Fallas Eb PDF

Maintenance
CONTROLLER
DIAGNOSTICS
NDR035EB, NR045EB [D861];
NDR030EB, NR035/040EB [E815];
NDR030DB, NR035/040DB [B295]
PART NO. 550073171 9000 YRM 1622

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 Yale® 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 YALE 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 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:
(NDR035EB, NR045EB) [D861];

(NDR030EB, NR035/040EB) [E815];
(NDR030DB, NR035/040DB) [B295]
©2015 Yale Materials Handling Corp. i

How To Use This Troubleshooting Manual Controller Diagnostics
How To Use This Troubleshooting Manual

GENERAL INSTRUCTIONS AND SAFETY Groups: The 9030 Electrical System is divided into
INFORMATION two groups that identify specific electrical trouble-
shooting procedures.
WARNING • 03 – General Maintenance/Diagnostic Data
The General Maintenance and Diagnostic Data
DO NOT add to or modify the lift truck. Any modi-
group includes general troubleshooting, dis-
fication that affects the safe operation of the truck
charging the capacitors, basic electrical trou-
cannot be undertaken without written authoriza-
bleshooting, multiplexing, User Iterface, and
tion of the Yale company.
status codes and descriptions.
Any change to the lift truck, the tires, or its equip- • 20 – Diagnostic Trouble Codes
ment can change the lifting capacity. The lift truck The Diagnostic Trouble Codes group includes
must be rated as equipped and the nameplate all troubleshooting procedures for status codes
must show the new rating capacity. reported by a given Node or system.
For a listing of all Diagnostic Trouble Codes and de-

WARNING
scriptions, see the Status Codes section of this man-
The technician must be aware of, and follow, all ual.
general safety precautions that are published in
the Operating Manual and that are posted as
GENERAL INSTRUCTIONS
Safety Decals on and in the lift truck.
1. Become familiar with the content, layout, and
Before starting, the technician should be familiar with access provisions of data in this manual. This
certain policies, requirements, and instructions used will improve your efficiency and decrease the
in the troubleshooting procedures. Using the trouble- time required to resolve the problems.
shooting procedures correctly helps the technician to
perform the procedure safely and prevents damage to 2. Once you begin a troubleshooting procedure,
the machine and support equipment. do not skip steps.
3. If you reach the end of a procedure without re-
HOW TO USE DIAGNOSTIC solving the problem and you are not directed to
TROUBLESHOOTING MANUAL another procedure contact Resident Service
Engineering through the Contact Management
Manual Layout: System.
4. Do not limit yourself, remember to apply your
Section: This manual consists of one section which is own experience and knowledge to assist in re-
further divided into groups. solving the problems, but do not compromise
• 9030 – Electrical System safety in doing so.
5. Most of the cross-reference data in the manual
will be electronically linked for rapid and easy
access. Use the links wherever the cursor
highlights an item as a linkable option.
Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
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................................................................................................................... 9030-03-3
PC Service Tool..............................................................................................................................9030-03-3
Breakout Kit ...................................................................................................................................9030-03-3
Digital Multimeter (DMM)................................................................................................................9030-03-3
Jumper Wires, Test Leads, and Test Lights................................................................................... 9030-03-3
Basic Electrical Troubleshooting............................................................................................................. 9030-03-3
Electrical Checks................................................................................................................................ 9030-03-4
Voltage Checks.............................................................................................................................. 9030-03-4
Amperage Checks..........................................................................................................................9030-03-4
Resistance Checks.........................................................................................................................9030-03-4
Contactor and Contactor Coil Checks............................................................................................ 9030-03-5
Multiplexing............................................................................................................................................. 9030-03-5
Multiplexing and the CANbus............................................................................................................. 9030-03-5
Troubleshooting the CANbus......................................................................................................... 9030-03-5
User Interface..........................................................................................................................................9030-03-6
User Interface, Setup, and Troubleshooting....................................................................................... 9030-03-6
Button Keypad................................................................................................................................9030-03-6
LED Indicator Lights....................................................................................................................... 9030-03-6
LCD Screen....................................................................................................................................9030-03-6
Dash Display Access......................................................................................................................9030-03-6
Status Code Toggling.....................................................................................................................9030-03-7
Automatic Diagnostics....................................................................................................................9030-03-7
Status Code Indication................................................................................................................... 9030-03-7
Status Codes and Descriptions...............................................................................................................9030-03-7
Status Codes...................................................................................................................................... 9030-03-7
Status Code Descriptions................................................................................................................... 9030-03-8
Warning Codes.............................................................................................................................9030-03-13
Group 20 - Diagnostic Trouble Codes
DTC xx101 - CANBus Communications - Traction................................................................................. 9030-20-2
DTC xx103 - CANBus Communications - Pump.....................................................................................9030-20-4
DTC xx104 - CANBus Communications - Steer......................................................................................9030-20-6
DTC xx105 - CANBus Communications - Caster Steer.......................................................................... 9030-20-8
DTC xx106 - CANBus Communications - Handle.................................................................................9030-20-10
DTC xx107 - CANBus Communications - CAN I/O...............................................................................9030-20-14
DTC xx108 - CANBus Communications - Remote Module...................................................................9030-20-17
DTC xx110 - CANBus Communications - Impact Module.....................................................................9030-20-20
DTC xx111 - CANBus Communciations - Auxiliary Pump.................................................................... 9030-20-22
DTC 30033 - Traction - Main Cont Coil - Circuit................................................................................... 9030-20-24
DTC 30035 - Traction - Brake Coil - Circuit.......................................................................................... 9030-20-27
Main Contactor/Brake Coil Short:
DTC 30034 - Traction - Main Cont Coil - Short
DTC 30036 - Traction - Brake Coil - Short........................................................................................9030-20-30
9030-1
DTC 30052 - Traction - Throttle - Sensor Fault.....................................................................................9030-20-33
DTC 90052 - CAN - Handle - Signal..................................................................................................... 9030-20-33
Traction Motor:
DTC 30060 - Traction - Motor - Circuit
DTC 30061 - Traction - Motor - Open...............................................................................................9030-20-36
DTC 30062 - Traction - Motor - Encoder...............................................................................................9030-20-39
Traction Main Contactor:
DTC 30067 - Traction - Main Contactor - Welded Tips
DTC 30068 - Traction - Main Contactor - Not Closed.......................................................................9030-20-42
Traction Capacitor Charge and DC Bus Voltage:
DTC 30069 - Traction - Capacitor - Charge
DTC 30086 - Traction - DC Bus - Voltage Low
DTC 30087 - Traction - DC Bus - Voltage High................................................................................9030-20-45
DTC 30085 - Traction - Key input - Voltage Low.................................................................................. 9030-20-48
Steer Motor:
DTC 40060 - Steer - Motor - Circuit
DTC 40061 - Steer - Motor - Open................................................................................................... 9030-20-51
DTC 40062 - Steer - Motor - Encoder................................................................................................... 9030-20-54
DTC 40070 - Steer - Steer Request - MTS Sensor...............................................................................9030-20-57
DTC 40072 - Steer - Steer Angle - Mismatch....................................................................................... 9030-20-60
DTC 40073 - Steer - Steer Angle - Center Fault................................................................................... 9030-20-63
DTC 40074 - Steer - Motor - Stalled..................................................................................................... 9030-20-66
DTC 40085 - Steer - Key input - Voltage Low.......................................................................................9030-20-69
Steer DC Bus Voltage:
DTC 40086 - Steer - DC Bus - Voltage Low
DTC 40087 - Steer - DC Bus - Voltage High.................................................................................... 9030-20-72
Steer Caster Motor:
DTC 41060 - Steer Caster - Motor - Circuit
DTC 41061 - Steer Caster - Motor - Open........................................................................................9030-20-75
DTC 41062 - Steer Caster - Motor - Encoder....................................................................................... 9030-20-77
DTC 41072 - Steer Caster - Steer Angle - Mismatch............................................................................9030-20-80
DTC 41073 - Steer Caster - Steer Angle - Center Fault....................................................................... 9030-20-83
DTC 41085 - Steer Caster - Key Input - Voltage Low........................................................................... 9030-20-85
Steer Caster DC Bus Voltage:
DTC 41086 - Steer Caster - DC Bus - Voltage Low
DTC 41087 - Steer Caster - DC Bus - Voltage High.........................................................................9030-20-88
Lift Pump Motor:
DTC 50060 - Pump - Motor - Circuit
DTC 50061 - Pump - Motor - Open.................................................................................................. 9030-20-91
DTC 50062 - Pump - Motor - Encoder.................................................................................................. 9030-20-93
DTC 50068 - Pump - Main Contactor - Not Closed...............................................................................9030-20-96
DTC 50069 - Pump - Capacitor - Charge..............................................................................................9030-20-99
Auxiliary Pump Motor:
DTC 51060 - Auxiliary Pump - Motor - Circuit
DTC 51061 - Auxiliary Pump - Motor - Open..................................................................................9030-20-102
DTC 51062 - Auxiliary Pump - Motor - Encoder..................................................................................9030-20-104
Auxiliary Pump DC Bus Voltage:
DTC 51086 - Auxiliary Pump - DC Bus - Voltage Low
DTC 51087 - Auxiliary Pump - DC Bus - Voltage High...................................................................9030-20-106
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............................................................................... 9030-20-109
9030-2
Impact Module:
DTC 80065 - Impact Module - Soft Impact
DTC 80066 - Impact Module - Hard Impact ...................................................................................9030-20-112
CAN I/O Lift Coil:
DTC 90001 - CAN I/O - Lift Coil - Circuit
DTC 90002 - CAN I/O - Lift Coil - Short..........................................................................................9030-20-114
CAN I/O Lower Coil:
DTC 90003 - CAN I/O - Lower Coil - Circuit
DTC 90004 - CAN I/O - Lower Coil - Short.....................................................................................9030-20-117
CAN I/O Load Hold Coil:
DTC 90005 - CAN I/O - Load Hold - Circuit
DTC 90006 - CAN I/O - Load Hold - Short..................................................................................... 9030-20-120
CAN I/O Auxiliary Forward Coil:
DTC 90007 - CAN I/O - Auxiliary Forward Coil - Circuit
DTC 90008 - CAN I/O - Auxiliary Forward Coil - Short...................................................................9030-20-122
CAN I/O Auxiliary Reverse Coil:
DTC 90009 - CAN I/O - Auxiliary Reverse Coil - Circuit
DTC 90010 - CAN I/O - Auxiliary Reverse Coil - Short...................................................................9030-20-125
CAN I/O Tilt Coil:
DTC 90011 - CAN I/O - Tilt Coil - Circuit
DTC 90012 - CAN I/O - Tilt Coil - Short..........................................................................................9030-20-128
CAN I/O Side-Shift Coil:
DTC 90017 - CAN I/O - Side-Shift Coil - Circuit
DTC 90018 - CAN I/O - Side-Shift Coil - Short............................................................................... 9030-20-130
CAN I/O Extend/Retract Coil:
DTC 90023 - CAN I/O - Extend/Retract Coil - Circuit
DTC 90024 - CANI/O - Extend/Retract Coil - Short........................................................................9030-20-132
CAN I/O Audible Alarm:
DTC 90037 - CAN I/O - Audible Alarm - Circuit
DTC 90038 - CAN I/O - Audible Alarm - Short............................................................................... 9030-20-134
CAN I/O Visible Alarm:
DTC 90039 - CAN I/O - Visible Alarm - Circuit
DTC 90040 - CAN I/O - Visible Alarm - Short.................................................................................9030-20-137
DTC 90043 - CAN I/O - TFD Coil - Circuit.......................................................................................... 9030-20-140
DTC 90053 - CAN I/O - Pressure - Sensor Fault................................................................................ 9030-20-143
DTC 90075 - CAN I/O - Steer - Security Line..................................................................................... 9030-20-146
DTC 90076 - CAN I/O - Steer Caster - Security Line..........................................................................9030-20-149
DTC 90085 - CAN I/O - Key input - Voltage Low................................................................................ 9030-20-152
DTC 90253 - CAN I/O - Lost - Wire.....................................................................................................9030-20-155
DTC 40253 - Steer - Lost - Wire......................................................................................................... 9030-20-155
Remote Module Auxiliary Forward Coil:
DTC 91007 - Remote Module - Auxiliary Forward Coil - Circuit
DTC 91008 - Remote Module - Auxiliary Forward Coil - Short.......................................................9030-20-157
Remote Module Auxiliary Reverse Coil:
DTC 91009 - Remote Module - Auxiliary Reverse Coil - Circuit
DTC 91010 - Remote Module - Auxiliary Reverse Coil - Short.......................................................9030-20-159
Remote Module Tilt Coil:
DTC 91011 - Remote Module - Tilt Coil - Circuit
DTC 91012 - Remote Module - Tilt Coil - Short..............................................................................9030-20-161
Remote Module Side-Shift Coil:
DTC 91017 - Remote Module - Side-Shift Coil - Circuit
DTC 91018 - Remote Module - Side-Shift Coil - Short................................................................... 9030-20-163
9030-3
Remote Module Extend/Retract Coil:
DTC 91023 - Remote Module - Extend/Retract Coil - Circuit
DTC 91024 - Remote Module - Extend/Retract Coil - Short...........................................................9030-20-165
DTC 91049 - Remote Module - Tilt - Sensor fault...............................................................................9030-20-167
DTC 91051 - Remote Module - Extend and Retract - Sensor Fault....................................................9030-20-170
9030-4
Electrical System General Maintenance and Diagnostic Data
Group 03
General Maintenance and Diagnostic Data
GENERAL TROUBLESHOOTING nents located on the reach attachment may be

caused by broken or shorted wires in the mast cable.
In the event the lift truck does not operate correctly, a Ensure the integrity of this cable before troubleshoot-
status code is displayed on the display panel. Once ing attachment related faults .
the status code is obtained, follow the procedures out-
lined in this manual only after reviewing the following The controllers are sealed units with no serviceable
information regarding the truck’s unique electrical sys- components. Troubleshooting is usually limited to ac-
tem and troubleshooting procedures. cessing status codes and following the diagnostic pro-
cedure provided for each status code.
NOTE: Due to the interaction of the CAN I/O control-
ler with all truck functions, almost any status code or Use standard testing procedures to verify inputs and
controller fault could be caused by an internal failure outputs when necessary.
of the CAN I/O controller. After all other status code
procedures have been followed and no problem is
found, the CAN I/O controller should be tested and re- CAUTION
placed as the last option to correct the problem. Never attempt to probe through the back of the
connector plugs of the motor controller. These
The onboard diagnostic system employed on the ve- plugs are special sealed plugs. Probing through
hicle can assist in the troubleshooting process. Read the back of the plugs will destroy the seal and can
and be familiar with the instructions for accessing and cause a short circuit. If a circuit must be tested for
using the display's diagnostic system in 2200 YRM voltage, check for voltage at an amp-type plug, a
1614 . switch, or component. If a circuit is suspect,
check the circuit for continuity by disconnecting
Prior to troubleshooting systems and components on the plug and testing continuity from the front (pin
the vehicle, ensure the battery voltage is correct and end) of the plug.
within specifications. Make sure the battery connector
contacts are clean of corrosion and the battery polar- Standard probes are too large to be inserted into
ity within the connector is correct. Inspect that all the center of female pins (sockets) of the special
fuses are correct and are not the cause of component sealed plugs and can damage or expand the pins.
failure. Ensure the key switch is in the ON position Expanded pins will not provide good connections
when conducting voltage checks or verifying the oper- once the plug is reconnected. The connectors are
ation of a component. Make sure the brake switch shaped to allow the insertion of a small flat-blade
and the operator presence switch, if equipped, are screwdriver into the connector. After inserting the
functioning properly and are closed. screwdriver into the connector, attach probes
with alligator clips to the shank of the screwdriver
Many faults noted by lift truck’s electrical system may to obtain readings. An additional method would
be the result of loose wiring connections and/or bro- be to use Breakout Kit #580002086 .
ken or shorted wiring within the lift truck. Begin the
troubleshooting process by carefully inspecting the Refer to 8000 YRM 1619 for wiring diagrams and ad-
wiring involving the device or devices noted by the on- ditional circuit information.
board diagnostic system. Faults noted with compo-
9030-03-1
General Maintenance and Diagnostic Data Electrical System
DISCHARGING THE CAPACITORS

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

the lift truck to prevent unexpected movement.
The capacitors in the transistor controllers can

hold an electrical charge after the battery is dis-
connected. To prevent an electrical shock and
personal injury, discharge the internal or external
capacitors before inspecting or repairing any
component in the electrical compartments. Make
certain that the battery has been disconnected.
DO NOT short across the motor controller termi-

nals with a screwdriver or jumper wire.
Make certain the Emergency Disconnect Switch

has not been activated. This will isolate the con- 1. POSITIVE CONNECTION B(+)
troller and prevent the capacitors from discharg- 2. NEGATIVE CONNECTION B(-)
ing properly. The proper way to disconnect the 3. INSULATED JUMPER WIRES
battery is by separating the battery connectors. 4. 200-OHM, 2-WATT RESISTOR
Figure 9030-03-1. Discharging the Internal

Capacitors
9030-03-2
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 #580002086 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.
9030-03-3
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.
9030-03-4
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 YRM 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.
9030-03-5
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
9030-03-6
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 2200YRM1614 for further information screen. If diagnostics are available with the code, the
regarding the User Interface for either Supervisor or diagnostics will be immediately entered.
Technician application.
Status Code Indication
Status Code Toggling
This feature indicates if a status code is available
This feature allows the operator to toggle the display when in the normal screen. If a status code is present,
from the normal screen display to the status code the mode indicator will display “!”.
screen. Pressing the 2 button will cause the display to
Status Codes and Descriptions

STATUS CODES NODE 41: STEER CASTER (Optional)
NODE 50: PUMP
Status codes give an indication to the operator that a
possible malfunction or incorrect truck use has occur- NODE 51: AUXILIARY PUMP (Americas Only)
red. Status codes are a code number of a symptom or NODE 60: HANDLE
malfunction. The wrench symbol will flash and the sta- NODE 80: IMPACT MODULE (Optional)
tus code number will be shown on the LCD screen if
an incorrect truck use or malfunction occurs during NODE 90: CAN I/O
operation. Have an authorized service person check NODE 91: REMOTE MODULE (Americas
and repair the lift truck if a status code number ap- Only)
pears. The symptoms for each status code are show
in this manual. This manual also provides in-depth Status Codes are displayed as four lines. Line one
troubleshooting procedures for each fault broken consist of the Node and Code number. The second
down into the following system or node: line consists of the Node name while lines three and
NODE 10: DISPLAY four contain code descriptions. For example, Status
Code 90106 is shown in the Status Code Structure
NODE 30: TRACTION Table 9030-03-1:
NODE 40: STEER
Table 9030-03-1. Status Code Structure
LINE NUMBER LINE DESCRIPTION

LINE 1 90106
LINE 2 CAN I/0
LINE 3 CANBus
LINE 4 From Handle
9030-03-7
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 Traction Controller.
10 103 The Display has detected a loss of CAN communication with the Lift Pump.
10 104 The Display has detected a loss of CAN communication with the Main Steer Control-
ler.
10 105 The Display has detected a loss of CAN communication with the Caster Steer Control-
ler.
10 106 The Display has detected a loss of CAN communication with the Handle.
10 107 The Display has detected a loss of CAN communication with the CAN I/O Controller.
10 108 The Display has detected a loss of CAN communication with the Remote Module.
10 110 The Display has detected a loss of CAN communication with the Impact Module.
10 111 The Display has detected a loss of CAN communication with the auxiliary steer motor.
* 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.

30 033 The Traction Controller has detected a fault in the Main Contactor Circuit.
30 034 The Traction Controller has detected a short in the MC Coil circuit.
30 035 The Traction Controller has detected a fault in the Brake Coil Circuit.
30 036 The Traction Controller has detected a short in the Brake Coil circuit.
30 052 The Traction Controller has detected a Throttle Sensor fault.
30 060 The Traction Controller has detected a fault in the Traction Motor circuit.
30 061 The Traction Controller has detected an open in the Traction Motor circuit.
30 062 The Traction Controller has detected a fault in the Traction Motor Encoder.
30 067 The Traction Controller has detected that the Main Contactor is stuck closed or has
welded tips.
30 068 The Traction Controller has detected that the Main Contactor is stuck open or not
closed.
30 069 The Traction Controller has detected a fault in the capacitor charge.
30 085 The Traction Controller has detected low input key voltage or a fault in the key input
circuit.
9030-03-8
Table 9030-03-3. Node 30 Status Codes (Continued)

30 086 The Traction Controller has detected low DC Bus voltage or a fault in the DC Bus cir-
cuit.
30 087 The Traction Controller has detected high DC Bus voltage or a fault in the DC Bus cir-
cuit.

40 060 The Steer Controller has detected a fault in the Steer Motor circuit.
40 061 The Steer Controller has detected an open in the Steer Motor circuit.
40 062 The Steer Controller has detected a fault in the Steer Motor Encoder.
40 070 The Steer Controller has detected a MTS Sensor fault.
40 072 The Steer Controller has detected that the MTS Sensor and Center Proximity Switch
do not agree.
40 073 The Steer Controller has detected a steer Center Proximity Switch fault or Steer Angle
circuit fault.
40 074 The Steer Controller has detected that the Steer Motor has stalled.
40 085 The Steer Controller has detected low input key voltage or a fault in the key input cir-
cuit.
40 086 The Steer Controller has detected low DC Bus voltage or a fault in the DC Bus circuit.
40 087 The Steer Controller has detected high DC Bus voltage or a fault in the DC Bus circuit.
Table 9030-03-5. Node 41 Status Codes (Optional)

41 060 The Steer Caster Controller has detected a fault in the Steer Caster Motor circuit.
41 061 The Steer Caster Controller has detected an open in the Steer Caster Motor circuit.
41 062 The Steer Caster Controller has detected a fault in the Steer Caster Motor Encoder.
41 072 The Steer Caster Controller has detected that the Steer Motor angle and Steer Caster
angle do not agree.
41 073 The Steer Caster Controller has detected a Center Proximity Switch fault or Steer
Caster Angle circuit fault.
41 085 The Steer Caster Controller has detected low input key voltage or a fault in the key
input circuit.
41 086 The Steer Caster Controller has detected low DC Bus voltage or a fault in the DC Bus
circuit.
41 087 The Steer Caster Controller has detected high DC Bus voltage or a fault in the DC Bus
circuit.
9030-03-9

50 060 The Lift Pump Controller has detected a fault in the Lift Motor circuit.
50 061 The Lift Pump Controller has detected an open in the Lift Motor circuit.
50 062 The Lift Pump Controller has detected a fault in the Lift Motor Encoder.
50 068 The Lift Pump Controller had detected DC Bus voltage too low.
50 069 The Lift Pump Controller has detected a fault in the capacitor charge.
Table 9030-03-7. Node 51 Status Codes (Americas Only)

51 060 The Auxiliary Pump has detected a fault in the Auxiliary Pump Motor circuit.
51 061 The Auxiliary Pump has detected an open in the Auxiliary Pump Motor circuit.
51 062 The Auxiliary Pump has detected a fault in the Auxiliary Pump Encoder.
51 086 The Auxiliary Pump has detected low DC Bus or a fault in the DC Bus circuit.
51 087 The Auxiliary Pump has detected high DC Bus voltage or a fault in the DC Bus circuit.
51 111 The Auxiliary Pump has detected a loss of CAN communication from the Lift Pump.

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 has detected a SS/EXT/RET axis fault.
Table 9030-03-9. Node 80 Status Codes (Optional)

80 065 The Impact Module has detected a Soft Impact.
80 066 The Impact Module has detected a Hard Impact.
9030-03-10

90 001 The CAN I/O Controller has detected a fault in the Lift Coil circuit.
90 002 The CAN I/O Controller has detected a short in the Lift Coil circuit.
90 003 The CAN I/O Controller has detected a fault in the Lower Coil circuit.
90 004 The CAN I/O Controller has detected a short in the Lower Coil circuit.
90 005 The CAN I/O Controller has detected a fault in the Load Hold circuit.
90 006 The CAN I/O Controller has detected a short in the Load Hold circuit.
90 007 The CAN I/O Controller has detected a fault in the Aux Fwd Coil circuit.
90 008 The CAN I/O Controller has detected a short in the Aux Fwd Coil circuit.
90 009 The CAN I/O Controller has detected a fault in the Aux Rev Coil circuit.
90 010 The CAN I/O Controller has detected a short in the Aux Rev Coil circuit.
90 011 The CAN I/O Controller has detected a fault in the Tilt Coil circuit.
90 012 The CAN I/O Controller has detected a short in the Tilt Coil circuit.
90 017 The CAN I/O Controller has detected a fault in the Side Shift Coil circuit.
90 018 The CAN I/O Controller has detected a short in the Side Shift Coil circuit.
90 023 The CAN I/O Controller has detected a fault in the EXT/RET Coil circuit.
90 024 The CAN I/O Controller has detected a short in the EXT/RET Coil circuit.
90 037 The CAN I/O Controller has detected a fault in the Audible Alarm circuit.
90 038 The CAN I/O Controller has detected a short in the Audible Alarm circuit.
90 039 The CAN I/O Controller has detected a fault in the Visible Alarm circuit.
90 040 The CAN I/O Controller has detected a short in the Visible Alarm circuit.
90 043 The CAN I/O Controller has detected a fault in the TFD Coil circuit.
90 053 The CAN I/O Controller has detected a fault in the Pressure sensor or Pressure Sen-
sor circuit fault.
90 075 The CAN I/O Controller has detected a fault in the Steer Security Line or loss of CAN
communication.
90 076 The CAN I/O Controller has detected a fault in the Steer Caster Security Line or loss
of CAN communication.
90 085 The CAN I/O Controller has detected low Key Input voltage or a fault in the key input
circuit.
9030-03-11
Table 9030-03-11. Node 91 Status Codes (Americas Only)

91 007 The Remote Module has detected a fault in the Aux Fwd circuit.
91 008 The Remote Module has detected a short in the Aux Fwd circuit.
91 009 The Remote Module has detected a fault in the Aux Rev circuit.
91 010 The Remote Module has detected a short in the Aux Rev circuit.
91 011 The Remote Module has detected a fault in the Tilt Coil circuit.
91 012 The Remote Module has detected a short in the Tilt Coil circuit.
91 017 The Remote Module has detected a fault in the Side Shift Coil circuit.
91 018 The Remote Module has detected a short in the Side Shift Coil circuit.
91 023 The Remote Module has detected a fault in the EXT/RET Coil circuit.
91 024 The Remote Module has detected a short in the EXT/RET Coil circuit.
91 049 The Remote Module has detected a Tilt Sensor fault or Tilt Sensor circuit fault.
91 051 The Remote Module has detected a fault in the EXT/RET Sensor or EXT/RET Sensor
circuit fault.
9030-03-12
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 9030-03-12. Warning Codes
CODE NODE STATUS DESCRIPTION SYMPTOM

TYPE
A controller has begun to reduce power to the motor in at-
tempt to manage increased temperatures that may dam-
age the motor. Motor cutback is initiated at
XX 080 Motor Cutback*
140°C (284°F). Truck performance will be reduced until
temperature lowers to an acceptable level. Motor temper-
ature input can be monitored in menu D2.32.6.
Motor cutback (XX080) was unsuccessful. Motor cutback
is initiated at 160°C (320°F). The truck will severely limit
XX 081 Motor Overheated* performance until the motor temperature returns to nor-
mal. Motor temperature input can be monitored in menu
D2.32.6.
A controller has begun to reduce power in attempt to
Thermal manage increased temperatures that may damage inter-
nal components. Controller cutback is initiated at
XX 082 Controller Cutback*
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.
Controller cutback (XX082) was unsuccessful. Controller
cutback is initiated at 110°C (230°F). The truck will se-
Controller Overhea-
XX 083 verely limit performance until the motor temperature re-
ted*
turns to normal. Motor temperature input can be moni-
tored in menu D2.32.5.
A controller has detected low temperature conditions.
XX 248 Low Temp* Move truck to a warmer ambient condition an allow suffi-
cient time to warm.
*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 YRM.
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 - Traction
POSSIBLE CAUSE
A. CANBUS COMMUNICATION FAULT

B. TRACTION CONTROLLER WIRING FAULT
NOTE
Please refer to the end of this procedure for supporting diagrams.
System YRM.
YES: Proceed to Step 3.
3. Locate input diagnostics (D2.10) and verify 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 traction controller connector CPS11. Measure voltage between the traction controller connec-
tor CPS11, socket A21 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.
2. Measure voltage between the traction controller connector CPS11, socket A20 and B(-).
Is CAN LO voltage approximately 2.5 Vdc?
9030-20-2
DTC xx101 (Cont)

CANBus Communications - Traction
YES: Disconnect battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the traction controller connector CPS11, socket A21 and socket A20.
Is resistance 60 ± 6 ohms?
YES: 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 - TRACTION CONTROLLER WIRING FAULT
1. Measure voltage between the traction controller B(+) terminal and B(-).
Is voltage 24 ± 2.5 Vdc / 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
DTC XX101 CANBUS COMMUNICATIONS - TRACTION DIAGRAMS
Troubleshooting Scenes
END FAULT
9030-20-3
DTC xx103
CANBus Communications - Pump
POSSIBLE CAUSE

B. PUMP CONTROLLER WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.10) and verify pump controller communication (D2.10.50).
YES: Suspect short to frame.
1. Disconnect the pump controller connector CPS12. Measure voltage between the pump controller connector
CPS12, socket A20 and B(-).
2. Measure voltage between the pump controller connector CPS12, socket A21 and B(-).
9030-20-4
DTC xx103 (Cont)

CANBus Communications - Pump
3. Measure resistance between the pump controller connector CPS12, socket A21 and socket A20.
CAUSE B - PUMP CONTROLLER WIRING FAULT
1. Measure voltage between the pump controller B(+) terminal and B(-).
NO: Inspect power and ground cables for damage and loose connections.
END POSSIBLE CAUSES
DTC XX103 CANBUS COMMUNICATIONS - PUMP DIAGRAMS
END FAULT
9030-20-5
DTC xx104
CANBus Communications - Steer
POSSIBLE CAUSE

B. STEER CONTROLLER WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.10) and verify steer controller communication (D2.10.40).
1. Disconnect the steer controller connector CPS059. Measure voltage between the caster steer controller con-
nector CPS059, socket A23 and B(-).
2. Measure voltage between the steer controller connector CPS059, socket A22 and B(-).
9030-20-6
DTC xx104 (Cont)

CANBus Communications - Steer
3. Measure resistance between the steer controller connector CPS059, socket A23 and socket A22.
CAUSE B - STEER CONTROLLER WIRING FAULT
1. Measure voltage between the steer controller B(+) terminal and B(-).
END POSSIBLE CAUSES
DTC XX104 CANBUS COMMUNICATIONS - STEER DIAGRAMS
END FAULT
9030-20-7
DTC xx105
CANBus Communications - Caster Steer
POSSIBLE CAUSE

B. CASTER STEER CONTROLLER WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.10) and verify caster steer controller communication (D2.10.41).
1. Disconnect the caster steer controller connector CPS082. Measure voltage between the caster steer control-
ler connector CPS082, socket A23 and B(-).
2. Measure voltage between the caster steer controller connector CPS082, socket A22 and B(-).
9030-20-8
DTC xx105 (Cont)

CANBus Communications - Caster Steer
3. Measure resistance between the caster steer controller connector CPS082, socket A23 and socket A22.
CAUSE B - CASTER STEER CONTROLLER WIRING FAULT
1. Measure voltage between the caster controller B(+) terminal and B(-).
END POSSIBLE CAUSES
DTC XX105 CANBUS COMMUNICATIONS - CASTER STEER DIAGRAMS
END FAULT
9030-20-9
DTC xx106
CANBus Communications - Handle
POSSIBLE CAUSE

B. HANDLE WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.10) and verify handle communication (D2.10.60).
Is the handle online?
1. Measure voltage between the handle connector CPS023/CPS023A, socket 5 (side-stance)/socket 3 (fore/aft)
and B(-).
and B(-).
9030-20-10
DTC xx106 (Cont)

3. Measure resistance between the handle connector CPS023/CPS023A, socket 4 and socket 5 (side-stance)
OR socket 2 and socket 3 (fore/aft).
CAUSE B - HANDLE WIRING FAULT
1. Disconnect the handle connector CPS023/CPS023A. Measure voltage between the handle connector, socket
6 (side-stance)/socket 1 (fore-aft) and B(-).
NO: Inspect circuit 201-B/201-C for open or short.
2. Measure voltage between the handle connector CPS023/CPS023A, socket 6 and socket 2 (side-stance),
socket 1 and socket 4 (fore-aft).
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 controller replacement.
NO: Inspect ground circuit 113-J/113-T for open or short.
END POSSIBLE CAUSES
9030-20-11
DTC xx106 (Cont)

DTC XX106 CANBUS COMMUNICATIONS - HANDLE DIAGRAMS
Side-Stance Handle Troubleshooting Scenes
9030-20-12
DTC xx106 (Cont)

Fore-Aft Handle Troubleshooting Scenes
END FAULT
9030-20-13
DTC xx107
CANBus Communications - CAN I/O
POSSIBLE CAUSE

B. CAN I/O WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.10) and verify CAN I/O controller communication (D2.10.90).
Is the CAN I/O module online?
1. Measure voltage between the CAN I/O connector CPS031, socket A21 and B(-).
2. Measure voltage between the CAN I/O connector CPS031, socket A10 and B(-).
9030-20-14
DTC xx107 (Cont)

3. Measure resistance between the CAN I/O connector CPS031, socket A10 and socket A21.
CAUSE B - CAN I/O WIRING FAULT
1. Disconnect CAN I/O connector CPS031 and measure voltage between the CAN I/O connector CPS031,
socket A32/A31 and B(-).
NO: Inspect circuits 206-X and 206-Y for open or short.
2. Measure voltage between the CAN I/O connector CPS031, sockets A6/A5 and B(-).
NO: Inspect circuits 285-T and 285-M for open or short.
3. Measure voltage between the CAN I/O connector CPS031, socket A6 and sockets A12/A13.
NO: Inspect ground circuits 013-S and 013-G for open or short.
END POSSIBLE CAUSES
9030-20-15
DTC xx107 (Cont)

DTC XX107 CANBUS COMMUNICATIONS - CAN I/O DIAGRAMS
END FAULT
9030-20-16
DTC xx108
CANBus Communications - Remote Module
POSSIBLE CAUSE

B. REMOTE MODULE WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.10) and verify remote module communication (D2.10.91).
Is the remote module online?
1. Measure voltage between the remote module connector CPS85, socket 1 and B(-).
2. Measure voltage between the remote module connector CPS85, socket 2 and B(-).
9030-20-17
DTC xx108 (Cont)

3. Measure resistance between the remote module connector CPS85, socket 2 and socket 1.
CAUSE B - REMOTE MODULE WIRING FAULT
1. Disconnect remote module connector CPS85. Measure voltage between the remote module connector
CPS85, socket 5 and B(-).
NO: Inspect circuit 285MK for open or short.
2. Measure voltage between the remote module connector CPS85, socket 5 and socket 6.
NO: Inspect ground circuit 113MK for open or short.
END POSSIBLE CAUSES
9030-20-18
DTC xx108 (Cont)

DTC XX108 CANBUS COMMUNICATIONS - REMOTE MODULE DIAGRAMS
END FAULT
9030-20-19
DTC xx110
CANBus Communications - Impact Module
POSSIBLE CAUSE

B. IMPACT MODULE WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.10) and verify impact module communication (D2.10.80).
Is the impact module online?
1. Measure voltage between the impact module connector CPS148, socket 2 and B(-).
9030-20-20
DTC xx110 (Cont)

CANBus Communications - Impact Module
3. Measure resistance between the impact module connector CPS148, socket 2 and socket 4.
CAUSE B - IMPACT MODULE WIRING FAULT
1. Disconnect impact module connector CPS148 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 285-C for open or short.
2. Measure voltage between the impact module connector CPS148, socket 1 and socket 3.
NO: Inspect ground circuit 113-C for open or short.
END POSSIBLE CAUSES
DTC XX110 CANBUS COMMUNICATIONS - IMPACT MODULE DIAGRAMS
END FAULT
9030-20-21
DTC xx111
CANBus Communciations - Auxiliary Pump
POSSIBLE CAUSE

B. FAULTY AUXILIARY PUMP
NOTE
System YRM.
3. Locate input diagnostics (D2.10) and verify auxiliary pump communication (D2.10.51).
Is auxiliary pump online?
NO: Proceed to .
1. Disconnect and measure voltage between the auxiliary motor connector CPS047, socket 1 and B(-).
2. Measure voltage between the auxiliary motor connector CPS047, socket 2 and B(-).
9030-20-22
DTC xx111 (Cont)

CANBus Communciations - Auxiliary Pump
3. Measure resistance between the auxiliary motor connector CPS047, socket 1 and socket 2.
YES: No communication faults are present, proceed to Cause B.
CAUSE B - FAULTY AUXILIARY PUMP
1. If no faults are found, replace auxiliary pump. 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
DTC XX111 CANBUS COMMUNCIATIONS - AUXILIARY PUMP DIAGRAMS
END FAULT
9030-20-23
DTC 30033
Traction - Main Cont Coil - Circuit
POSSIBLE CAUSE
A. MAIN CONTACTOR COIL WIRING FAULT

B. MAIN CONTACTOR COIL FAULT
C. FAULTY TRACTION CONTROLLER
NOTE
System YRM.
3. Locate input diagnostics (D2.30) and view the main contactor position (D2.30.16).
Is the main contactor closed at correct time?
4. Locate output diagnostics (D3.30) and actuate main contactor coil (D3.30.7).
Does contactor operate correctly when actuated?
CAUSE A - MAIN CONTACTOR COIL WIRING FAULT
1. Disconnect the main contactor coil's positive socket terminal TS013 and measure voltage between socket ter-
minal TS013 and B(-).
NO: Inspect circuit 245-A and 245-B for open or short.
NOTE: Key in OFF position.
9030-20-24
DTC 30033 (Cont)

2. Disconnect traction controller connector CPS11 and contactor coil's negative socket terminal TS012. Measure
resistance between the main contactor coil negative socket terminal TS012 and the traction controller connec-
tor CPS11, socket A16.
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground control circuit 024-A for open or source of excessive resistance.
CAUSE B - MAIN CONTACTOR COIL FAULT
1. Measure resistance between the main contactor coil terminals.

Is resistance 32 ± 4.0 ohms?
YES: Reconnect TS012 and TS013 and proceed to Cause C.
NO: Replace faulty contactor coil.
CAUSE C - FAULTY 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
9030-20-25
DTC 30033 (Cont)

DTC 30033 TRACTION - MAIN CONT COIL - CIRCUIT DIAGRAMS
END FAULT
9030-20-26
DTC 30035
Traction - Brake Coil - Circuit
POSSIBLE CAUSE
A. ELECTRIC BRAKE COIL WIRING FAULT

B. ELECTRIC BRAKE COIL FAILURE
NOTE
System YRM.
NOTE: Apply brake.
3. Locate input diagnostics (D2.30) and view brake connect (D2.30.14) to verify brake coil state.
Is electric brake applied?
YES: Problem may be intermittent.
4. Locate output diagnostics (D3.30) and actuate brake coil (D3.30.6).
Does brake operate correctly when actuated?
YES: Proceed to Cause C
CAUSE A - ELECTRIC BRAKE COIL WIRING FAULT
1. Disconnect the electric brake connector CPS041 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 245-C and 245-B for open or short.
9030-20-27
DTC 30035 (Cont)

2. Disconnect traction controller connector CPS11. Measure resistance between the electric brake coil connec-
tor CPS041, socket 2 and the traction controller connector CPS11, socket A18.
NO: Inspect ground control circuit 096-A for open or source of excessive resistance.
CAUSE B - ELECTRIC BRAKE COIL FAILURE
1. Measure resistance between the electric brake coil connector CPS041, pin 1 and pin 2.
Is resistance 11.9 ± 1.0 ohm?
YES: Proceed to Cause C.
NO: Replace faulty coil.
END POSSIBLE CAUSES
9030-20-28
DTC 30035 (Cont)

DTC 30035 TRACTION - BRAKE COIL - CIRCUIT DIAGRAMS
END FAULT
9030-20-29
Main Contactor/Brake Coil Short

CODES
DTC 30034 - Traction - Main Cont Coil - Short

DTC 30036 - Traction - Brake Coil - Short
POSSIBLE CAUSE
A. VOLTAGE INPUT WIRING FAULT

B. MAIN CONTACTOR OR BRAKE COIL FAILURE
NOTE
System YRM.
NOTE: Key in ON position and brake applied.
3. Locate input diagnostics (D2.30) and view brake connect (D2.30.14) and main contactor connect (D2.30.16)
to verify status of both the brake and contactor coil.
Are both coils inoperative?
4. Locate output diagnostics (D3.30) and actuate the brake coil (D3.30.6) and the main contactor coil (D3.30.7).
Do both coils function properly?
YES: Replace faulty traction controller.
NO: If main contactor coil is inoperative, proceed to Cause AStep 1. If brake coil is inoperative, proceed to
Cause AStep 2.
CAUSE A - VOLTAGE INPUT WIRING FAULT
1. Disconnect the main contactor coil's positive terminal TS013 and measure voltage between terminal TS013
and B(-).
9030-20-30
Main Contactor/Brake Coil Short (Cont)

YES: Proceed to Cause BStep 1.
NO: Inspect circuit 245-B and 245-A for open or short.
2. Disconnect the electric brake connector CPS041 and measure voltage between socket 1 and B(-).
YES: Proceed to Cause BStep 1.
NO: Inspect circuit 245-C and 245-A for open or short.
CAUSE B - MAIN CONTACTOR OR BRAKE COIL FAILURE
1. Disconnect the main contactor coil terminal connectors TS012 and TS013. Measure resistance between the
main contactor coil terminals TS012 and TS013.
2. Disconnect the electric brake connector CPS041 and measure resistance between sockets 1 and 2.
Is resistance 11.9 ± 1.0 ohm?
END POSSIBLE CAUSES
9030-20-31
Main Contactor/Brake Coil Short (Cont)

DIAGRAMS
END FAULT
9030-20-32
CODES
DTC 30052 - Traction - Throttle - Sensor Fault

DTC 90052 - CAN - Handle - Signal
POSSIBLE CAUSE
A. AFT HANDLE WIRING FAULT

B. AFT THROTTLE WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.30) and view the aft enable switch (D2.30.34) to ensure the aft handle is ena-
bled.
Is the aft enable switch ON when hand is placed in handle?
4. Locate and view aft throttle (D2.30.33) to verify throttle input.
Does throttle respond to switch position input?
NO: Proceed to Cause B.
CAUSE A - AFT HANDLE WIRING FAULT
1. Disconnect the aft handle connector CPS035. Measure voltage between the aft handle connector CPS035,
socket 1 and B(-).
YES: Connect the aft handle connector CPS035 and proceed to Step 2.
NO: Inspect circuit 285-F for open or short. Inspect aft handle connector harness for damage.
9030-20-33
(Cont)
NOTE: Hold aft handle to actuate optic sensor.
2. Connect Breakout Kit #580002086 to the traction controller and measure voltage between the traction control-
ler connector CPS11, pin A4 and B(-).
NO: Inspect aft enable input circuit 030-A for open or short, if no circuit faults are found, replace optic sensor.
CAUSE B - AFT THROTTLE WIRING FAULT
NOTE: Key in ON position and operate throttle switch.
1. Using the Breakout Kit #580002086 , measure voltage between the traction controller connector CPS11, pin
A3 and B(-).
Does input voltage follow throttle switch position?
NO: Inspect throttle input circuit 029-A for open or short, if no circuit faults are found, replace throttle switch.
END POSSIBLE CAUSES
9030-20-34
(Cont)
DTC 30052 TRACTION - THROTTLE - SENSOR FAULT DIAGRAMS
END FAULT
9030-20-35
Traction Motor
CODES
DTC 30060 - Traction - Motor - Circuit

DTC 30061 - Traction - Motor - Open
POSSIBLE CAUSE
A. TRACTION MOTOR CABLE FAULT

B. TRACTION MOTOR FAULT
NOTE
System YRM.
NOTE: 50A DC voltage will be applied to each phase and then actual current is measured and displayed.
3. Locate output diagnostics (D3.30) and conduct line DC current tests (D3.30.1, D3.30.2, D3.30.3) to diagnose
faults on individual phase cables.
Is DC current present?
YES: No circuit fault present, problem may be intermittent.
CAUSE A - TRACTION MOTOR CABLE FAULT
NOTE: Disconnect battery.
1. Disconnect the traction motor cables from the traction controller and traction motor. Measure continuity of in-
dividual cables to isolate fault.
Is continuity present?
NO: Repair or replace faulty phase cable.
9030-20-36
Traction Motor (Cont)

CAUSE B - TRACTION MOTOR FAULT
1. Measure resistance between the traction motor terminals U and V.

Is resistance between .322 and .383 ohms?
NO: Repair or replace faulty traction motor.
2. Measure resistance between the traction motor terminals U and W.
3. Measure resistance between the traction motor terminals W and V.
END POSSIBLE CAUSES
9030-20-37
Traction Motor (Cont)

DIAGRAMS
END FAULT
9030-20-38
DTC 30062
Traction - Motor - Encoder
POSSIBLE CAUSE
A. ENCODER WIRING FAULT

B. ENCODER FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.30) and view motor encoder count (D2.30.3) to verify signal.
Is encoder signal responding to actual traction motor speed?
YES: Fault may be intermittent. Visually inspect encoder for damage.
CAUSE A - ENCODER WIRING FAULT
1. Disconnect the traction motor encoder connector CPS014 and measure voltage between socket 1 and B(-).
Is voltage 12 ± 1.5 Vdc?
NO: Inspect circuit 281-A for open or short.
2. Measure voltage between the encoder connector CPS014, socket 1 and socket 4.
NO: Inspect ground circuit 104-B for open or short.
3. Disconnect the traction controller connector CPS11. Measure resistance between socket A7 of the traction
controller connector and socket 3 of the encoder connector CPS014.
9030-20-39
DTC 30062 (Cont)

NO: Inspect signal circuit 577-A for open or source of excessive resistance.
4. Measure resistance between socket A14 of the traction controller connector CPS11 and socket 2 of the en-
coder connector CPS014.
YES: Reconnect the encoder connector CPS014 and proceed to Cause B.
CAUSE B - ENCODER FAULT
NOTE: Connect battery.
NOTE: Operate traction motor while performing this test.
1. Connect Breakout Kit #580002086 to the traction controller connector CPS11 and measure voltage between
socket A7, A14 and B(-).
Does voltage signal relate to traction motor movement?
NO: Replace faulty encoder.
END POSSIBLE CAUSES
9030-20-40
DTC 30062 (Cont)

DTC 30062 TRACTION - MOTOR - ENCODER DIAGRAMS
END FAULT
9030-20-41
Traction Main Contactor

CODES
DTC 30067 - Traction - Main Contactor - Welded Tips

DTC 30068 - Traction - Main Contactor - Not Closed
POSSIBLE CAUSE

B. MAIN CONTACTOR STUCK CLOSED
C. MAIN CONTACTOR STUCK OPEN
D. FAULTY TRACTION CONTROLLER
NOTE
System YRM.
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.
1. Disconnect the main contactor coil's positive socket terminal TS013. Measure voltage between the main con-
tactor coil's positive socket terminal TS013 and B(-).
9030-20-42
Traction Main Contactor (Cont)

2. Disconnect traction controller connector CPS11. Measure continuity between the main contactor coil's nega-
tive socket terminal TS012 and socket A16 of the traction controller connector CPS11.
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 024-A for open or short.
CAUSE B - MAIN CONTACTOR STUCK CLOSED
NOTE: Disconnect precharge circuit connector TS049 from main contactor.
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: Reconnect TS049 and proceed to Cause D.
NO: Replace faulty main contactor.
CAUSE D - FAULTY TRACTION CONTROLLER
END POSSIBLE CAUSES
9030-20-43
Traction Main Contactor (Cont)

DIAGRAMS
END FAULT
9030-20-44
Traction Capacitor Charge and DC Bus Voltage

CODES
DTC 30069 - Traction - Capacitor - Charge

DTC 30086 - Traction - DC Bus - Voltage Low
DTC 30087 - Traction - DC Bus - Voltage High
POSSIBLE CAUSE
A. INTEGRATED FUSE BOARD WIRING FAULT

B. FAULTY INTEGRATED FUSE BOARD
C. TRACTION CONTROLLER WIRING FAULT
NOTE
System YRM.
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) and view CAP voltages (D2.30.8, D2.30.9, D2.30.10) to verify capacitor volt-
age.
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 D.
CAUSE A - INTEGRATED FUSE BOARD WIRING FAULT
1. Disconnect the main contactor precharge terminal TS049 from main contactor. Measure voltage between pre-
charge terminal TS049 and B(-).
Is precharge voltage same as battery voltage?
YES: Connect terminal TS049 and proceed to Cause B.
NO: Inspect precharge circuit 002 for open, short, or source of excessive resistance.
9030-20-45
Traction Capacitor Charge and DC Bus Voltage (Cont)

CAUSE B - FAULTY INTEGRATED FUSE BOARD
1. Disconnect the integrated fuse board connector CPS001 and measure voltage between the integrated fuse
board, pin 6 and B(-).
YES: Connect connector CPS001 and proceed to Cause C.
NO: Replace faulty integrated fuse board.
CAUSE C - TRACTION CONTROLLER WIRING FAULT
1. Measure voltage between the traction controller B(+) terminal and B(-).
YES: Proceed to Cause D.
NO: Inspect traction controller B(+) bus bar and cables for damage or loose connections.
END POSSIBLE CAUSES
9030-20-46
Traction Capacitor Charge and DC Bus Voltage (Cont)

DIAGRAMS
Cause A and Cause C Troubleshooting Scenes
Cause D Troubleshooting Scenes
END FAULT
9030-20-47
DTC 30085
Traction - Key input - Voltage Low
POSSIBLE CAUSE
A. FAULTY INTEGRATED FUSE BOARD

B. KEY INPUT WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.30) and view key input voltages (D2.30.11, D2.30.13) to verify actual key voltage
and minimum captured key voltage.
Was voltage below 24 ± 2.5 Vdc / 36 ± 3.5 Vdc?
YES: Check battery state of charge and proceed to Cause A.
NO: If battery is fully charged and code returns, proceed to Cause C.
CAUSE A - FAULTY INTEGRATED FUSE BOARD
9030-20-48
DTC 30085 (Cont)

CAUSE B - KEY INPUT WIRING FAULT
1. Disconnect the traction controller connector CPS11. Measure voltage between the traction controller connec-
tor CPS11, socket A1 and B(-).
NO: Inspect circuit 206-G for open, short, or source of excessive resistance.
END POSSIBLE CAUSES
9030-20-49
DTC 30085 (Cont)

DTC 30085 TRACTION - KEY INPUT - VOLTAGE LOW DIAGRAMS
Cause A Troubleshooting Scenes
Cause B Troubleshooting Scenes
END FAULT
9030-20-50
Steer Motor
CODES
DTC 40060 - Steer - Motor - Circuit

DTC 40061 - Steer - Motor - Open
POSSIBLE CAUSE
A. STEER MOTOR CABLE FAULT

B. STEER MOTOR FAULT
C. FAULTY STEER CONTROLLER
NOTE
System YRM.
CAUSE A - STEER MOTOR CABLE FAULT
1. Disconnect the steer motor cables from the steer controller and steer motor. Measure continuity of individual
cables to isolate fault.
9030-20-51
Steer Motor (Cont)

CAUSE B - STEER MOTOR FAULT
1. Measure resistance between the steer motor terminals U and V.

NO: Repair or replace faulty steer motor.
2. Measure resistance between the steer motor terminals U and W.
3. Measure resistance between the steer motor terminals W and V.
CAUSE C - FAULTY STEER CONTROLLER
END POSSIBLE CAUSES
9030-20-52
Steer Motor (Cont)

DIAGRAMS
END FAULT
9030-20-53
DTC 40062
Steer - Motor - Encoder
POSSIBLE CAUSE
A. FAULTY BATTERY
B. ENCODER WIRING FAULT
C. ENCODER FAULT
D. FAULTY STEER CONTROLLER
NOTE
System YRM.
Is encoder signal responding to actual traction motor speed?
CAUSE A - FAULTY BATTERY
1. Check battery state of charge.
Is battery voltage within specifications?
YES: Proceed to .
NO: Charge or replace faulty battery.
CAUSE B - ENCODER WIRING FAULT
1. Disconnect the steer motor encoder connector CPS060 and measure voltage between socket 1 and B(-).
YES: Proceed to .
9030-20-54
DTC 40062 (Cont)

NO: Inspect ground circuit 105 for open or short.
3. Disconnect the steer controller connector CPS059. Measure resistance between socket A4 of the steer con-
troller connector and socket 3 of the encoder connector CPS060.
4. Measure resistance between socket A3 of the steer controller connector and socket 2 of the encoder connec-
tor CPS060.
YES: Reconnect the encoder connector CPS060 and proceed to Cause C.
CAUSE C - ENCODER FAULT
NOTE: Operate steer motor while performing this test.
1. Connect Breakout Kit #580002086 to the steer controller connector CPS059 and measure voltage between
Does voltage signal relate to steer motor movement?
CAUSE D - FAULTY STEER CONTROLLER
END POSSIBLE CAUSES
9030-20-55
DTC 40062 (Cont)

DTC 40062 STEER - MOTOR - ENCODER DIAGRAMS
END FAULT
9030-20-56
DTC 40070
Steer - Steer Request - MTS Sensor
POSSIBLE CAUSE
A. STEER UNIT WIRING FAULT

B. STEER UNIT FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.40) and verity steer angle (D2.40.19) being commanded by the steer tiller.
Does the steer angle follow steer tiller input?
CAUSE A - STEER UNIT WIRING FAULT
1. Disconnect steer unit connector CPS045 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 280-B and 250-C for open or short.
2. Measure voltage between the steer unit connector CPS045, socket 1 and socket 2.
3. Disconnect the main steer controller connector CPS059. Measure resistance between the main steer connec-
tor CPS059, socket A20 and the steer unit connector CPS045, socket 3.
9030-20-57
DTC 40070 (Cont)

NO: Inspect signal input circuit 573-A for open, short, or source of excessive resistance.
4. Measure resistance between the main steer connector CPS059, socket A17 and the steer unit connector
CPS045, socket 4.
YES: Reconnect battery and steer unit connector CPS045. Proceed to Cause B.
NO: Inspect signal circuit 574-A for open, short, or source of excessive resistance.
CAUSE B - STEER UNIT FAULT
NOTE: Key to ON position. Operate steering.
Does voltage signal relate to steer unit movement?
NO: Replace faulty steer unit.
END POSSIBLE CAUSES
9030-20-58
DTC 40070 (Cont)

DTC 40070 STEER - STEER REQUEST - MTS SENSOR DIAGRAMS
END FAULT
9030-20-59
DTC 40072
Steer - Steer Angle - Mismatch
POSSIBLE CAUSE
A. STEER UNIT FAULT

