Controller Diagnostics S/N B219N02284L : E30HSD, E35HSD, E40HSD (B219)

CONTROLLER
DIAGNOSTICS S/N
B219N02284L=>
E30HSD2, E35HSD2, E40HSD2 [B219]
PART NO. 4093651 9000 SRM 1649

SAFETY PRECAUTIONS
TROUBLESHOOTING PROCEDURES
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Controller Diagnostics S/N B219N02284L=> Table of Contents
TABLE OF CONTENTS
SECTION 9030 - ELECTRICAL SYSTEM

Group 03 - General Maintenance and Diagnostic Data.....................................................................9030-03-1
Group 20 - Diagnostic Trouble Codes............................................................................................... 9030-20-1
This section is for the following models:
(E30HSD2, E35HSD2, E40HSD2) [B219]
©2017 HYSTER COMPANY i

How To Use This Troubleshooting Manual Controller Diagnostics S/N B219N02284L=>
How To Use This Troubleshooting Manual

GENERAL INSTRUCTIONS AND SAFETY • 20 – Diagnostic Trouble Codes
INFORMATION The Diagnostic Trouble Codes group includes
all troubleshooting procedures for status codes
reported by a given Node or system.
WARNING
DO NOT add to or modify the lift truck. Any modi- For a listing of all Diagnostic Trouble Codes and de-
fication that affects the safe operation of the truck scriptions, see the Status Codes section of this man-
cannot be undertaken without written authoriza- ual.
tion of the Hyster company.
Any change to the lift truck, the tires, or its equip-

GENERAL INSTRUCTIONS
ment can change the lifting capacity. The lift truck
1. Become familiar with the content, layout, and
must be rated as equipped and the nameplate
access provisions of data in this manual. This
must show the new rating capacity.
will improve your efficiency and decrease the
time required to resolve the problems.
WARNING 2. Once you begin a troubleshooting procedure,
The technician must be aware of, and follow, all do not skip steps.
general safety precautions that are published in 3. If you reach the end of a procedure without re-
the Operating Manual and that are posted as solving the problem and you are not directed to
Safety Decals on and in the lift truck. another procedure contact Resident Service
Engineering through the Contact Management
Before starting, the technician should be familiar with System.
certain policies, requirements, and instructions used
in the troubleshooting procedures. Using the trouble- 4. Do not limit yourself, remember to apply your
shooting procedures correctly helps the technician to own experience and knowledge to assist in re-
perform the procedure safely and prevents damage to solving the problems, but do not compromise
the machine and support equipment. safety in doing so.
5. Most of the cross-reference data in the manual
HOW TO USE DIAGNOSTIC will be electronically linked for rapid and easy
TROUBLESHOOTING MANUAL access. Use the links wherever the cursor
highlights an item as a linkable option.
Manual Layout:
Section: This manual consists of one section which is

further divided into groups:
• 9030 – Electrical System
Groups: The 9030 Electrical System is divided into

two groups that identify specific electrical trouble-
shooting procedures:
• 03 – General Maintenance/Diagnostic Data
The General Maintenance and Diagnostic Data
group includes general troubleshooting, dis-
charging the capacitors, basic electrical trou-
bleshooting, multiplexing, User Iterface, and
status codes and descriptions.
Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
ii
SECTION 9030
ELECTRICAL SYSTEM
TABLE OF CONTENTS
Group 03 - General Maintenance and Diagnostic Data

General Troubleshooting.................................................................................................................... 9030-03-1
Discharging the Capacitors.................................................................................................................9030-03-2
Electrical Test Equipment................................................................................................................... 9030-03-4
PC Service Tool..............................................................................................................................9030-03-4
Breakout Kit ...................................................................................................................................9030-03-4
Digital Multimeter (DMM)................................................................................................................9030-03-4
Jumper Wires, Test Leads, and Test Lights................................................................................... 9030-03-4
Basic Electrical Troubleshooting............................................................................................................. 9030-03-4
Electrical Checks................................................................................................................................ 9030-03-5
Voltage Checks.............................................................................................................................. 9030-03-5
Amperage Checks..........................................................................................................................9030-03-5
Resistance Checks.........................................................................................................................9030-03-5
Contactor and Contactor Coil Checks............................................................................................ 9030-03-6
Multiplexing............................................................................................................................................. 9030-03-6
Multiplexing and the CANbus............................................................................................................. 9030-03-6
Troubleshooting the CANbus......................................................................................................... 9030-03-6
User Interface..........................................................................................................................................9030-03-7
User Interface, Setup, and Troubleshooting....................................................................................... 9030-03-7
Button Keypad................................................................................................................................9030-03-7
LED Indicator Lights....................................................................................................................... 9030-03-7
LCD Screen....................................................................................................................................9030-03-7
Dash Display Access......................................................................................................................9030-03-7
Status Code Toggling.....................................................................................................................9030-03-8
Automatic Diagnostics....................................................................................................................9030-03-8
Status Code Indication................................................................................................................... 9030-03-8
Status Codes and Descriptions...............................................................................................................9030-03-8
Status Codes...................................................................................................................................... 9030-03-8
Status Code Descriptions................................................................................................................... 9030-03-9
Warning Codes................................................................................................................................. 9030-03-12
Group 20 - Diagnostic Trouble Codes
DTC xx101 - CANBus Communications - Right Traction........................................................................9030-20-2
DTC xx102 - CANBus Communications - Left Traction.......................................................................... 9030-20-5
DTC xx103 - CANBus Communications - Lift......................................................................................... 9030-20-8
DTC xx109 - CANBus Communications - Display................................................................................ 9030-20-11
DTC xx106 - CANBus Communications - Handle.................................................................................9030-20-14
Lift Coil:
DTC 30001 - Right Traction - Lift Coil - Circuit
DTC 30002 - Right Traction - Lift Coil - Short...................................................................................9030-20-17
Lower Coil:
DTC 30003 - Right Traction - Lower Coil - Circuit
DTC 30004 - Right Traction - Lower Coil - Short..............................................................................9030-20-21
Load Hold Coil:
DTC 30005 - Traction - Load Hold Coil - Circuit
DTC 30006 - Traction - Load Hold Coil - Short ................................................................................9030-20-25
9030-1
Side-Shift Left Coil:
DTC 30019 - Traction - Side-Shift Left Coil - Circuit
DTC 30020 - Traction - Side-Shift Left Coil - Short ......................................................................... 9030-20-29
Side-Shift Right Coil:
DTC 30021 - Traction - Side-Shift Right Coil - Circuit
DTC 30022 - Traction - Side-Shift Right Coil - Short ....................................................................... 9030-20-32
Main Contactor Coil:
DTC 30033 - Traction - Main Contactor Coil - Circuit
DTC 30034 - Traction - Main Contactor Coil - Short.........................................................................9030-20-35
Brake Coil:
DTC 30035 - Right Traction - Brake Coil - Circuit
DTC 30036 - Right Traction - Brake Coil - Short
DTC 31035 - Left Traction - Brake Coil - Circuit
DTC 31036 - Left Traction - Brake Coil - Short.................................................................................9030-20-38
DTC 30062 - Right Traction Motor - Encoder....................................................................................... 9030-20-42
Main Contactor:
DTC 30067 - Traction - Main Contactor - Welded Tips
DTC 30068 - Traction - Main Contactor - Not Closed.......................................................................9030-20-45
Capacitor Charge:
DTC 30069 - Right Traction - Capacitor - Charge
DTC 31069 - Left Traction - Capacitor - Charge
DTC 50069 - Hoist - Capacitor - Charge.......................................................................................... 9030-20-49
DTC 30085 - Traction - Key Input - Voltage Low.................................................................................. 9030-20-53
DTC 30227 - Right Traction - Motor - Stalled........................................................................................9030-20-55
Motor and Cable:
DTC 30060 - Right Traction - Motor - Circuit
DTC 30061 - Right Traction - Motor - Short
DTC 31060 - Left Traction - Motor - Circuit
DTC 31061 - Left Traction - Motor - Short
DTC 50060 - Hoist - Motor - Circuit
DTC 50061 - Hoist - Motor - Short....................................................................................................9030-20-58
DC Bus Voltage:
DTC 30086 - Right Traction - DC Bus - Voltage Low
DTC 30087 - Right Traction - DC Bus - Voltage High
DTC 31086 - Left Traction - DC Bus - Voltage Low
DTC 31087 - Left Traction - DC Bus - Voltage High
DTC 50086 - Pump - DC Bus - Voltage Low
DTC 50087 - Pump - DC Bus - Voltage High................................................................................... 9030-20-62
Tilt Up Coil:
DTC 31013 - Left Traction - Tilt Up Coil - Circuit
DTC 31014 - Left Traction - Tilt Up Coil - Short ...............................................................................9030-20-66
Tilt Down Coil:
DTC 31015 - Left Traction - Tilt Down Coil - Circuit
DTC 31016 - Left Traction - Tilt Down Coil - Short .......................................................................... 9030-20-69
4th Function In Coil:
DTC 31025 - Left Traction - 4th In Coil - Circuit
DTC 31026 - Left Traction - 4th In Coil - Short ................................................................................ 9030-20-72
4th Function Out Coil:
DTC 31027 - Left Traction - 4th Out Coil - Circuit
DTC 31028 - Left Traction - 4th Out Coil - Short ............................................................................. 9030-20-75
Auxiliary Prop Valve:
DTC 31045 - Left Traction - Auxiliary Prop Valve - Circuit
DTC 31046 - Left Traction - Auxiliary Prop Valve - Short................................................................. 9030-20-78
DTC 31062 - Left Traction - Motor - Encoder........................................................................................9030-20-81
9030-2
DTC 31068 - Left Traction - Main Contactor - Not Closed.................................................................... 9030-20-85
DTC 31085 - Left Traction - Key Input - Voltage Low........................................................................... 9030-20-89
DTC 31227 - Left Traction - Motor - Stalled.......................................................................................... 9030-20-91
DTC 50062 - Hoist Motor - Encoder......................................................................................................9030-20-95
DTC 50085 - Pump - Key Input - Voltage Low......................................................................................9030-20-99
DTC 50228 - Pump - Lift/Lower - Stalled............................................................................................ 9030-20-101
Handle:
DTC 60054 - Handle - Traction - Axis Fault
DTC 60055 - Handle - Lift/Lower - Axis Fault
DTC 60056 - Handle - Tilt - Axis Fault
DTC 60057 - Handle - SS/Ext/Ret - Axis Fault
DTC 50057 - Pump - Handle - CAN I/O..........................................................................................9030-20-105
Handle Release :
DTC 60200 - Handle - Release - Lift/Lower
DTC 60201 - Handle - Release - Throttle
DTC 60211 - Handle - Release
DTC 60213 - Handle - Release - Brake
DTC 60221 - Handle - Release - Tilt Up
DTC 60222 - Handle - Release - Tilt Down
DTC 60223 - Handle - Release - Shift Left
DTC 60224 - Handle - Release - Shift Right...................................................................................9030-20-108
9030-3
9030-4
Electrical System General Maintenance and Diagnostic Data
Group 03
General Maintenance and Diagnostic Data
GENERAL TROUBLESHOOTING Troubleshooting is usually limited to accessing status

codes and following the diagnostic procedure provi-
In the event the lift truck does not operate correctly, a ded for each status code.
status code is displayed on the display panel. Once
the status code is obtained, follow the procedures out- Use standard testing procedures to verify inputs and
lined in this manual only after reviewing the following outputs when necessary.
information regarding the truck’s unique electrical sys-
tem and troubleshooting procedures.
CAUTION
The onboard diagnostic system employed on the ve- Never attempt to probe through the back of the
hicle can assist in the troubleshooting process. Read connector plugs of the motor controller. These
and be familiar with the instructions for accessing and plugs are special sealed plugs. Probing through
using the display's diagnostic system in 2200 SRM . the back of the plugs will destroy the seal and can
cause a short circuit. If a circuit must be tested for
Prior to troubleshooting systems and components on voltage, check for voltage at an amp-type plug, a
the vehicle, ensure the battery voltage is correct and switch, or component. If a circuit is suspect,
within specifications. Make sure the battery connector check the circuit for continuity by disconnecting
contacts are clean of corrosion and the battery polar- the plug and testing continuity from the front (pin
ity within the connector is correct. Inspect that all end) of the plug.
fuses are correct and are not the cause of component
failure. Ensure the key switch is in the ON position Standard probes are too large to be inserted into
when conducting voltage checks or verifying the oper- the center of female pins (sockets) of the special
ation of a component. Make sure the brake switch sealed plugs and can damage or expand the pins.
and the operator presence switch, if equipped, are Expanded pins will not provide good connections
functioning properly and are closed. once the plug is reconnected. The connectors are
shaped to allow the insertion of a small flat-blade
Many faults noted by lift truck’s electrical system may screwdriver into the connector. After inserting the
be the result of loose wiring connections and/or bro- screwdriver into the connector, attach probes
ken or shorted wiring within the lift truck. Begin the with alligator clips to the shank of the screwdriver
troubleshooting process by carefully inspecting the to obtain readings. An additional method would
wiring involving the device or devices noted by the on- be to use Breakout Kit #1397311 .
board diagnostic system. .
Refer to 8000 SRM 1420 for wiring diagrams and ad-
The controllers are sealed units with no serviceable ditional circuit information.
components.
9030-03-1
General Maintenance and Diagnostic Data Electrical System
DISCHARGING THE CAPACITORS component in the electrical compartments. Make

certain that the battery has been disconnected.
When working with the electrical systems of the truck,
it is necessary to discharge the internal or external ca- DO NOT short across the motor controller termi-
pacitors of the controllers associated with each circuit nals with a screwdriver or jumper wire.
affected.
Make certain the Emergency Disconnect Switch
has not been activated. This will isolate the con-
WARNING troller and prevent the capacitors from discharg-
ing properly. The proper way to disconnect the
DO NOT make repairs or adjustments unless you
battery is by separating the battery connectors.
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate CAUTION
a lift truck that needs repairs. Report the need for To avoid controller damage, always disconnect
repairs to your supervisor immediately. If repair is the battery, discharge the internal or external ca-
necessary, attach a DO NOT OPERATE tag to the pacitors, and never put power to the controller
control handle and disconnect the battery. while any power wires are disconnected. Never
short any controller terminal or motor terminal to
Disconnect the battery and discharge the internal
the battery. Make sure to use proper procedure
or external capacitors before opening any com-
when servicing the controller.
partment covers or inspecting or repairing the
electrical system. DO NOT place tools on top of 1. Move the lift truck to a safe, level area and com-
the battery. If a tool causes a short circuit, the pletely lower the mast. Turn the key switch to the
high current flow from the battery can cause per- OFF position and attach a DO NOT OPERATE
sonal injury or property damage. tag to the control handle. Block the drive wheel to
prevent unexpected movement.
Some checks and adjustments are performed with
the battery connected. DO NOT connect the bat- 2. Disconnect the battery power cable connector
tery until the procedure instructs you to do so. from the truck connector located on the right side
Never wear jewelry or other metallic items on your of the frame. Pull the battery cable connector han-
fingers, arms, or neck when working near electri- dle to separate the battery connector from the
cal components. Metal items can accidentally truck connector.
make an electrical connection and cause injury.
3. Remove the operator compartment cover.
Before performing any tests or adjustments, block
the lift truck to prevent unexpected movement. 4. Discharge the internal or external capacitors in
the controllers by connecting a 200-ohm, 2-watt
The capacitors in the transistor controllers can resistor across the controller B(+) and B(-) termi-
hold an electrical charge after the battery is dis- nals of the motor controller. Remove the resistor
connected. To prevent an electrical shock and after discharging the capacitors. See Fig-
personal injury, discharge the internal or external ure 9030-03-1 and Figure 9030-03-2.
capacitors before inspecting or repairing any
9030-03-2
1. POSITIVE CONNECTION B(+)

2. NEGATIVE CONNECTION B(-) 1. POSITIVE CONNECTION B(+)
3. INSULATED JUMPER WIRES 2. NEGATIVE CONNECTION B(-)
4. 200-OHM, 2-WATT RESISTOR 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 9030-03-1. Discharging the Internal
Capacitors - Lift Controller Figure 9030-03-2. Discharging the Internal
Capacitors - Traction Controller
9030-03-3
Jumper Wires, Test Leads, and Test Lights

ELECTRICAL TEST EQUIPMENT
When using jumper wires, test leads, and test lights,
Before beginning intrusive circuit checks, verify the take care not to force tips into connector sockets. Use
vehicle battery state of charge. Visually inspect sus- appropriate clips and adapters to prevent damage to
pected connectors for loose, damaged, or corroded connectors. Expanded or damaged sockets can
terminals. Check for blown fuses and inspect circuits cause poor continuity between connections.
for cause of overcurrent conditions. Physically check
mechanical operation to ensure a switch, relay, or sol- Jumper wires allow testing across a suspected open
enoid is not sticking or damaged. in the circuit. Jumper wires can be used for located
opens, shorts, and performing voltage drops. If a cir-
NOTE: Measuring continuity between two terminals cuit operates correctly with the jumper wire in place,
of a switch while operating the switch will determine and is faulty when the jumper wire is removed, a fault
its functionality. can be found in the bypassed location.
Jumper wires can also be used to eliminate sections

PC Service Tool of the circuit to diagnose either power or grounds. Us-
ing the jumper wire to provide a component a known
The PC Service Tool is a Windows based service ap- good ground can help reduce the amount of checks
plication that is used to communicate with the truck’s needed to diagnose a circuit.
electrical control system. It can be used to monitor the
status and condition of various systems. With this ca- Jumper wires can be used to bypass components
pability, the PC Service Tool can be used to monitor such as switches. If a faulty switch is suspected, re-
component operation, or determine if abnormal moving it from the circuit with a jumper wire can deter-
events have occurred in the truck, and assist with di- mine if a switch or component is at fault.
agnostics and troubleshooting.
Jumper wires can be used to check for open or faulty
Breakout Kit #1397311 relay contacts which are often sealed and can take
additional steps to properly diagnose.
The Breakout Kit allows the technician to perform cir-
cuit input and output checks at the controllers’ con- Test lights can be used when quick voltage or ground
nectors. The Breakout kits primary function allows the checks are necessary. Many features operate on
technician to diagnose circuit faults while the vehicle’s switched voltage, and using a test light as a load de-
circuits are connected and operating. This is done by vice may be helpful. The test light may also be used
installing the breakout kit in series with the controller to verify continuity to B-. Discretion should be used
and its circuits. when troubleshooting a circuit using a test light, as
the light may illuminate even though there may be an
Digital Multimeter (DMM) excessive amount of resistance on the ground circuit
or when a low voltage or amperage situation exists.
Digital multimeters provide several measurement
functions in one tool. A DMM should be capable of ac-
curately measuring voltage, amperage, and resist-
ance. Ensure that the multimeter used in trouble-
shooting procedures is accurate and that the test
leads do not have excessive resistance. A faulty me-
ter or damaged test leads will cause inaccurate read-
ings and incorrect electrical diagnoses.
9030-03-4
Basic Electrical Troubleshooting

ELECTRICAL CHECKS Amperage Checks
The following electrical checks are used to diagnose An ammeter is used to measure amperage or current
circuit and component faults on trucks. Review the fol- flow through a circuit. An ampere is the measurement
lowing information so that it may be applied when di- of electron flow, which can be used to measure the
agnosing a fault or status code. amount of electrons that are flowing through a circuit.
Ohm’s Law states that current flow in a circuit is equal
Voltage Checks to the circuit voltage divided by total circuit resistance,
known as the potential difference. Since amperage is
Voltage is electrical pressure or force that pushes cur- the current in the circuit, increasing voltage also in-
rent through a circuit. The force is measured in volts. creases the current, or amperage levels.
Low voltage to a load device will cause the device to Measuring amperage is always performed by placing
be inoperative or operate poorly. This can be caused the ammeter in series with the device or circuit. This
by a low battery source, high circuit resistance, poor will cause all current to flow through the protected me-
connections, or an open circuit; the resistance of poor ter. The circuit must be operating in order to measure
connections or poor ground acts as an additional load amperage. Never measure amperage on high amper-
in the circuit, causing low voltage pushing current, or age circuits or in parallel to a circuit, this can result in
amperage, through a device. the damage of the meter and the electrical system.
A voltmeter is used to perform: Resistance Checks

• Measurement of force
The ohmmeter is used to measure a circuit or device's
• Presence of voltage resistance in ohms. Ohmmeters use low internal volt-
• Voltage drops age and current which flow through an isolated circuit
or device being tested. The voltage of the meter bat-
When using a voltmeter to determine if voltage is tery and the amount of current flow in the circuit are
present and capable of operating a device, connect used to calculate the circuit’s resistance. It is neces-
the positive meter lead to the power circuit of a de- sary to disconnect or isolate the circuit being test so
vice’s connector and connect the negative meter lead not to damage the vehicle’s electrical system or the
to the negative battery terminal. ohmmeter.
Measuring the voltage drop is performed by connect- An ohmmeter is used to perform:

ing the positive test lead to the positive side of the de- • Resistance of a load device
vice while simultaneously connecting the negative
meter lead to the negative side of the device. The test • Resistance of conductors
can also be performed across a section of wire that is • Value of resistors
faulty and suspected of having excessive resistance. • Operation of variable resistors
A voltage drop must be performed while the device is
operating. In a circuit with a single load device, the • CANbus termination resistors
device will drop the total voltage of the circuit. If the • Continuity
device drops less than battery voltage, it can be as-
sumed that the circuits are using the remaining volt-
age as a source of excessive resistance or a poor
connection exists, assuming the battery state-of-
charge is correct.
9030-03-5
Contactor and Contactor Coil Checks Is resistance <1 ohm?
1. Measure voltage between the coil's positive termi- YES- Proceed to Step 3.
nal and B(-).
NO- Inspect ground control circuit. Verify that control-
NOTE: Key in ON position.
ler is receiving device input signal.
Is voltage same as truck's battery voltage?
3. Measure battery voltage between main contac-
tor's battery B(+) terminal and B(-).
YES- Proceed to Step 2.
NO- Inspect the Coil's battery B(+) input circuit for
open or short. Is voltage same as truck's battery voltage?
2. Disconnect coil's ground control circuit. Measure YES- Repair or replace faulty contactor.
resistance between ground circuit terminal and
B(-). NO- Inspect main contactor battery cable for loose,
damaged, or corroded connections.
NOTE: Actuate coil ground control.
Multiplexing
MULTIPLEXING AND THE CANBUS. If CAN HI is shorted to B(-) or CAN LO is shorted to
battery voltage, network communication will stop.
Controller Area Network (CAN) Bus communication
allows multiple modules to communicate with each If you measure battery voltage on the data link, there
other using the same digital data on a shared net- is a short to power in the circuit.
work, this method of communication is known as mul-
tiplexing. The CANbus is a pair of twisted insulated If you measure 0 volts while the CANBus is active,
wires that interconnect all the modules on the net- there is a short to B(-) or an open in the circuit.
work. The data transmitted is a digital encoded for-
mat. Digital means only two states are used to trans- Internal control module failures can stop the entire
mit data, High/On and Low/Off. This eliminates the network from communicating. If there are no harness
need for each module to be hard wired to each sen- problems, disconnect control modules one at a time
sor. Using Multiplexing, sensor information that may until CANbus communication returns.
be received by one module, can then be shared with
all other modules. The information is sent out over the With both 120 ohm termination resistors connected to
CANbus in an encoded form and any other module the CANbus, resistance between the two circuits
that requires the information can pick it out from the should read 60 ohms.
data stream.
If CANbus resistance is 120 ohms, there is an open
Troubleshooting the CANbus circuit or a termination resistor is missing.
NOTE: Refer to the latest Diagram SRM for the most If resistance is 0 ohms, the two circuits are shorted to-
current circuit information. gether.
When the CANbus is active and modules are commu- 1. Measure voltage between the diagnostic connec-
nicating, CAN HI and CAN LO voltage will be approxi- tor, socket A and B(-).
mately 5 volts when added together. If both CAN HI
and CAN LO have consistent 2.5 volt, there is no NOTE: Key in ON position.
communication on the CANbus.
9030-03-6
Is voltage approximately 2.5 volts? B(-) or open. If voltage is above 5 volts, the CAN
LO is shorted to power.
YES- Proceed to Step 2.
3. Measure resistance between the diagnostic con-
NO- Inspect CAN HI circuit for open or short; if volt- nector, socket A and socket B.
age is 0 volts, the CAN HI circuit is shorted to B(-)
or open. If voltage is above 5 volts, the CAN HI is Is resistance 60 ± 6 ohms?
shorted to power.
YES- CANbus communication is operating cor-
2. Measure voltage between the diagnostic connec- rectly.
tor, socket B and B(-).
NO- If resistance is 120 ohms; the CANbus has an
NOTE: Key in ON position. open circuit, missing, or damaged termination re-
sistor. If resistance is 0 ohms, the CANbus circuits
Is voltage approximately 2.5 volts? are shorted together. If resistance is open; the CAN
HI and/or CAN LO connection to the diagnostic port
YES- Disconnect the battery and proceed Step 3.
may be open. Use the wiring diagrams to detect
NO- Inspect the CAN LO circuit for open or short; If and correct open circuit.
voltage is 0 volts, the CAN LO circuit is shorted to
User Interface
USER INTERFACE, SETUP, AND • Temperature Indicator
TROUBLESHOOTING • Operator Symbol
The dash display has a LCD screen for displaying • Warning Indicator
truck system information. The display has five indica-
tor lights for truck function status. There are five num- LCD Screen
ber keys for password. Number keys 1-4 are also
used for navigating the on-board setup and service The LCD screen displays the following when the key
menus. The dash display also contains a battery is in the ON position:
state-of-charge indicator and is equipped to allow op- 1. Indicator symbols will illuminate from left to
erator selectable drive modes. right.
2. The truck horn will beep.
Button Keypad
3. The battery state-of-charge will illuminate.
The button keypad is located on the right side of the 4. Performance mode will be displayed.
display. It consists of four buttons arranged in a circle 5. Steer angle indicator will be displayed.
with a fifth button in the center. The buttons are num-
bered 1 through 5, starting with button 1 at the top 6. Truck speed indicator will be displayed.
and continuing clockwise and ending with button 5 sit- 7. Truck hours will be displayed.
uated in the center of the keypad.
Dash Display Access
LED Indicator Lights
The operator passwords are a series of five-digit num-
The LED indicator lights are located on the display bers. Each of the five number digits can be the num-
below the LCD screen and to the left of the button bers 1 through 5. If enabled, the password number
keypad. The lights illuminate to notify the operator of series must be entered into the memory by a techni-
certain conditions. The function of each light (in order cian or supervisor and assigned to an operator. A cer-
from left to right) is as follows: tified dealer technician can use a personal computer
• Battery Indicator (PC), connected to the lift truck, to check and assign
passwords.
• Wrench Indicator
9030-03-7
After the key is moved to the ON position, the LCD switch from the normal display screen to the status
screen will show ENTER PASSWORD, if this function code screen. Pressing the 4 button will cause the dis-
is enabled. Use the numbered push buttons to enter play to return from the status code screen to the nor-
the five-digit password. The password can be entered mal display.
as many times as needed. If the password is entered
incorrectly, the message PASSWORD ERROR will Automatic Diagnostics
appear and the operator will be prompted to ENTER
PASSWORD again. This feature allows for immediate access to diagnos-
tics associated with status codes. To use this feature,
Refer to User Interface manual User Interface SERV- press the 5 button while viewing the status code
ICE TECHNICIAN S/N B219N02284L=> screen. If diagnostics are available with the code, the
2200SRM1653 for further information regarding the diagnostics will be immediately entered.
User Interface for either Supervisor or Technician ap-
plication. Status Code Indication
Status Code Toggling This feature indicates if a status code is available

when in the normal screen. If a status code is present,
This feature allows the operator to toggle the display the mode indicator will display “!”.
from the normal screen display to the status code
screen. Pressing the 2 button will cause the display to
Status Codes and Descriptions

STATUS CODES NODE 60: HANDLE
Status codes give an indication to the operator that a Status Codes are displayed as four lines. Line one
possible malfunction or incorrect truck use has occur- consist of the Node and Code number. The second
red. Status codes are a code number of a symptom or line consists of the Node name while lines three and
malfunction. The wrench symbol will flash and the sta- four contain code descriptions. For example, Status
tus code number will be shown on the LCD screen if Code 31013 is shown in the Status Code Structure
an incorrect truck use or malfunction occurs during Table 9030-03-1. This Status Code is set when a Tilt
operation. Have an authorized service person check Up coil circuit fault is detected by the left Traction con-
and repair the lift truck if a status code number ap- troller.
pears. The symptoms for each status code are shown
in this manual. This manual also provides in-depth Table 9030-03-1. Status Code Structure
troubleshooting procedures for each fault broken
down into the following system or node: LINE NUMBER LINE DESCRIPTION
NODE 10: DISPLAY LINE 1 31013
NODE 30: RIGHT TRACTION LINE 2 Left Traction
NODE 31: LEFT TRACTION LINE 3 Tilt Up Coil
NODE 50: PUMP LINE 4 Circuit
9030-03-8
STATUS CODE DESCRIPTIONS

Status Codes can be reported by any Node that detects a fault.
Table 9030-03-2. Node 10 Status Codes
NODE STATUS DESCRIPTION

10 099 The Display has detected an Internal Fault. *.
10 101 The Display has detected a loss of CAN communication with the Right Traction Controller.
*
10 102 The Display has detected a loss of CAN communication with the Left Traction Controller. *
10 103 The Display has detected a loss of CAN communication with the Hoist Motor Controller. *
10 109 Loss of Display CAN communication. *
* Any Node or system that detects an internal fault is capable of reporting a 099 Status Code. Refer to the xx099 Status Code
troubleshooting procedures for all Internal Fault Codes regardless of what Node has reported the fault.

30 001 The Right Traction Controller has detected a fault in the Lift Coil circuit.
30 002 The Right Traction Controller has detected a short in the Lift Coil circuit.
30 003 The Right Traction Controller has detected a fault in the Lower Coil circuit.
30 004 The Right Traction Controller has detected a short in the Lower Coil circuit.
30 005 The Right Traction Controller has detected a fault in the Load Hold Coil circuit.
30 006 The Right Traction Controller has detected a short in the Load Hold Coil circuit.
30 019 The Right Traction Controller has detected a fault in the Side-Shift Left Coil circuit.
30 020 The Right Traction Controller has detected a short in the Side-Shift Left Coil circuit.
30 021 The Right Traction Controller has detected a fault in the Side-Shift Right Coil circuit.
30 022 The Right Traction Controller has detected a short in the Side-Shift Right Coil circuit.
30 033 The Right Traction Controller has detected a fault in the Main Contactor Coil circuit.
30 034 The Right Traction Controller has detected a short in the Main Contactor Coil circuit.
30 035 The Right Traction Controller has detected a fault in the Brake Coil circuit.
30 036 The Right Traction Controller has detected a short in the Brake Coil circuit.
30 060 The Right Traction Controller has detected a fault in the traction motor or traction motor
circuit.
30 061 The Right Traction Controller has detected a short in the Traction Motor or circuit.
30 062 The Right Traction Controller has detected a motor encoder fault.
30 067 The Right Traction Controller has detected that the Main Contactor is stuck closed or has
welded tips.
30 068 The Right Traction Controller has detected that the Main Contactor is not closed or stuck
open.
30 069 The Right Traction Controller has detected a fault in Capacitor charge.
9030-03-9
Table 9030-03-3. Node 30 Status Codes (Continued)

30 085 The Right Traction Controller has detected low key input voltage or a fault in the key input
circuit.
30 086 The Right Traction Controller has detected Low DC Bus Voltage or a fault in the DC Bus
circuit.
30 087 The Right Traction Controller has detected High DC Bus Voltage or a fault in the DC Bus
circuit.
30 227 The Right Traction motor has stalled.

31 013 The Left Traction Controller has detected a fault in the Tilt Up Coil circuit.
31 014 The Left Traction Controller has detected a short in the Tilt Up Coil circuit.
31 015 The Left Traction Controller has detected a fault in the Tilt Down Coil circuit.
31 016 The Left Traction Controller has detected a short in the Tilt Down Coil circuit.
31 025 The Left Traction Controller has detected a fault in the 4th IN Coil circuit.
31 026 The Left Traction Controller has detected a short in the 4th IN Coil circuit.
31 027 The Left Traction Controller has detected a fault in the 4th OUT Coil circuit.
31 028 The Left Traction Controller has detected a short in the 4th OUT Coil circuit.
31 035 The Left Traction Controller has detected a fault in the Brake Coil circuit.
31 036 The Left Traction Controller has detected a short in the Brake Coil circuit.
31 045 The Left Traction Controller has detected a fault in the Auxiliary Prop Valve Coil circuit.
31 046 The Left Traction Controller has detected a short in the Auxiliary Prop Valve Coil Circuit.
31 060 The Left Traction Controller has detected a fault in the traction motor or traction motor
circuit.
31 061 The Left Traction Controller has detected a short in the Traction Motor or circuit.
31 062 The Left Traction Controller has detected a motor encoder fault.
31 068 The Left Traction Controller has detected that the Main Contactor is not closed or stuck
open.
31 069 The Left Traction Controller has detected a fault in the Capacitor charge.
31 085 The Left Traction Controller has detected low key input voltage or a fault in the key input
circuit. See Troubleshooting Procedure .
31 086 The Left Traction Controller has detected Low DC Bus Voltage or a fault in the DC Bus
circuit.
31 087 The Left Traction Controller has detected High DC Bus Voltage or a fault in the DC Bus
circuit.
31 227 The Left Traction motor has stalled. See Troubleshooting Procedure .
9030-03-10

50 057 The Hoist Motor Controller has detected a SS/EX/RET Axis fault.
50 060 The Hoist Motor Controller has detected a fault in the Hoist Motor or circuit.
50 061 The Hoist Motor Controller has detected an short in the Hoist Motor or circuit.
50 062 The Hoist Motor Controller has detected a fault in the encoder.
50 069 The Hoist Motor Controller has detected a fault in the Capacitor charge.
50 085 The Hoist Motor Controller has detected Low Key Input voltage.
50 086 The Hoist Motor Controller has detected Low DC Bus voltage.
50 087 The Hoist Motor Controller has detected High DC Bus voltage.
50 228 The Hoist Motor Controller has detected that Lift/Lower functions have stalled.

60 054 The Handle has detected a Traction Axis fault.
60 055 The Handle has detected a Lift/Lower Axis fault.
60 056 The Handle has detected a Tilt Axis fault.
60 057 The Handle had detected a SS/EX/RET Axis fault.
60 200 The Handle has detected a Lift/Lower Release fault.
60 201 The Handle has detected a Throttle Release fault.
60 211 The Handle has detected a Handle Release fault.
60 213 The Handle has detected a Brake Release fault.
60 221 The Handle has detected a Tilt Up Release fault.
60 222 The Handle has detected a Tilt Down Release fault.
60 223 The Handle has detected a Shift-Left Release fault.
60 224 The Handle has detected a Shift-Right Release fault.
9030-03-11
WARNING CODES electrical diagnosis. The following table of warning co-

des and descriptions may assist in troubleshooting
This section contains Status Codes that may not re- other faults the truck may encounter.
quire troubleshooting. It is possible that a warning
code may accompany an actual fault requiring further
Table 9030-03-7. Warning Codes
CODE NODE STATUS DESCRIPTION SYMPTOM

TYPE
XX 080 Motor Cutback* A controller has begun to reduce power to the motor in
attempt to manage increased temperatures that may
damage the motor. Motor cutback is initiated at
140°C (284°F). Truck performance will be reduced until
temperature lowers to an acceptable level. Motor
temperature input can be monitored in menu D2.32.6.
XX 081 Motor Overheated* Motor cutback (XX080) was unsuccessful. Motor cutback
is initiated at 160°C (320°F). The truck will severely limit
performance until the motor temperature returns to
normal. Motor temperature input can be monitored in
menu D2.32.6.
XX 082 Controller Cutback* A controller has begun to reduce power in attempt to
Thermal manage increased temperatures that may damage
internal components. Controller cutback is initiated at
90°C (194°F). Truck performance will be reduced until
temperature lowers to an acceptable level. Controller
temperature input can be monitored in menu D2.32.5.
XX 083 Controller Controller cutback (XX082) was unsuccessful. Controller
Overheated* cutback is initiated at 110°C (230°F). The truck will
severely limit performance until the motor temperature
returns to normal. Motor temperature input can be
monitored in menu D2.32.5.
XX 248 Low Temp* A controller has detected low temperature conditions.
Move truck to a warmer ambient condition an allow
sufficient time to warm.
32 229 Truck Locked Out Truck functions are locked out. Unlock truck functions by
disabling the Settings Menu item S15 TRUCK
LOCKOUT.
32 230 Checklist Not Operator Checklist was not completed or one of the items
Complete failed. Correct failed issue by operator and re-key truck. If
Checklist functionality is not needed, disable feature
Startup
through the Settings Menu S12 CHECKLIST
32 231 Maint Reminder Truck is nearing maintenance. Truck performance may be
turned down by the truck if maintenance is not performed.
If Maint Reminder functionality is not needed, disable
feature through the Settings Menu S13 MAINT
REMINDER.
9030-03-12
Table 9030-03-7. Warning Codes (Continued)
CODE NODE STATUS DESCRIPTION SYMPTOM

TYPE
32 244 Check Battery Battery installed is not the battery intended for truck
configuration or battery may be damaged. Inspect battery
and verify proper voltage battery being used and that the
battery is not damaged. Voltage should be between
19.2V and 28.8V and can be monitored in menu D2.32.8
CAP V.
32 245 Lift Interrupt Low Battery has been reduced to Lift Interrupt voltage levels.
Startup
Battery Truck will not lift and will sound horn when lifting is
(cont.)
attempted. If Lift Interrupt functionality is not needed,
disable feature through the Settings Menu S9 LIFT
INTERRUPT.
32 246 Serial Number The truck serial number in the display does not match the
Mismatch truck serial number in the master controller. If a new
controller is installed into the truck, the serial number of
the truck is automatically written to the new controller.
32 232 Download Software Software revisions for the truck controllers do not match a
known truck configuration. Re-download software/CDF
Software/ File using the Field Software Tool.
Parameter
Incorrect 32 247 Download Parameter Parameter value(s) in controller(s) are not set correctly.
Re-download the truck software/CDF file using the Field
Software Tool.
32 233 Calibrate Throttle Calibration of throttle is needed. Perform calibration in
Menu C4. Refer to the appropriate User Interface manual
for further calibration information.
Calibration
32 235 Calibrate Lift/Lower Calibration of Lift/Lower is needed. Perform calibration in
Menu C5. Refer to the appropriate User Interface manual
for further calibration information.
NA NA Operator Sensing The leg and egress sensors perform a self-check during
Operator
Self-check truck startup. If sensor faults are present, a warning will
Sensing
appear on the display. Repair or replace sensor indicated
System
on display.
*Any Node or system that detects a thermal fault is capable of reporting a Status Code.
9030-03-13
NOTES
9030-03-14
Electrical System Diagnostic Trouble Codes
Group 20
Diagnostic Trouble Codes
DTC xx099
Internal - Fault
POSSIBLE CAUSE
A. INTERNAL FAULT
COMPONENT OPERATIONAL CHECK
NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.
PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System SRM.
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Cause A.
NO: Problem may be intermittent.
CAUSE A - INTERNAL FAULT
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.
END POSSIBLE CAUSES
END FAULT
9030-20-1
Diagnostic Trouble Codes Electrical System
DTC xx101
CANBus Communications - Right Traction
POSSIBLE CAUSE
A. CANBUS COMMUNICATION FAULT

B. RIGHT TRACTION CONTROLLER WIRING FAULT
NOTE
Please refer to the end of this procedure for supporting diagrams.
System SRM.
YES: Proceed to Step 3.
3. Locate input diagnostics (D2.10) and verify right traction controller communication (D2.10.30).
Is the controller online?
YES: Fault may be intermittent.
4. Using input diagnostics (D2.10), determine if other nodes are offline.
Are other nodes offline?
YES: Verify CAN HI and CAN LO voltages of offline node(s).
NO: Proceed to Cause A.
CAUSE A - CANBUS COMMUNICATION FAULT
NOTE: Key in ON position
1. Disconnect the right traction controller connector CPS41. Measure voltage between the traction controller
connector CPS41, socket 28 and B(-).
Is CAN HI voltage approximately 2.5 Vdc?
NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.
9030-20-2
DTC xx101 (Cont)

2. Measure voltage between the right traction controller connector CPS41, socket 27 and B(-).
Is CAN LO voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the right traction controller connector CPS41, socket 27 and socket 28.
Is resistance 60 ± 6 ohms?
YES: No communication faults are present, connect battery and proceed to Cause B.
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.
If resistance is 0 ohms, the CANbus circuits are shorted together.
CAUSE B - RIGHT TRACTION CONTROLLER WIRING FAULT
1. Measure voltage between the traction controller B(+) terminal and B(-).
Is voltage 36 ± 3.5 Vdc?
YES: Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an
accurate problem description leading to controller replacement.
NO: Inspect power and ground cables for damage and loose connections
END POSSIBLE CAUSES
9030-20-3
DTC xx101 (Cont)

DTC XX101 CANBUS COMMUNICATIONS - RIGHT TRACTION DIAGRAMS
Troubleshooting Scene
END FAULT
9030-20-4
DTC xx102
CANBus Communications - Left Traction
POSSIBLE CAUSE

B. LEFT TRACTION CONTROLLER WIRING FAULT
NOTE
System SRM.
3. Locate input diagnostics (D2.10) and verify left traction controller communication (D2.10.31).
1. Disconnect the left traction controller connector CPS42. Measure voltage between the traction controller con-
nector CPS42, socket 28 and B(-).
2. Measure voltage between the left traction controller connector CPS42, socket 27 and B(-).
9030-20-5
DTC xx102 (Cont)

3. Measure resistance between the left traction controller connector CPS42, socket 27 and socket 28.
CAUSE B - LEFT TRACTION CONTROLLER WIRING FAULT
1. Measure voltage between the traction controller B(+) terminal and B(-).
END POSSIBLE CAUSES
9030-20-6
DTC xx102 (Cont)

DTC XX102 CANBUS COMMUNICATIONS - LEFT TRACTION DIAGRAMS
END FAULT
9030-20-7
DTC xx103
CANBus Communications - Lift
POSSIBLE CAUSE

B. HOIST MOTOR CONTROLLER WIRING FAULT
NOTE
System SRM.
3. Locate input diagnostics (D2.10) and verify lift controller communication (D2.10.50).
YES: Suspect short to frame.
1. Disconnect the hoist motor controller connector CPS15. Measure voltage between the connector CPS15,
socket 21 / 12 and B(-).
9030-20-8
DTC xx103 (Cont)

2. Measure voltage between the hoist motor controller connector CPS15, socket 20 and B(-).
3. Measure resistance between the hoist motor controller connector CPS15, socket 21 / 12 and socket 20.
CAUSE B - HOIST MOTOR CONTROLLER WIRING FAULT
1. Measure voltage between the hoist motor controller B(+) terminal and B(-).
NO: Inspect power and ground cables for damage and loose connections.
END POSSIBLE CAUSES
9030-20-9
DTC xx103 (Cont)

DTC XX103 CANBUS COMMUNICATIONS - LIFT DIAGRAMS
END FAULT
9030-20-10
DTC xx109
CANBus Communications - Display
POSSIBLE CAUSE

B. DISPLAY CONTROLLER WIRING FAULT
NOTE
System SRM.
YES: If display diagnostic menu is operational, proceed to Step 3. If display is inoperative, proceed to Cause
A.
1. Disconnect the display connector CPS20 and measure voltage between socket 3 and B(-).
2. Measure voltage between the display connector CPS20, socket 4 and B(-).
3. Measure resistance between the display connector CPS20, socket 3 and socket 4.
9030-20-11
DTC xx109 (Cont)

CAUSE B - DISPLAY CONTROLLER WIRING FAULT
1. Measure voltage between the display connector CPS20, socket 4 and B(-).
END POSSIBLE CAUSES
9030-20-12
DTC xx109 (Cont)

DTC XX109 CANBUS COMMUNICATIONS - DISPLAY DIAGRAMS
END FAULT
9030-20-13
DTC xx106
CANBus Communications - Handle
POSSIBLE CAUSE

B. HANDLE WIRING FAULT
NOTE
System SRM.
YES: If display diagnostic menu is operational, proceed to Step 3. If handle is inoperative, proceed to Cause
A.
Are other nodes online?
1. Disconnect the handle connector CPS040 and measure voltage between socket 4 and B(-).
2. Measure voltage between the handle connector CPS040, socket 5 and B(-).
3. Measure resistance between the handle connector CPS040, socket 4 and socket 5.
9030-20-14
DTC xx106 (Cont)

CAUSE B - HANDLE WIRING FAULT
1. Measure voltage between the handle connector CPS040, socket 6 and B(-).
YES: Replace faulty handle. Make sure to indicate the DTC code(s) on the warranty claim to include an accu-
rate problem description leading to handle replacement.
NO: Inspect power and ground circuits for open, short, or source of excessive resistance.
END POSSIBLE CAUSES
9030-20-15
DTC xx106 (Cont)

DTC XX106 CANBUS COMMUNICATIONS - HANDLE DIAGRAMS
END FAULT
9030-20-16
Lift Coil
CODES
DTC 30001 - Right Traction - Lift Coil - Circuit

DTC 30002 - Right Traction - Lift Coil - Short
POSSIBLE CAUSE
A. LIFT COIL WIRING FAULT

B. LIFT COIL FAULT
C. FAULTY RIGHT TRACTION CONTROLLER
NOTE
System SRM.
CAUSE A - LIFT COIL WIRING FAULT
1. Disconnect the lift coil and measure voltage between socket TBF41A and B(-).
NO: Inspect circuit 200A for open or short. Inspect 10A Fuse FU4.
NOTE: Key in OFF position.
2. Disconnect the right traction controller connector CPS41. Measure resistance between the traction controller
connector CPS41, socket 23 and the lift coil connector, socket TBF41B.
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground control circuit 800A for open or short.
9030-20-17
Lift Coil (Cont)

CAUSE B - LIFT COIL FAULT
1. Measure resistance across the lift coil terminals.

Is coil resistance 20 ± 2 ohms?
YES: Proceed to Cause C.
NO: Replace faulty coil.
CAUSE C - FAULTY RIGHT TRACTION CONTROLLER
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.
END POSSIBLE CAUSES
9030-20-18
Lift Coil (Cont)

DIAGRAMS
9030-20-19
Lift Coil (Cont)
END FAULT
9030-20-20
Lower Coil
CODES
DTC 30003 - Right Traction - Lower Coil - Circuit

DTC 30004 - Right Traction - Lower Coil - Short
POSSIBLE CAUSE
A. LOWER COIL WIRING FAULT

B. LOWER COIL FAULT
NOTE
System SRM.
CAUSE A - LOWER COIL WIRING FAULT
1. Disconnect the lower coil and measure voltage between socket TBF40A and B(-).
connector CPS41, socket 24 and the lower coil connector, socket TBF40B.
9030-20-21
Lower Coil (Cont)

CAUSE B - LOWER COIL FAULT
1. Measure resistance across the lower coil terminals.

NO: Replace faulty coil.
END POSSIBLE CAUSES
9030-20-22
Lower Coil (Cont)

DIAGRAMS
9030-20-23
Lower Coil (Cont)
END FAULT
9030-20-24
Load Hold Coil

CODES
DTC 30005 - Traction - Load Hold Coil - Circuit

DTC 30006 - Traction - Load Hold Coil - Short
POSSIBLE CAUSE
A. LOAD HOLD COIL WIRING FAULT

B. LOAD HOLD COIL FAULT
NOTE
System SRM.
CAUSE A - LOAD HOLD COIL WIRING FAULT
1. Disconnect the load hold coil and measure voltage between socket TBF43A and B(-).
connector CPS41, socket 34 and the load hold coil connector, socket TBF43B.
9030-20-25
Load Hold Coil (Cont)

CAUSE B - LOAD HOLD COIL FAULT
1. Measure resistance across the load hold coil terminals.

NO: Replace faulty load hold coil.
END POSSIBLE CAUSES
9030-20-26

DIAGRAMS
9030-20-27
END FAULT
9030-20-28
Side-Shift Left Coil

CODES
DTC 30019 - Traction - Side-Shift Left Coil - Circuit

DTC 30020 - Traction - Side-Shift Left Coil - Short
POSSIBLE CAUSE
A. SIDE-SHIFT LEFT COIL WIRING FAULT

B. SIDE-SHIFT LEFT COIL FAULT
NOTE
System SRM.
CAUSE A - SIDE-SHIFT LEFT COIL WIRING FAULT
1. Disconnect the side-shift left coil and measure voltage between socket TBF47A and B(-).
connector CPS41, socket 33 and the side-shift left coil connector, socket TBF47B.
9030-20-29
Side-Shift Left Coil (Cont)

CAUSE B - SIDE-SHIFT LEFT COIL FAULT
1. Measure resistance across the side-shift left coil terminals.

NO: Replace faulty side-shift left coil.
END POSSIBLE CAUSES
9030-20-30
Side-Shift Left Coil (Cont)

DIAGRAMS
END FAULT
9030-20-31
Side-Shift Right Coil

CODES
DTC 30021 - Traction - Side-Shift Right Coil - Circuit

DTC 30022 - Traction - Side-Shift Right Coil - Short
POSSIBLE CAUSE
A. SIDE-SHIFT RIGHT COIL WIRING FAULT

B. SIDE-SHIFT RIGHT COIL FAULT
NOTE
System SRM.
CAUSE A - SIDE-SHIFT RIGHT COIL WIRING FAULT
1. Disconnect the side-shift right coil and measure voltage between socket TBF42A and B(-).
connector CPS41, socket 11 and the side-shift right coil connector, socket TBF42B.
9030-20-32
Side-Shift Right Coil (Cont)

CAUSE B - SIDE-SHIFT RIGHT COIL FAULT
1. Measure resistance across the side-shift right coil terminals.

NO: Replace faulty side-shift right coil.
END POSSIBLE CAUSES
9030-20-33
Side-Shift Right Coil (Cont)

DIAGRAMS
END FAULT
9030-20-34
Main Contactor Coil

CODES
DTC 30033 - Traction - Main Contactor Coil - Circuit

DTC 30034 - Traction - Main Contactor Coil - Short
POSSIBLE CAUSE
A. CONTACTOR COIL WIRING FAULT

B. CONTACTOR COIL FAULT
NOTE
System SRM.
3. Locate input diagnostics (D2.30) and verify the main contactor position (D2.30.16).
Is the main contactor closed at correct time?
4. Locate output diagnostics (D3.30) and actuate the main contactor coil (D3.30.7).
Does contactor operate correctly when actuated?
CAUSE A - CONTACTOR COIL WIRING FAULT
1. Disconnect the contactor coil connector TF21 and measure voltage between socket TF21 and B(-).
NO: Inspect circuit 010 for open or short.
2. Disconnect the right traction controller connector CPS41. Measure resistance between line contactor coil con-
nector TB22 and the traction controller connector CPS41, socket 12.
9030-20-35
Main Contactor Coil (Cont)

NO: Inspect ground control circuit 0725 for open or source of excessive resistance.
CAUSE B - CONTACTOR COIL FAULT
1. Measure resistance between the coil terminals.
Is coil resistance between 65 and 85 ohms?
NO: Replace faulty contactor coil.
END POSSIBLE CAUSES
9030-20-36
Main Contactor Coil (Cont)

DIAGRAMS
END FAULT
9030-20-37
Brake Coil
CODES
DTC 30035 - Right Traction - Brake Coil - Circuit

DTC 30036 - Right Traction - Brake Coil - Short
DTC 31035 - Left Traction - Brake Coil - Circuit
DTC 31036 - Left Traction - Brake Coil - Short
POSSIBLE CAUSE
A. BRAKE COIL WIRING FAULT

B. BRAKE COIL FAULT
C. FAULTY TRACTION CONTROLLER
NOTE
System SRM.
3. Locate input diagnostics (D2.30) and verify brake coil circuit connect (D2.30.14).
Is the brake coil circuit connected?
4. Locate output diagnostics (D3.30) and actuate brake coil (D3.30.6).

