chapter 5) for complete

Major Faults The following pages provide troubleshooting procedures for

Does a voltmeter between the NO Does recharging NO Check battery and

Is FU2 OK? NO Replace FU2.

Continued next page.

Continued from previous page.

Unplug JPS10. Is Is JPF3

Is JPN5 YES Tighten JPN5.

If there is still a problem,

“A” from page 6-9.

Is there continuity be- Replace the cable between Power Panel

“B” from page 6-9.

Is there continuity NO Replace the key switch harness.

Is there continuity be- NO Replace the Hydraulic Driver Assembly.

Is there continuity be- NO Replace the Vehicle Manager.

Is there continuity be- Replace the Power Supply ribbon cable.

“C” from page 6-9.

Is there continuity Replace the key switch harness.

Is there continuity be- Replace the Hydraulic Driver Assembly.

Truck Completely Inoperative,

Remove covers from power section.

Replace the VFC. OK? NO Replace Distribution

During Powerup, Operator's

Are you standing on

Run Test I00 and

Speed Limited with No Code

Check for continuity on

When replacing REC1, Apply oxide inhibitor

Figure 6-1: Power Panel Assembly

Positive Test Negative Test Acceptable Reading

NOTE: If the Power Transistor test shows that is shorted, replace

Figure 6-2: Voltage Test Points for Power Transistor Q1

200K - 10M Ohms

Figure 6-3: Resistance Test Points for Power Transistor Q1

Figure 6-4: Power Transistor (Q1) Schematic

Figure 6-5: Transistor Module for Field Wiring Assembly

Positive Lead of Meter Negative Lead of Meter

If any position of this test fails, replace the transistor assembly.

Figure 6-6: Field Wiring Module Schematic

Procedure 1. Disconnect the drive motor power lead at MD-S1.

Figure 6-7: HCM Test

Meter Connection Reading (VDC)

Meter Connection Reading (VDC)

Cleaning Wear safety glasses.

Inspection Visually inspect all parts for:

Guidelines When inspecting contactors, remember:

Procedure 1. Disconnect the motor from the truck circuit.

Figure 6-8: Drive Motor Terminals and Circuits

Motor Most motor overheating can be prevented by understanding the

Hydraulics General topics covered in this section are:

Bad Connections When checking connections to pumps, cylinders, manifold valves,

Trouble Probable Cause Remedy

Trouble Probable Cause Remedy

Lift/Lower/ Reach The following table is designed to refer service personnel to

2. Check the indicated component for contamination: