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Manual Fallas Reach Caterpillar
Manual Fallas Reach Caterpillar
Introduction
Troubleshooting 6:
PDMM-0057 6-1
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
! 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
CATERPILLAR® Reach Service Manual Troubleshooting
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.
! 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.
PDMM-0057 6-3
Troubleshooting CATERPILLAR® Reach Service Manual
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.
6-4 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
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
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
6-6 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Introduction
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
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
YES
Disconnect battery.
Remove Covers.
Replace line fil-
Is the vehicle equipped with a line YES ter fuse.
filter?
NO
YES
NO Replace FU4.
Is FU4 OK?
YES
6-8 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Introduction
NO
YES
PDMM-0057 6-9
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
Is there continuity
between FU2 to JPF 3- NO Replace the Power Panel Driver Assembly.
9, 10, and 11?
YES
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
CATERPILLAR® Reach Service Manual Troubleshooting
Introduction
YES
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
YES
PDMM-0057 6-11
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
YES
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
CATERPILLAR® Reach Service Manual Troubleshooting
Introduction
NO
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
Troubleshooting CATERPILLAR® Reach Service Manual
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.
6-14 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
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
PDMM-0057 6-15
Troubleshooting CATERPILLAR® Reach Service Manual
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.
6-16 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Introduction
DVM
.3 to .9 volts
OL
- +
E B
- +
C - +
OL
.3 to .9 volts
DVM
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
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
E B
6-18 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
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
PDMM-0057 6-19
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
6-20 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
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.
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
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
One Cycle
T1
T2
T3
T4
Vehicle Manager The following tests the power supply on vehicles with software version
Power Supply Test 4.0 and up.
The following tests the power supply on vehicles with software below
version 4.0:
6-22 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
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.
PDMM-0057 6-23
Troubleshooting CATERPILLAR® Reach Service Manual
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
1(+)
Drive
Motor
MD A2
S2
MD1
MD
MD
S1 A1
6-24 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
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
Troubleshooting CATERPILLAR® Reach Service Manual
Introduction
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
CATERPILLAR® Reach Service Manual Troubleshooting
Hydraulics
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
Troubleshooting CATERPILLAR® Reach Service Manual
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.
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
CATERPILLAR® Reach Service Manual Troubleshooting
Hydraulics
Hydraulic
Problems
Pump Problems
PDMM-0057 6-29
Troubleshooting CATERPILLAR® Reach Service Manual
Hydraulics
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
CATERPILLAR® Reach Service Manual Troubleshooting
Hydraulics
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.
PDMM-0057 6-31
Troubleshooting CATERPILLAR® Reach Service Manual
Hydraulics
! CAUTION
Do not use brake fluid in the hydraulic system.
6-32 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Hydraulics
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.
PDMM-0057 6-33
Troubleshooting CATERPILLAR® Reach Service Manual
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.
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
CATERPILLAR® Reach Service Manual Troubleshooting
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:
PDMM-0057 6-35
Troubleshooting CATERPILLAR® Reach Service Manual
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
6-36 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Informational Codes
Informational
Codes
Code 00 - All
Systems
Functioning
Code 10 - Power Up
Self Test
PDMM-0057 6-37
Troubleshooting CATERPILLAR® Reach Service Manual
Informational Codes
Code 11 - Drive
Motor
Temperature HOT
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
CATERPILLAR® Reach Service Manual Troubleshooting
Informational Codes
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.
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.
PDMM-0057 6-39
Troubleshooting CATERPILLAR® Reach Service Manual
Informational Codes
Code 13 - Power
Panel Temperature
HOT
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.
8. Vehicle Manager 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
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Fault Codes
Code 20 -
Temperature
Sensor Circuits
Not Responding
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
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 21 - Short
Detected In Armature
Circuit
Possible causes:
1. Q1 may be shorted. See Power Transistor (Q1) Test and
troubleshoot accordingly.
2. The CCM may be bad.
3. The cable between the CCM and the Vehicle Manager may be bad.
4. The motor or motor cable may be bad.
5. The Vehicle Manager 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
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CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 22 - Power
Panel Overheated
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.
4. The CCM may be bad.
5. The Power Panel Driver Assembly may be bad.
6. The Vehicle Manager may be bad.
PDMM-0057 6-43
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 23 - Open
Detected In Armature
Circuit
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.
5. The CCM may be bad.
6. The cable between the CCM and the Vehicle Manager may be bad.
7. The Vehicle Manager may be bad.
6-44 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 24 - Armature
Current Sensor
Circuit Not
Responding
Possible causes:
1. Check the cables from:
• Q1 to CCM
• CCM to Vehicle Manager
PDMM-0057 6-45
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 25 - Short
Detected In Field
Circuit
Possible causes:
1. Check the cables from:
• 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.
4. The Vehicle Manager may be bad.
5. The motor may have an internal short.
6-46 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 26 - Open
Detected In Field
Circuit
Possible causes:
1. FU8 may be open.
2. Check the cables from:
• 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)
3. The Field Wiring Assembly may be bad.
4. TM1 or TM2 may be bad.
5. The HCM may be bad.
6. The Vehicle Manager may be bad.
7. The drive motor may have an open circuit in the windings.
PDMM-0057 6-47
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 27 - Field
Current Sensor
Circuits Not
Responding
Possible causes:
1. Check the cables from:
• Field Wiring Assembly to H-Bridge Control Module (HCM)
• HCM to Vehicle Manager
2. The HCM may be bad.
3. The Vehicle Manager may be bad.
6-48 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 30 - Excessive
Acceleration
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.
4. The Vehicle Manager 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
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 32 - No
Movement Detected
When Travel Is
Requested
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,
4. The Vehicle Manager may be bad.
Corrective Actions and The encoder may not be generating pulses correctly.
Checks
• Run Test I16 - Encoder Count
6-50 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 34 - Drive
Motor Overheated
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.
7. The Vehicle Manager 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
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
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.
5. The Vehicle Manager may be bad.
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
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 40 - B
Contactor Detected
Closed When
Commanded Open
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
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 41 - B
Contactor Detected
Open When
Commanded Closed
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
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 42 - P
Contactor Detected
Closed When
Commanded Open
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.
6. The Vehicle Manager may be bad.
7. The pump sense circuit may be defective.
8. The Pump Sense line (JPF2-7) may be shorted to B+.
PDMM-0057 6-55
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 43 - P
Contactor Detected
Open When
Commanded Closed
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.
6. The Vehicle Manager 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-.
6-56 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 44 - PC
Contactor Detected
Closed When
Commanded Open
Possible causes:
1. Defective PC coil driver.
2. Welded PC contactor tips.
3. Binding contactor plunger.
4. Defective return spring.
5. Bad contactor panel harness.
6. The Vehicle Manager may be bad.
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
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 45 - PC
Contactor Detected
Open When
Commanded Closed
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,
10. The Vehicle Manager 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
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 49 - IS
Contactor Detected
Closed When
Commanded Open
Possible causes:
1. Defective 1S coil driver.
2. Welded 1S contactor tips.
3. Defective 1S contactor coil.
4. Defective 1S contactor spring.
5. Bad contactor panel harness.
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.
9. The Vehicle Manager 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
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 4A - IS
Contactor Is Detected
Open When
Commanded Closed
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.
6-60 PDMM-0057
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Fault Codes
Possible causes:
1. Check pressure sensor cable JPN9.
2. Cable between Hydraulic Driver Assembly and Vehicle Manager
may be bad.
3. Pressure sensor may be defective.
4. Hydraulic Driver Assembly may be bad.
5. The +12-volt power supply may be bad.
PDMM-0057 6-61
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 73 - Armature
Current Sensor Out
Of Range
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
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 74 - Power
Panel Temperature
Sensor Out Of Range
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
Checks not be functioning correctly.
• Run Test A10 - Panel Temperature Sensor Voltage
• Run Test I12 - Power Panel Temperature Limit Signal
PDMM-0057 6-63
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 75 - Diag
Sense Line Out Of
Range
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
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 77 - Battery
Voltage Reading Out
Of Range
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.
3. The Power Panel Driver Assembly may be bad.
4. The battery may be the wrong voltage.
Corrective Actions and The battery voltage sense line or its related wiring and circuitry may
Checks not be functioning correctly.
• Run Test A15 - Battery Voltage
PDMM-0057 6-65
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 79 - +12-Volt
Sense Reading Out
Of Range
Possible causes:
1. The Power Supply may be bad.
2. A 12-volt device may be shorted.
Corrective Actions and The battery voltage sense line or its related wiring and circuitry may
Checks not be functioning correctly.
• Run Test A15 - Battery Voltage
6-66 PDMM-0057
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Fault Codes
Code 7B - Traction
Motor Temperature
Sensor Out Of Range
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)
6. The Vehicle Manager may be bad.
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
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
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.
5. The Vehicle Manager may be bad.
Corrective Actions and The battery voltage sense line or its related wiring and circuitry may
Checks not be functioning correctly.
• Run Test A15 - Battery Voltage
6-68 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code 7E - Field
Current Reading Out
Of Range
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:
• A12 - Field Current Sensor Voltage
• I14 - Field Current Limit Signal
PDMM-0057 6-69
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 80 - Throttle
Controller Reading
Out Of Range
Possible Causes:
1. Learn Mode may need to be run.
2. Potentiometer VR1 may be bad.
3. Check cable JPS4, JPC1.
4. The Vehicle Manager may be bad.
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
CATERPILLAR® Reach Service Manual Troubleshooting
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.
System 1. Alarm sounds: Yes
Response 2. Operator's Display: CODE 84...Inform Service Personnel
3. PC Contactor: De-energized
4. VFC Display: 84
5. Speed Limit: 0.0 mph
How to The key switch must be cycled OFF/ON to clear this fault.
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
troubleshoot accordingly.
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
• Run Test I16 - Encoder Count
PDMM-0057 6-71
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 85 - Remote NOTE: This code should only apply to vehicles with remote lift/lower
Lower Reading Out Of option.
Range
Possible Causes:
1. Resistor R2 may be bad.
2. Check cable between Hydraulic Driver Assembly and Vehicle
Manager.
3. Hydraulic Driver Assembly may be bad.
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
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Fault Codes
Code 86 - Remote This code should only apply to vehicles with remote lift/lower option.
Lift Reading Out Of
Range
Possible Causes:
1. Resistor R3 may be bad.
2. Check cable between Hydraulic Driver Assembly and Vehicle
Manager.
3. Hydraulic Driver Assembly may be bad.
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
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code 87 - Release
Throttle To Resume
Operation
NOTE: Excessive play in the handle could prevent the vehicle from
returning to its learned neutral position.
6-74 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code A0 - Software
Does Not Match
Vehicle Setup
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
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code A1 -
Uninitialized
Operator's Display
6-76 PDMM-0057
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Fault Codes
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.
NOTE: None of the program modes (Maintenance, Learn, or Config)
can be entered until this code is cleared.
PDMM-0057 6-77
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code A3 - EPROM
Failure Or Computer
Not Enabled
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
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
Code A4 - COP
Timeout
PDMM-0057 6-79
Troubleshooting CATERPILLAR® Reach Service Manual
Fault Codes
Code EC - Operating
System Error
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.
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.
5. The Vehicle Manager may be bad.
6-80 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Fault Codes
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
Troubleshooting CATERPILLAR® Reach Service Manual
Analog Test The following pages contain a summary of the analog input tests.
Summary NOTE: These tests were performed on a 36-volt truck.
! 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
CATERPILLAR® Reach Service Manual Troubleshooting
PDMM-0057 6-83
Troubleshooting CATERPILLAR® Reach Service Manual
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:
6-84 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
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
Connect test meter properly before testing.
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
For information on how to use maintenance mode, refer to Chapter 3.
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.
2. The test is a success if the voltage displayed is within these limits:
PDMM-0057 6-85
Troubleshooting CATERPILLAR® Reach Service Manual
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
For information on how to use maintenance mode, refer to Chapter 3.
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.
3. The test is a success if the voltage displayed is within these limits:
6-86 PDMM-0057
CATERPILLAR® Reach Service Manual Troubleshooting
Analog Tests
PDMM-0057 6-87
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Analog Tests
Test: A04 - Throttle This test displays the voltage that the Vehicle Manager reads from the
Pot Voltage throttle pot (VR1).
! CAUTION
Connect test meter properly before testing.
Related Codes and Tests Code 80 - Throttle Controller Reading Out of Range
For information on how to use maintenance mode, refer to Chapter 3.
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).
1. The test is a success if the voltage displayed is within these limits:
6-88 PDMM-0057
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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
Connect test meter properly before testing.
Related Codes and Tests Code 86 - Remote Lift Reading Out of Range
For information on how to use maintenance mode, refer to Chapter 3.
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
PDMM-0057 6-89
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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
Connect test meter properly before testing.
Related Codes and Tests Code 85 - Remote Lower Reading Out Of Range
For information on how to use maintenance mode, refer to Chapter 3.
Expected Results The ODI will display the voltage which the Vehicle Manager reads from
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:
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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
Connect test meter properly before testing.
Expected Results The Operator's Display will display the voltage which the Vehicle
Manager reads from the drive motor temperature sensor.
1. The test is a success if the voltage displayed is within these limits:
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Analog Tests
! 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.
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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
Connect test meter properly before testing.
Expected Results The Operator's Display will show the voltage which the Vehicle
Manager reads from the temperature sensor on the lift pump motor.
1. The test is a success if the voltage displayed is within these limits:
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Analog Tests
! 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 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.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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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
Connect test meter properly before testing.
Expected Results The Operator's Display will display the voltage which the Vehicle
Manager reads from the Power Panel temperature sensor (HT).
1. The test is a success if the voltage displayed is within these limits:
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Analog Tests
! CAUTION
Do not use a heat gun, lighter, or other source of strong
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.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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Analog Tests
Test: A11 - This test displays the voltage which is read from the current sensor
Armature Current “donut” on the CCM.
Expected Results The Operator's Display will show the voltage which the Vehicle
Manager reads from the current sensor.
• 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.
Possible causes of test 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.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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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
Connect test meter properly before testing.
Expected Results The Operator's Display will display the voltage which the Vehicle
Manager reads from the current sensor.
• 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.
Possible causes of test 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.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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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
For information on how to use maintenance mode, refer to Chapter 3.
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.
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.
Possible causes of test failure:
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Analog Tests
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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
Connect test meter before testing.
Related Codes and Tests Code 79 - +12-Volt Sense Reading Out Of Range
For information on how to use maintenance mode, refer to Chapter 3.
Expected Results The ODI will show the voltage which the Vehicle Manager reads +12
volt power supply.
1. The test is a success if the voltage displayed is within these limits:
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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
Connect test meter properly before testing.
Related Codes and Tests Code 77 - Battery Voltage Reading Out Of Range
For information on how to use maintenance mode, refer to Chapter 3.
NOTE: This voltage is the voltage which the VM uses when calculating
the battery state of charge.
Expected Results The ODI will display the voltage which the Vehicle Manager reads from
the Battery sense line.
NOTE: If the reading fluctuates by more than 0.8 volts in 10 seconds,
then the test is a failure.
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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
Connect test meter properly before testing.
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.
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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.
Expected Results The display will show the position of key switch (S1):
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Analog Tests
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Analog Tests
! CAUTION
Connect test meter properly before testing.
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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
Connect test meter properly before testing.
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
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Deadman
Switch Resistance
Switch
Down Depressed Less than one ohm
Up Extended More than two megohms
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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
Connect test meter properly before testing.
Related Codes and Tests Code 83 - Emergency Power Off Switch Detected Down
For information on how to use maintenance mode, refer to Chapter 3.
Expected Results The display will show the state of the switch:
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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.
Expected Results The display will show the state of 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.
Possible causes of test failure:
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.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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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.
Expected Results The display will show the state of the switch:
Operator’s
Fork Position Mast Switch #2 Audible Alarm
Display
Raised Open Sounding Out
Lowered Closed Off In
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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
For information on how to use maintenance mode, refer to Chapter 3.
Expected Results The display will show position of lift bypass switch S12:
Audible Operator’s
Switch S12
Alarm Display
Open Off Off
Closed Sounding On
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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
Expected Results The display will show the state of the switch:
Operator’s
Switch S13 Audible Alarm
Display
Open Sounding Out
Closed Off In
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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
Connect test meter properly before testing.
Expected Results The display will show the state of the switch:
Audible Operator’s
Reach Button
Alarm Display
Pressed Sounding In
Not Pressed Off Out
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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Test I07 - Retract Using this test, the state of the retract switch (S5) can be monitored.
Switch This test will show what the Vehicle Manager is reading from the
switch.
! CAUTION
Connect test meter properly before testing
Expected Results The display will show the state of the switch:
Operator’s
Retract Button Audible Alarm
Display
Depressed Sounding In
Not Depressed Off Out
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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Test I08 - Tilt-Up Using this test, the state of the tilt-up switch (S6) can be monitored.
Switch This test will show what the Vehicle Manager is reading from the
switch.
! CAUTION
Connect test meter before testing.
Expected Results The display will show the state of the switch:
Operator’s
Tilt-Up Button Audible Alarm
Display
Not Pressed Off Up
Pressed Sounding Down
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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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
Connect test meter properly before testing.
Expected Results The display will show the state of the switch:
Operator’s
Tilt-Down Button Audible Alarm
Display
Not Pressed Off Up
Pressed Sounding Down
NOTE: After replacing boards, be sure to run Learn Mode BEFORE re-
running the test.
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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
Connect test meter properly before testing.
Expected Results The display will show the state of the switch:
Audible Operator’s
Sideshift-Right Button
Alarm Display
Not Pressed Off Up
Pressed Sounding Down
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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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
Connect test meter properly before testing.
Expected Results The display will show the state of the switch:
Operator’s
Sideshift-Left Button Audible Alarm
Display
Not Depressed Off Up
Depressed Sounding Down
Sideshift-Left
Resistance
Button
More than two Mego-
Extended
hms
Depressed Less than one ohm
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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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
Connect test meter properly before testing.
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,
then the test is a failure.
• The red LED on the CCM should also be on. If this is not
observed, then the CCM may be bad.
• Reconnect JPT1.
Possible causes of test failure:
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.
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NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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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
Connect test meter properly before testing.
Related Codes and Tests Code 24 - Armature Current Sensor Circuit Not Responding.
Test A11 - Armature Current Sensor Voltage
For information on how to use maintenance mode, refer to Chapter 3.
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,
then the test is a failure.
d. Reconnect cable at JPT2.
Pin 2
Pin 7
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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
Connect test meter properly before testing.
Related Codes and Tests Code 27 - Field Current Sensor Circuits Not Responding.
Test A12 - Field Current Sensor Voltage
For information on how to use maintenance mode, refer to Chapter 3.
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,
then the test is a failure.
d. Reconnect cable at JPH2.
Pin 2
Pin 7
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Test I15 - Horn This test verifies that the horn button and input to the Vehicle
Button Manager works correctly.
Expected Results
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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
Connect test meter properly before testing.
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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.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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Test I17- Lift This test displays the state of the lift switch (S20) and lower switch
Switch & Lower (S21).
Switch Status
! CAUTION
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
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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)
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! CAUTION
Connect test meter properly before testing.
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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
Connect test meter properly before testing.
Expected Results
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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
Connect test meter properly before testing.
Expected Results
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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
Connect test meter properly before testing.
Related Codes Test A02 - Lift Pump (P) Contactor Sense Voltage
and Tests Code 42 - P Contactor Detected Closed When Commanded Open
Code 43 - P Contactor Detected Open When Commanded Closed
For information on how to use maintenance mode, refer to Chapter 3.
! 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
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.
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1. The P 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 P contactor may be binding or not operating
correctly. Visually inspect for proper operation:
a. Check the contactor tips for signs of welding.
b. Check that the return spring is functioning correctly.
3. There may be an open in the P contactor's coil circuit. Check as
follows:
a. Turn off power.
b. Unplug JPF2 from the Power Panel Driver Assembly.
c. Using an ohmmeter, measure across harness between JPF2-1
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
associated wiring.
4. The Power Panel Driver Assembly may be defective. Replace with a
known good unit and rerun this test.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
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Test O04 - Toggle Using this test, DIRA solenoid can be turned off and on, verifying its
Solenoid DIRA correct operation.
A successful test proves that the wiring and related circuitry in the
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
Connect test meter properly before testing.
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.
Possible causes of test failure:
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.
d. If the resistance is less than 10 ohms or more than 75 ohms,
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.
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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.
3. The Hydraulic Driver Assembly may be defective. Replace with a
known good unit and test again.
NOTE: After replacing boards, be sure to run Learn Mode before re-
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
troubleshoot accordingly.
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Test O05 - Toggle NOTE: Enter and exit test with horn button.
Solenoid DIRB Using this test, DIRB solenoid can be turned off and on, verifying its
correct operation.
A successful test proves that the wiring and related circuitry in the
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
Connect test meter properly before testing.
Expected Results
DIRB Ammeter
Operator's Display
Solenoid Reading
Open 0.5 - 1.0 amp On
0.0 - 0.02
Closed Off
amp
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2. The DIRB 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.
3. The Hydraulic Driver Assembly may be defective. Replace with a
known good unit and test again.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
4. There may be a hydraulic problem in the valve portion of DIRB
which is preventing it from operating properly. Investigate and
troubleshoot accordingly.
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Test O06 - Toggle NOTE: Enter and exit test with horn button.
Reach Solenoid Using this test, the Reach solenoid can be turned off and on, verifying
its correct operation.
A successful test proves that the wiring and related circuitry in the
Vehicle Manager, Hydraulic Driver Assembly, and reach coil driver are
all functioning correctly. It also proves that the reach solenoid and its
harness are electrically functional.
! CAUTION
Connect test meter properly before testing.
Expected Results
Reach Ammeter
Operator's Display
Solenoid Reading
0.25 - 0.75
Open On
amp
0.0 - 0.02
Closed Off
amp
If this is not observed, then the test is a failure. Otherwise the test is a
failure.
• Reconnect wire to TS19-3.
Possible causes of test failure:
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
the solenoid coil and its associated wiring.
d. Check for continuity between JPS9-17 on the Vehicle Manager
and JPN14-17 on the Hydraulic Driver Assembly.
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2. The reach 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.
3. The Hydraulic Driver Assembly may be defective. Replace with a
known good unit and test again.
NOTE: After replacing boards, be sure to run Learn Mode before re-
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.
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Test O07 - Toggle NOTE: Enter and exit test with horn button.
Tilt Solenoid Using this test, the tilt solenoid can be turned off and on, verifying its
correct operation.
A successful test proves that the wiring and related circuitry in the
Vehicle Manager, Hydraulic Driver Assembly, and tilt coil driver are all
functioning correctly. It also proves that the tilt solenoid and its
harness are electrically functional.
! CAUTION
Connect test meter properly before testing.
Expected Results
Tilt Operator's
Ammeter Reading
Solenoid Display
Open 0.25 - 0.75 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 to TS19-1.
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Test O08 - Toggle NOTE: Enter and exit test with horn button.
Sideshift Solenoid Using this test, the sideshift solenoid can be turned off and on,
verifying its correct operation.
A successful test proves that the wiring and related circuitry in the
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
Connect test meter properly before testing.
Expected Results
Sideshift Operator's
Ammeter Reading
Solenoid Display
Open 0.25 - 0.75 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 to TS19-2.
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2. The sideshift 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.
3. The Hydraulic Driver Assembly may be defective. Replace with a
known good unit and test again.
NOTE: After replacing boards, be sure to run Learn Mode
before re-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.
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Test O09 - Toggle NOTE: Enter and exit test with horn button.
Equalizing Using this test, the equalizing solenoid (E/Q) can be turned off and
Solenoid (E/Q) on, verifying its correct operation.
A successful test proves that the wiring and related circuitry in the
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
Connect test meter properly before testing.
Expected Results
Equalizing 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 to EQ-1.
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2. The E/Q 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.
3. The Hydraulic Driver Assembly may be defective. Replace with a
known good unit and test again.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
4. There may be a hydraulic problem in the valve portion of E/Q
which is preventing it from operating properly. Investigate and
troubleshoot accordingly.
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Test O10 - Toggle NOTE: Enter and exit test with horn button.
2ND-Stage Using this test, the 2ND-stage solenoid can be turned off and on,
Solenoid verifying its correct operation.
A successful test proves that the wiring and related circuitry in the
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
Connect test meter properly before testing.
Expected Results
Equalizing 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 to 2ND-1.
Possible causes of test failure:
1. There may be an open or short in the 2ND solenoid coil. Check as
follows:
a. Turn off power.
b. Unplug JPN1 from the Hydraulic Driver Assembly.
c. Using an ohmmeter, measure across harness between JPN1-3
and JPN1-6.
d. If the resistance is less than 10 ohms or more than 75 ohms,
then there is a problem in the E/Q coil circuit. Troubleshoot
the solenoid coil and its associated wiring.
e. Reconnect JPN1.
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2. The 2ND 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.
3. The Hydraulic Driver Assembly may be defective. Replace with a
known good unit and test again.
NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
4. There may be a hydraulic problem in the valve portion of 2ND
solenoid which is preventing it from operating properly.
Investigate and troubleshoot accordingly.
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Test O11 - Toggle NOTE: Enter and exit test with horn button.
Load-Holding Using this test, load-holding solenoid (L/H) can be turned off and on,
Solenoid verifying its correct operation.
A successful test proves that the wiring and related circuitry in the
Vehicle Manager, Hydraulic Driver Assembly, and L/H coil driver are
all functioning correctly. It also proves that L/H solenoid and its
harness are electrically functional.
! CAUTION
Connect test meter properly before testing.
Expected Results
L/H 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 to L/H-1
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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
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:
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NOTE: After replacing boards, be sure to run Learn Mode before re-
running the test.
JPH2-5 (-)
JPH2-6 (+)
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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.
A successful test proves that the wiring and related circuitry in the
VFC, distribution board, and CCM are all functioning properly.
Procedure 1. Elevate the drive tire off the floor. See WARNING.
! 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.
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.
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Therefore, in this example, the voltage will ramp between 30.0 and
36.0 volts.
If this is not observed, then the test is a failure. Otherwise the test is a
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.
2. The cable between the CCM and the Vehicle Manager may be bad.
Check for continuity on all lines.
3. The CCM may be bad. Replace it with a known good unit, and
rerun the test.
4. The Vehicle Manager may be bad.
NOTE: After replacing boards, be sure to run Learn Mode BEFORE re-
running the test.
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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.
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
The voltmeter should display the following:
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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.
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 (+)
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Test O17 - HCM Using this test, proper operation of the PWM (Pulse Width Modulation)
PWM Ramp to the H-Bridge (HCM) can be verified.
A successful test proves that the wiring and related circuitry in the
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 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.
! CAUTION
Do not run this test for an extended period of time as it
may damage the HCM or field wiring assembly.
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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.
Expected Results
Voltmeter
Horn Operator's Display
Reading
Sounding B+ On
Off 0.0 Off
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Test O19 - Audible Using this test, the operation of the audible alarm in the Operator's
Alarm Test Display can be verified.
A successful test proves that the wiring and related circuitry in the
Vehicle Manager, distribution board, and Operator's Display are all
functioning, and that the audible alarm is functioning.
Expected Results
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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.
A successful test proves that the wiring and related circuitry in the
Vehicle Manager, distribution board, and Hydraulic Driver Assembly
are all functioning.
Expected Results
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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.
A successful test proves that the wiring and related circuitry in the
Vehicle Manager, distribution board, and Hydraulic Driver Assembly
are all functioning.
Expected Results
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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.
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6: Troubleshooting
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
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
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Code Operator’s Display Message: Code Title: Effect: Cleared By: Related Tests
44 Code 44, Inform Service Per- PC contactor detected X Fix & cycle key O00, A00
sonnel closed when commanded switch OFF/ON
open
45 Code 45, Inform Service Per- PC contactor detected X Fix & cycle key O00, A00
sonnel open when commanded switch OFF/ON
closed
49 Code 49, Inform Service Per- 1S contactor detected 1 Fix & cycle key O01, A01
sonnel closed when commanded switch OFF/ON
open
4A Code 4A, Inform Service Per- 1S contactor detected X Fix & cycle key O01, A01
sonnel open when commanded switch OFF/ON
closed
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
sonnel out-of-range switch OFF/ON
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
sonnel out-of-range switch OFF/ON
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
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Code Operator’s Display Message: Code Title: Effect: Cleared By: Related Tests
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
sonnel switch OFF/ON
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
sonnel switch OFF/ON
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
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