Does brake coil operate correctly when actuated?
CAUSE A - BRAKE COIL WIRING FAULT
1. Disconnect the brake contactor coil connector CPS24/26 and measure voltage between socket 2 and B(-).
9030-20-38
Brake Coil (Cont)

YES: Disconnect battery and proceed to Step 1 for right traction controller brake coil. Disconnect battery and
proceed to Step 2 for left traction controller brake coil.
NO: Inspect circuits 096/097 and 096A/097A for open or short. Inspect connectors for loose or damaged con-
nections.
2. Disconnect the right traction controller connector CPS41. Measure resistance between brake contactor coil
connector CPS24, socket 1 and the traction controller connector CPS4, socket 4.
NO: Inspect ground control circuits 202 and 202A for open or source of excessive resistance.
3. Disconnect the left traction controller connector CPS42. Measure resistance between brake contactor coil
connector CPS26, socket 1 and the traction controller connector CPS42, socket 4.
NO: Inspect ground control circuits 203 and 203A for open or source of excessive resistance.
CAUSE B - BRAKE COIL FAULT
1. Measure resistance between the brake coil connector CPS24/26, terminals.
NO: Replace faulty brake coil.
CAUSE C - FAULTY TRACTION CONTROLLER
END POSSIBLE CAUSES
9030-20-39
Brake Coil (Cont)

DIAGRAMS
Right Traction Troubleshooting Scene
9030-20-40
Brake Coil (Cont)
Left Traction Troubleshooting Scene
END FAULT
9030-20-41
DTC 30062
Right Traction Motor - Encoder
POSSIBLE CAUSE
A. ENCODER WIRING FAULT

B. ENCODER FAULT
NOTE
System SRM.
CAUSE A - ENCODER WIRING FAULT
1. Disconnect the traction motor encoder connector CPS83 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 281A for open or short.
2. Measure voltage between the encoder connector CPS83, socket 1 and socket 4.
NO: Inspect ground circuit 101-A for open or short.
3. Disconnect the traction controller connector CPS41. Measure resistance between socket 13 of the traction
controller connector and socket 2 of the encoder connector CPS83.
NO: Inspect signal circuit 571A for open or source of excessive resistance.
9030-20-42
DTC 30062 (Cont)

4. Measure resistance between socket 14 of the traction controller connector CPS41 and socket 3 of the en-
coder connector CPS83.
YES: Reconnect the encoder connector CPS83 and proceed to Cause B.
CAUSE B - ENCODER FAULT
NOTE: Connect battery.
NOTE: Operate traction motor while performing this test.
1. Connect Breakout Kit #1397311 to the traction controller connector CPS11 and measure voltage between
socket 13, 14 and B(-).
Does voltage signal relate to traction motor movement?
NO: Replace faulty encoder.
END POSSIBLE CAUSES
9030-20-43
DTC 30062 (Cont)

DTC 30062 RIGHT TRACTION MOTOR - ENCODER DIAGRAMS
END FAULT
9030-20-44
Main Contactor
CODES
DTC 30067 - Traction - Main Contactor - Welded Tips

DTC 30068 - Traction - Main Contactor - Not Closed
POSSIBLE CAUSE
A. MAIN CONTACTOR COIL WIRING FAULT

B. MAIN CONTACTOR STUCK CLOSED
C. MAIN CONTACTOR STUCK OPEN
D. FAULTY RIGHT TRACTION CONTROLLER
NOTE
System SRM.
3. Locate status tests (D1) and view the main contactor (D1.2) to verify main contactor position.
Does main contactor remain open or closed when coil is energized/de-energized?
NO: Fault may be intermittent, inspect main contactor tips for damage or debris.
4. Locate output diagnostics (D3.30) and actuate main contactor coil (D3.30.7).
CAUSE A - MAIN CONTACTOR COIL WIRING FAULT
1. Disconnect the main contactor coil's positive terminal TS21 and measure voltage between socket TS21 and
B(-).
9030-20-45
Main Contactor (Cont)

2. Disconnect right traction controller connector CPS41 and the contactor coil negative terminal TS22. Measure
continuity between socket TS22 and socket 12 of the right traction controller connector CPS41.
Is continuity present?
YES: Reconnect battery and all connectors. Proceed to Cause B if contactor is stuck closed or Cause C if
contactor is stuck open.
NO: Inspect ground control circuit 075 for open or short.
CAUSE B - MAIN CONTACTOR STUCK CLOSED
1. Measure voltage between the main contactor B(+) output terminal and B(-).
YES: Replace faulty main contactor.
NO: Proceed to Cause D.
CAUSE C - MAIN CONTACTOR STUCK OPEN
Is voltage present?
YES: Proceed to Cause D.
NO: Replace faulty main contactor.
CAUSE D - FAULTY RIGHT TRACTION CONTROLLER
END POSSIBLE CAUSES
9030-20-46

DIAGRAMS
Cause A Troubleshooting Scene
9030-20-47
Cause B and C Troubleshooting Scene
END FAULT
9030-20-48
Capacitor Charge
CODES
DTC 30069 - Right Traction - Capacitor - Charge

DTC 31069 - Left Traction - Capacitor - Charge
DTC 50069 - Hoist - Capacitor - Charge
POSSIBLE CAUSE
A. CONTROLLER WIRING FAULT

B. FAULTY CONTROLLER
NOTE
NOTE: Shorted mast proximity switch, tiller sensor, steer motor, or horn can cause capacitor charge faults. Verify
that there are no codes related to these components when troubleshooting 30069, 31069, or 50069.
System SRM.
YES: Disconnect battery and discharge the capacitor. Connect battery and re-key the vehicle prior to perform-
ing Step 3.
3. Locate input diagnostics (D2.30/31/50) and view CAP voltages (D2.30/50.8, D2.30/50.9, D2.30/50.10) or
(D2.31.7, D2.31.8, D2.31.9) to verify capacitor voltage.
Is CAP voltage same as battery voltage?
YES: Verify battery state of charge and recheck condition. If actual voltage does not agree with display, pro-
ceed to Cause B.
CAUSE A - CONTROLLER WIRING FAULT
1. Measure voltage between the appropriate controller B(+) terminal and B(-).
Is precharge voltage same as battery voltage?
NO: Inspect controller B(+) cables for damage or loose connections.
9030-20-49
Capacitor Charge (Cont)

CAUSE B - FAULTY CONTROLLER
END POSSIBLE CAUSES
9030-20-50

DIAGRAMS
9030-20-51
Hoist Troubleshooting Scene
END FAULT
9030-20-52
DTC 30085
Traction - Key Input - Voltage Low
POSSIBLE CAUSE
A. KEY INPUT WIRING

B. FAULTY RIGHT TRACTION CONTROLLER
NOTE
System SRM.
3. Locate input diagnostics (D2.30) and view key input voltages (D2.30.11 and D2.30.13) to verify current key
voltage and minimum captured key voltage.
YES: Check battery state of charge and proceed to Cause A.
NO: If battery is fully charged and code returns, proceed to Cause B.
CAUSE A - KEY INPUT WIRING
1. Disconnect the right traction controller connector CPS41 and measure voltage between socket 10 / 7 and
B(-).
NO: Inspect circuit 010 for open, short, or source of excessive resistance.
CAUSE B - FAULTY RIGHT TRACTION CONTROLLER
END POSSIBLE CAUSES
9030-20-53
DTC 30085 (Cont)

Traction - Key Input - Voltage Low
DTC 30085 TRACTION - KEY INPUT - VOLTAGE LOW DIAGRAMS
Troubleshooting Scenes
END FAULT
9030-20-54
DTC 30227
Right Traction - Motor - Stalled
POSSIBLE CAUSE

B. FAULTY TRACTION MOTOR
NOTE
System SRM.
3. Locate input diagnostics (D2.30) and view traction motor speed (D2.30.2) to verify signal.
Is encoder signal responding to traction input?
4. View the motor current (D2.30.7) to verify traction motor operation.
Is traction motor current within specifications?
YES: Inspect motor for damage or signs of binding.
NO: Proceed to Cause B.
1. Disconnect the right traction motor encoder connector CPS83 and measure voltage between socket 1 and
B(-).
NO: Inspect circuit 281-A for open or short.
9030-20-55
DTC 30227 (Cont)

NO: Inspect ground circuit 101A for open or short.
3. Disconnect the right traction controller connector CPS41. Measure resistance between socket 13 of the trac-
tion controller connector and socket 2 of the encoder connector CPS83.
4. Measure resistance between socket 14 of the right traction controller connector and socket 3 of the encoder
connector CPS83.
CAUSE B - FAULTY TRACTION MOTOR
NOTE: Disconnect battery.
1. Measure resistance between the motor terminals U and V.

Is resistance between .322 and .383 ohm?
NO: Repair or replace faulty motor.
2. Measure resistance between the motor terminals U and W.
3. Measure resistance between the motor terminals W and V.
END POSSIBLE CAUSES
9030-20-56
DTC 30227 (Cont)

DTC 30227 RIGHT TRACTION - MOTOR - STALLED DIAGRAMS
END FAULT
9030-20-57
Motor and Cable

CODES
DTC 30060 - Right Traction - Motor - Circuit

DTC 30061 - Right Traction - Motor - Short
DTC 31060 - Left Traction - Motor - Circuit
DTC 31061 - Left Traction - Motor - Short
DTC 50060 - Hoist - Motor - Circuit
DTC 50061 - Hoist - Motor - Short
POSSIBLE CAUSE
A. MOTOR CABLE FAULT

B. MOTOR FAULT
C. FAULTY CONTROLLER
NOTE
System SRM.
CAUSE A - MOTOR CABLE FAULT
1. Disconnect the motor cables from the controller and motor. Measure continuity of individual cables to isolate
fault.
NO: Repair or replace faulty phase cable.
9030-20-58
Motor and Cable (Cont)

CAUSE B - MOTOR FAULT

Is resistance between .322 and .383 ohms?
CAUSE C - FAULTY CONTROLLER
1. If no faults are found, replace left/right traction controller. Make sure to indicate the DTC code(s) on the war-
ranty claim to include an accurate problem description leading to controller replacement.
END POSSIBLE CAUSES
9030-20-59

DIAGRAMS
9030-20-60
Hoist Troubleshooting Scene
END FAULT
9030-20-61
DC Bus Voltage
CODES
DTC 30086 - Right Traction - DC Bus - Voltage Low

DTC 30087 - Right Traction - DC Bus - Voltage High
DTC 31086 - Left Traction - DC Bus - Voltage Low
DTC 31087 - Left Traction - DC Bus - Voltage High
DTC 50086 - Pump - DC Bus - Voltage Low
DTC 50087 - Pump - DC Bus - Voltage High
POSSIBLE CAUSE
A. CONTROLLER WIRING FAULT

B. FAULTY CONTROLLER
NOTE
System SRM.
YES: Disconnect battery and discharge the capacitor. Connect battery and re-key the vehicle prior to perform-
ing Step 3.
3. Locate necessary input diagnostics (D2.30/31/50) and view CAP voltages to verify capacitor voltage.
• Right Traction (D2.30.8)
• Left Traction (D2.31.7)
• Pump (D2.50.8)
Is CAP voltage same as battery voltage?
YES: Verify battery state of charge and recheck condition. If capacitor voltage is within specifications after
retest and code remains, proceed to Cause B.
9030-20-62
DC Bus Voltage (Cont)

CAUSE A - CONTROLLER WIRING FAULT
1. Measure voltage between the appropriate controller B(+) terminal and B(-).
Is precharge voltage same as battery voltage?
NO: Inspect B(+) cable for damage or loose connections.
CAUSE B - FAULTY CONTROLLER
END POSSIBLE CAUSES
9030-20-63

DIAGRAMS
9030-20-64
Pump Troubleshooting Scene
END FAULT
9030-20-65
Tilt Up Coil
CODES
DTC 31013 - Left Traction - Tilt Up Coil - Circuit

DTC 31014 - Left Traction - Tilt Up Coil - Short
POSSIBLE CAUSE
A. TILT UP COIL WIRING FAULT

B. TILT UP COIL FAULT
C. FAULTY LEFT TRACTION CONTROLLER
NOTE
System SRM.
YES: Proceed to Step 3
NOTE: Operate tilt up coil.
3. Locate input diagnostics (D2.31) and verify tilt up coil is receiving input (D2.31.35).
Is tilt coil receiving input?
4. Locate output diagnostics (D3.31) and actuate tilt up coil (D3.30.18).
Does coil energize when actuated?
CAUSE A - TILT UP COIL WIRING FAULT
1. Disconnect the tilt up coil and measure voltage between socket TBF48A and B(-).
9030-20-66
Tilt Up Coil (Cont)

2. Disconnect the left traction controller connector CPS42. Measure resistance between the traction controller
connector CPS42, socket 11 and the tilt up coil connector, socket TBF41B.
CAUSE B - TILT UP COIL FAULT
1. Measure resistance across the tilt up coil terminals.

NO: Replace faulty tilt up coil.
CAUSE C - FAULTY LEFT TRACTION CONTROLLER
END POSSIBLE CAUSES
9030-20-67
Tilt Up Coil (Cont)

DIAGRAMS
END FAULT
9030-20-68
Tilt Down Coil

CODES
DTC 31015 - Left Traction - Tilt Down Coil - Circuit

DTC 31016 - Left Traction - Tilt Down Coil - Short
POSSIBLE CAUSE
A. TILT DOWN COIL WIRING FAULT

B. TILT DOWN COIL FAULT
NOTE
System SRM.
NOTE: Operate tilt down coil.
3. Locate input diagnostics (D2.31) and verify tilt down coil is receiving input (D2.31.34).
Is tilt coil receiving input?
4. Locate output diagnostics (D3.31) and actuate tilt down coil (D3.30.19).
CAUSE A - TILT DOWN COIL WIRING FAULT
1. Disconnect the tilt down coil and measure voltage between socket TBF45A and B(-).
9030-20-69
Tilt Down Coil (Cont)

connector CPS42, socket 11 and the tilt down coil connector, socket TBF45B.
CAUSE B - TILT DOWN COIL FAULT
1. Measure resistance across the tilt down coil terminals.

NO: Replace faulty tilt down coil.
END POSSIBLE CAUSES
9030-20-70
Tilt Down Coil (Cont)

DIAGRAMS
END FAULT
9030-20-71
4th Function In Coil

CODES
DTC 31025 - Left Traction - 4th In Coil - Circuit

DTC 31026 - Left Traction - 4th In Coil - Short
POSSIBLE CAUSE
A. 4TH IN COIL WIRING FAULT

B. 4TH IN COIL FAULT
NOTE
System SRM.
CAUSE A - 4TH IN COIL WIRING FAULT
1. Disconnect the 4th In coil and measure voltage between socket TBF46A and B(-).
connector CPS42, socket 33 and the 4th In coil connector, socket TBF46B.
9030-20-72
4th Function In Coil (Cont)

CAUSE B - 4TH IN COIL FAULT
1. Measure resistance across the 4th In coil terminals.

NO: Replace faulty 4th In coil.
END POSSIBLE CAUSES
9030-20-73
4th Function In Coil (Cont)

DIAGRAMS
END FAULT
9030-20-74
4th Function Out Coil

CODES
DTC 31027 - Left Traction - 4th Out Coil - Circuit

DTC 31028 - Left Traction - 4th Out Coil - Short
POSSIBLE CAUSE
A. 4TH OUT COIL WIRING FAULT

B. 4TH OUT COIL FAULT
NOTE
System SRM.
CAUSE A - 4TH OUT COIL WIRING FAULT
1. Disconnect the 4th Out coil and measure voltage between socket TBF44A and B(-).
connector CPS42, socket 34 and the 4th Out coil connector, socket TBF44B.
9030-20-75
4th Function Out Coil (Cont)

CAUSE B - 4TH OUT COIL FAULT
1. Measure resistance across the 4th Out coil terminals.

NO: Replace faulty 4th Out coil.
END POSSIBLE CAUSES
9030-20-76
4th Function Out Coil (Cont)

DIAGRAMS
END FAULT
9030-20-77
Auxiliary Prop Valve

CODES
DTC 31045 - Left Traction - Auxiliary Prop Valve - Circuit

DTC 31046 - Left Traction - Auxiliary Prop Valve - Short
POSSIBLE CAUSE
A. AUXILIARY PROP COIL WIRING FAULT

B. AUXILIARY PROP COIL FAULT
NOTE
System SRM.
NOTE: Operate aux prop coil.
3. Locate input diagnostics (D2.31) and verify auxiliary prop coil is receiving input (D2.31.32).
Is auxiliary prop coil receiving input?
4. Locate output diagnostics (D3.31) and actuate aux prop coil (D3.30.20).
CAUSE A - AUXILIARY PROP COIL WIRING FAULT
1. Disconnect the auxiliary prop coil connector TBF49A and measure voltage between socket TBF49A and B(-).
NO: Inspect supply circuit 200A for open or short.
9030-20-78
Auxiliary Prop Valve (Cont)

2. Disconnect the left traction controller connector CPS42. Measure resistance between auxiliary prop coil con-
nector TBF49B and the traction controller connector CPS42, socket 24.
NO: Inspect ground control circuit 820A for open or source of excessive resistance.
CAUSE B - AUXILIARY PROP COIL FAULT
1. Measure resistance between the aux prop coil terminals.
NO: Replace faulty auxiliary prop coil.
END POSSIBLE CAUSES
9030-20-79
Auxiliary Prop Valve (Cont)

DIAGRAMS
END FAULT
9030-20-80
DTC 31062
Left Traction - Motor - Encoder
POSSIBLE CAUSE

B. ENCODER FAULT
C. FAULTY CONTROLLER
NOTE
System SRM.
9030-20-81
DTC 31062 (Cont)

NOTE: Operate traction motor while performing this test.
1. Connect Breakout Kit #1397311 to the traction controller connector CPS42 and measure voltage between
CAUSE C - FAULTY CONTROLLER
END POSSIBLE CAUSES
9030-20-82
DTC 31062 (Cont)

DTC 31062 LEFT TRACTION - MOTOR - ENCODER DIAGRAMS
9030-20-83
DTC 31062 (Cont)

END FAULT
9030-20-84
DTC 31068
Left Traction - Main Contactor - Not Closed
POSSIBLE CAUSE
A. MAIN CONTACTOR COIL WIRING FAULT

B. MAIN CONTACTOR STUCK CLOSED
C. MAIN CONTACTOR STUCK OPEN
D. FAULTY LEFT TRACTION CONTROLLER
NOTE
System SRM.
3. Locate status tests (D1) and view the main contactor (D1.2) to verify main contactor position.
Does main contactor remain open or closed when coil is energized/de-energized?
NO: Fault may be intermittent, inspect main contactor tips for damage or debris.
4. Locate output diagnostics (D3.30) and actuate main contactor coil (D3.30.7).
CAUSE A - MAIN CONTACTOR COIL WIRING FAULT
1. Disconnect the main contactor coil's positive terminal TS21 and measure voltage between socket TS21 and
B(-).
2. Disconnect right traction controller connector CPS41 and the contactor coil negative terminal TS22. Measure
continuity between socket TS22 and socket 12 of the right traction controller connector CPS41.
9030-20-85
DTC 31068 (Cont)

YES: Reconnect battery and all connectors. Proceed to Cause B if contactor is stuck closed or Cause C if
contactor is stuck open.
NO: Inspect ground control circuit 075 for open or short.
CAUSE B - MAIN CONTACTOR STUCK CLOSED
YES: Replace faulty main contactor.
NO: Proceed to Cause D.
CAUSE C - MAIN CONTACTOR STUCK OPEN
Is voltage present?
YES: Proceed to Cause D.
NO: Replace faulty main contactor.
CAUSE D - FAULTY LEFT TRACTION CONTROLLER
END POSSIBLE CAUSES
9030-20-86
DTC 31068 (Cont)

DTC 31068 LEFT TRACTION - MAIN CONTACTOR - NOT CLOSED DIAGRAMS
Cause A Troubleshooting Scene
9030-20-87
DTC 31068 (Cont)

Cause B and C Troubleshooting Scene
END FAULT
9030-20-88
DTC 31085
Left Traction - Key Input - Voltage Low
POSSIBLE CAUSE
A. KEY INPUT WIRING

B. FAULTY LEFT TRACTION CONTROLLER
NOTE
System SRM.
1. Disconnect the left traction controller connector CPS42 and measure voltage between socket 10 and B(-).
CAUSE B - FAULTY LEFT TRACTION CONTROLLER
END POSSIBLE CAUSES
9030-20-89
DTC 31085 (Cont)

Left Traction - Key Input - Voltage Low
DTC 31085 LEFT TRACTION - KEY INPUT - VOLTAGE LOW DIAGRAMS
END FAULT
9030-20-90
DTC 31227
Left Traction - Motor - Stalled
POSSIBLE CAUSE

B. FAULTY TRACTION MOTOR
NOTE
System SRM.
3. Locate input diagnostics (D2.31) and view traction motor speed (D2.31.2) to verify signal.
Is encoder signal responding to traction input?
4. View the motor current (D2.31.6) to verify traction motor operation.
Is traction motor current within specifications?
9030-20-91
DTC 31227 (Cont)

CAUSE B - FAULTY TRACTION MOTOR

END POSSIBLE CAUSES
9030-20-92
DTC 31227 (Cont)

DTC 31227 LEFT TRACTION - MOTOR - STALLED DIAGRAMS
9030-20-93
DTC 31227 (Cont)

END FAULT
9030-20-94
DTC 50062
Hoist Motor - Encoder
POSSIBLE CAUSE

B. ENCODER FAULT
C. FAULTY HOIST CONTROLLER
NOTE
System SRM.
1. Disconnect the hoist motor encoder connector CPS85 and measure voltage between socket 1 and B(-).
3. Disconnect the hoist controller connector CPS15. Measure resistance between socket 7 of the hoist controller
connector and socket 2 of the encoder connector CPS85.
9030-20-95
DTC 50062 (Cont)

4. Measure resistance between socket 14 of the hoist controller connector CPS15 and socket 3 of the encoder
connector CPS85.
NOTE: Operate motor while performing this test.
1. Connect Breakout Kit #1397311 to the hoist controller connector CPS14 and measure voltage between
CAUSE C - FAULTY HOIST CONTROLLER
END POSSIBLE CAUSES
9030-20-96
DTC 50062 (Cont)

DTC 50062 HOIST MOTOR - ENCODER DIAGRAMS
9030-20-97
DTC 50062 (Cont)

END FAULT
9030-20-98
DTC 50085
Pump - Key Input - Voltage Low
POSSIBLE CAUSE
A. KEY INPUT WIRING

B. FAULTY HOIST MOTOR CONTROLLER
NOTE
System SRM.
1. Disconnect the hoist motor controller connector CPS15 and measure voltage between socket 1 and B(-).
CAUSE B - FAULTY HOIST MOTOR CONTROLLER
END POSSIBLE CAUSES
9030-20-99
DTC 50085 (Cont)

Pump - Key Input - Voltage Low
DTC 50085 PUMP - KEY INPUT - VOLTAGE LOW DIAGRAMS
END FAULT
9030-20-100
DTC 50228
Pump - Lift/Lower - Stalled
POSSIBLE CAUSE

B. FAULTY PUMP MOTOR
C. FAULTY HOIST MOTOR CONTROLLER
NOTE
System SRM.
3. Locate input diagnostics (D2.50) and view pump motor speed (D2.50.2) to verify signal.
Is encoder signal responding to pump input?
4. View the motor current (D2.50.7) to verify pump motor operation.
Is pump motor current within specifications?
1. Disconnect the pump motor encoder connector CPS85 and measure voltage between socket 1 and B(-).
9030-20-101
DTC 50228 (Cont)

3. Disconnect the hoist motor controller connector CPS15. Measure resistance between socket 7 of connector
CPS15 and socket 2 of the encoder connector CPS85.
4. Measure resistance between socket 14 of the hoist motor controller connector and socket 3 of the encoder
connector CPS85.
CAUSE B - FAULTY PUMP MOTOR
1. Measure resistance between the pump motor terminals U and V.

2. Measure resistance between the pump motor terminals U and W.
3. Measure resistance between the pump motor terminals W and V.
CAUSE C - FAULTY HOIST MOTOR CONTROLLER
END POSSIBLE CAUSES
9030-20-102
DTC 50228 (Cont)

DTC 50228 PUMP - LIFT/LOWER - STALLED DIAGRAMS
9030-20-103
DTC 50228 (Cont)

END FAULT
9030-20-104
Handle
CODES
DTC 60054 - Handle - Traction - Axis Fault

DTC 60055 - Handle - Lift/Lower - Axis Fault
DTC 60056 - Handle - Tilt - Axis Fault
DTC 60057 - Handle - SS/Ext/Ret - Axis Fault
DTC 50057 - Pump - Handle - CAN I/O
POSSIBLE CAUSE
A. JOYSTICK WIRING FAULT

B. JOYSTICK COMMUNICATION FAULT
C. FAULTY JOYSTICK
NOTE
System SRM.
NO: Fault may be intermittent.
NOTE: Forward throttle, tilt up, left side-shift, and extend functions are positive percentages between 0 and 100.
Reverse throttle, tilt down, right side-shift, and retract functions are negative percentages between 0 and 100.
3. Locate input diagnostics (D2.60) and verify the following joystick inputs:
• Traction (D2.60.19)
• Lift/Lower (D2.60.20)
• Tilt (D2.60.10)
• Side-shift and extend/retract (D2.60.12)
Does value follow joystick input?
9030-20-105
Handle (Cont)
CAUSE A - JOYSTICK WIRING FAULT
1. Disconnect joystick connector CPS52 and measure voltage between socket 1 and B(-).
Is voltage approximately 12 ± 1.5 Vdc?
NO: Inspect circuit 284B for open or short.
2. Measure voltage between the joystick connector CPS52, socket 1 and socket 4.
Is voltage approximately 12 ± 1.5 Vdc?
CAUSE B - JOYSTICK COMMUNICATION FAULT
1. Measure voltage between the joystick connector CPS52, socket 2 and B(-).
2. Measure voltage between the joystick connector CPS52, socket 3 and B(-).
3. Measure resistance between joystick connector CPS52, socket 2 and socket 3.
YES: No communication faults are present, proceed to Cause C.
CAUSE C - FAULTY JOYSTICK
1. If no faults are found, replace joystick.
END POSSIBLE CAUSES
9030-20-106
Handle (Cont)
DIAGRAMS
END FAULT
9030-20-107
Handle Release
CODES
DTC 60200 - Handle - Release - Lift/Lower

DTC 60201 - Handle - Release - Throttle
DTC 60211 - Handle - Release
DTC 60213 - Handle - Release - Brake
DTC 60221 - Handle - Release - Tilt Up
DTC 60222 - Handle - Release - Tilt Down
DTC 60223 - Handle - Release - Shift Left
DTC 60224 - Handle - Release - Shift Right
POSSIBLE CAUSE
A. HANDLE CONTROL FAULT

B. FAULTY HANDLE
NOTE
System SRM.
NO: Fault may be intermittent.
NOTE: Forward throttle, Tilt up, Lift, and Shift left functions are positive percentages between +1% and +100%.
Reverse throttle, Tilt down, Lower and Shift right functions are negative percentages between -1% and -100%.
3. Locate input diagnostics (D2.60) and verify the following handle inputs:
• Tilt Up (D2.60.10)
• Tilt Down (D2.60.11)
• Shift Left (D2.60.13)
• Shift Right (D2.60.12)
• Throttle (D2.60.19)
• Lift/Lower (D2.60.20)
Does value follow handle input?
9030-20-108
Handle Release (Cont)

CAUSE A - HANDLE CONTROL FAULT
1. Inspect handle controls for damage or sticking buttons.
Is damage present on the Handle controls?
YES: Repair or replace faulty handle.
2. Using the display or PC Service Tool, operate controls and observe signals.
Does signal follow handle command?
CAUSE B - FAULTY HANDLE
1. If no faults are found, replace handle. Make sure to indicate the DTC code(s) on the warranty claim to include
an accurate problem description leading to controller replacement.
END POSSIBLE CAUSES
9030-20-109
Handle Release (Cont)

DIAGRAMS
END FAULT
9030-20-110
TECHNICAL PUBLICATIONS
9000 SRM 1649 4/17 (3/17)(10/14)(9/13)

Controller Diagnostics S/N B219N02284L : E30HSD, E35HSD, E40HSD (B219)

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Controller Diagnostics S/N B219N02284L : E30HSD, E35HSD, E40HSD (B219)

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CONTROLLER

PART NO. 4093651 9000 SRM 1649

SECTION 9030 - ELECTRICAL SYSTEM

This section is for the following models:

(E30HSD2, E35HSD2, E40HSD2) [B219]

©2017 HYSTER COMPANY i

How To Use This Troubleshooting Manual

Any change to the lift truck, the tires, or its equip-

Section: This manual consists of one section which is

Groups: The 9030 Electrical System is divided into

Group 03 - General Maintenance and Diagnostic Data

General Maintenance and Diagnostic Data

GENERAL TROUBLESHOOTING Troubleshooting is usually limited to accessing status

DISCHARGING THE CAPACITORS component in the electrical compartments. Make

1. POSITIVE CONNECTION B(+)

Jumper Wires, Test Leads, and Test Lights

Jumper wires can also be used to eliminate sections

Basic Electrical Troubleshooting

A voltmeter is used to perform: Resistance Checks

Measuring the voltage drop is performed by connect- An ohmmeter is used to perform:

Contactor and Contactor Coil Checks Is resistance <1 ohm?

Status Code Toggling This feature indicates if a status code is available

Status Codes and Descriptions

STATUS CODE DESCRIPTIONS

Table 9030-03-2. Node 10 Status Codes

NODE STATUS DESCRIPTION

Table 9030-03-3. Node 30 Status Codes

NODE STATUS DESCRIPTION

Table 9030-03-3. Node 30 Status Codes (Continued)

NODE STATUS DESCRIPTION

Table 9030-03-4. Node 31 Status Codes

NODE STATUS DESCRIPTION

Table 9030-03-5. Node 50 Status Codes

NODE STATUS DESCRIPTION

Table 9030-03-6. Node 60 Status Codes

NODE STATUS DESCRIPTION

WARNING CODES electrical diagnosis. The following table of warning co-

Table 9030-03-7. Warning Codes

CODE NODE STATUS DESCRIPTION SYMPTOM

Table 9030-03-7. Warning Codes (Continued)

CODE NODE STATUS DESCRIPTION SYMPTOM

Diagnostic Trouble Codes

COMPONENT OPERATIONAL CHECK

CAUSE A - INTERNAL FAULT

END POSSIBLE CAUSES

A. CANBUS COMMUNICATION FAULT

COMPONENT OPERATIONAL CHECK

CAUSE A - CANBUS COMMUNICATION FAULT

NOTE: Key in ON position

DTC xx101 (Cont)

CAUSE B - RIGHT TRACTION CONTROLLER WIRING FAULT

NOTE: Key in ON position

END POSSIBLE CAUSES

DTC xx101 (Cont)

A. CANBUS COMMUNICATION FAULT

COMPONENT OPERATIONAL CHECK

CAUSE A - CANBUS COMMUNICATION FAULT

NOTE: Key in ON position

NOTE: Key in ON position.

DTC xx102 (Cont)

CAUSE B - LEFT TRACTION CONTROLLER WIRING FAULT

NOTE: Key in ON position