B. ENCODER FAULT
NOTE
NOTE: Ensure correct steer motor is installed and gear ratio is correct.
System YRM.
3. Locate input diagnostics (D2.40) and view target steer angle (D2.40.18) and actual steer angle (D2.40.19) to
verify input rationality.
Does target steering angle and actual steering angle agree?
CAUSE A - STEER UNIT FAULT
NOTE: Connect battery and turn key to ON position. Operate steering.
Does voltage signal relate to steer unit movement?
9030-20-60
DTC 40072 (Cont)

NOTE: Operate steer motor while performing this test.
1. With Breakout Kit #580002086 connected, measure voltage between socket A3, A4 and B(-).
Does voltage signal relate to steer motor movement?
END POSSIBLE CAUSES
9030-20-61
DTC 40072 (Cont)

DTC 40072 STEER - STEER ANGLE - MISMATCH DIAGRAMS
9030-20-62
END FAULT
DTC 40073
Steer - Steer Angle - Center Fault
POSSIBLE CAUSE
A. CENTER PROXIMITY SWITCH WIRING FAULT

B. CENTER PROXIMITY SWITCH FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.40) and view the center proximity switch (D2.40.17) to verify switch operation.
Does the proximity switch display ON when steering is turned right of center and OFF when turned
left of center?
CAUSE A - CENTER PROXIMITY SWITCH WIRING FAULT
1. Disconnect center proximity switch connector CPS051 and measure between socket 1 and B(-).
NO: Inspect circuit 285-P for open or short.
2. Disconnect the main steer controller connector CPS059. Measure resistance between the controller connec-
tor CPS059, socket A13 and the center proximity switch connector CPS051, socket 3.
9030-20-63
DTC 40073 (Cont)

3. Measure resistance between the main steer controller connector CPS059, socket A12 and the center proxim-
ity switch connector CPS051, socket 2.
YES: Connect battery and the center proximity switch connector CPS051. Proceed to Cause B.
NO: Inspect ground input circuit 515-P for open, short, or source of excessive resistance.
CAUSE B - CENTER PROXIMITY SWITCH FAULT
NOTE: Turn the steer tiller right of center to provide sensor ground.
1. Connect Breakout Kit #580002086 to the steer controller connector CPS059 and measure continuity between
socket A12 and A13.
Is continuity present when steering is turned to right?
NO: Replace center proximity switch.
END POSSIBLE CAUSES
9030-20-64
DTC 40073 (Cont)

DTC 40073 STEER - STEER ANGLE - CENTER FAULT DIAGRAMS
END FAULT
9030-20-65
DTC 40074
Steer - Motor - Stalled
POSSIBLE CAUSE

B. FAULTY STEER MOTOR
NOTE
System YRM.
3. Locate input diagnostics (D2.40) and view steer motor encoder count (D2.40.3) to verify signal.
Is encoder signal responding to steering input?
4. View the steer motor current (D2.40.7) to verify steer motor operation.
Is steer motor current within specifications?
YES: Inspect steer motor for damage or signs of binding.
1. Disconnect the steer motor encoder connector CPS060 and measure voltage between socket 1 and B(-).
YES: Proceed to .
9030-20-66
DTC 40074 (Cont)

3. Disconnect the steer controller connector CPS059. Measure resistance between socket A4 of the steer con-
4. Measure resistance between socket A3 of the steer controller connector and socket 2 of the encoder connec-
tor CPS060.
YES: Reconnect the encoder connector CPS060 and proceed to Cause B.
CAUSE B - FAULTY STEER MOTOR
1. Measure resistance between the steer motor terminals U and V.

Is resistance between .322 and .383 ohm?
2. Measure resistance between the steer motor terminals U and W.
3. Measure resistance between the steer motor terminals W and V.
END POSSIBLE CAUSES
9030-20-67
DTC 40074 (Cont)

DTC 40074 STEER - MOTOR - STALLED DIAGRAMS
END FAULT
9030-20-68
DTC 40085
Steer - Key input - Voltage Low
POSSIBLE CAUSE

B. KEY INPUT WIRING
NOTE
System YRM.
3. Locate input diagnostics (D2.40) and view key input voltages (D2.40.11, D2.40.13) to verify key voltage and
minimum captured key voltage.
9030-20-69
DTC 40085 (Cont)

CAUSE B - KEY INPUT WIRING
1. Disconnect the main steer controller connector CPS059 and measure voltage between socket A15 and B(-).
YES: Suspect faulty steer controller.
NO: Inspect circuit 206-P for open, short, or source of excessive resistance.
END POSSIBLE CAUSES
9030-20-70
DTC 40085 (Cont)

DTC 40085 STEER - KEY INPUT - VOLTAGE LOW DIAGRAMS
END FAULT
9030-20-71
Steer DC Bus Voltage

CODES
DTC 40086 - Steer - DC Bus - Voltage Low

DTC 40087 - Steer - DC Bus - Voltage High
POSSIBLE CAUSE

C. MAIN STEER CONTROLLER WIRING FAULT
D. FAULTY STEER CONTROLLER
NOTE
System YRM.
ing Step 3.
age.
YES: Verify battery state of charge and recheck condition. If capacitor voltage is within specifications after
retest and code remains, proceed to Cause D.
9030-20-72
Steer DC Bus Voltage (Cont)

1. Measure voltage between the integrated fuse board, pin 6 and B(-).
CAUSE C - MAIN STEER CONTROLLER WIRING FAULT
1. Measure voltage between the main steer controller B(+) terminal and B(-).
NO: Inspect main steer B(+) cable for damage or loose connections.
CAUSE D - FAULTY STEER CONTROLLER
END POSSIBLE CAUSES
9030-20-73
Steer DC Bus Voltage (Cont)

DIAGRAMS
Cause A and Cause B Troubleshooting Scenes
Cause C Troubleshooting Scenes
END FAULT
9030-20-74
Steer Caster Motor

CODES
DTC 41060 - Steer Caster - Motor - Circuit

DTC 41061 - Steer Caster - Motor - Open
POSSIBLE CAUSE
A. STEER CASTER MOTOR CABLE FAULT

B. STEER CASTER MOTOR FAULT
C. FAULTY STEER CASTER CONTROLLER
NOTE
System YRM.
CAUSE A - STEER CASTER MOTOR CABLE FAULT
1. Disconnect the caster motor cables from the caster controller and caster motor. Measure continuity of individ-
ual cables to isolate fault.
9030-20-75
Steer Caster Motor (Cont)

CAUSE B - STEER CASTER MOTOR FAULT
1. Measure resistance between the caster motor terminals U and V.

NO: Repair or replace faulty caster motor.
2. Measure resistance between the caster motor terminals U and W.
3. Measure resistance between the caster motor terminals W and V.
CAUSE C - FAULTY STEER CASTER CONTROLLER
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-76
DTC 41062
Steer Caster - Motor - Encoder
POSSIBLE CAUSE
A. FAULTY BATTERY
B. ENCODER WIRING FAULT
C. ENCODER FAULT
D. FAULTY STEER CASTER CONTROLLER
NOTE
System YRM.
Is encoder signal responding to actual steer caster motor position?
CAUSE A - FAULTY BATTERY
1. Check battery state of charge.
Is battery voltage within specifications?
YES: Proceed to .
NO: Charge or replace faulty battery.
CAUSE B - ENCODER WIRING FAULT
1. Disconnect the steer caster motor encoder connector CPS083 and measure voltage between socket 1 and
B(-).
9030-20-77
DTC 41062 (Cont)

YES: Proceed to .
NO: Inspect circuit 250-D for open or short.
NO: Inspect ground circuit 105-B for open or short.
3. Disconnect the steer caster controller connector CPS082. Measure resistance between socket A4 of the steer
caster controller connector and socket 3 of the encoder connector CPS083.
NO: Inspect signal circuit 603-B for open or source of excessive resistance.
4. Measure resistance between socket A3 of the steer caster controller connector and socket 2 of the encoder
connector CPS083.
YES: Reconnect the encoder connector CPS083 and proceed to Cause C.
NO: Inspect signal circuit 602-B for open or source of excessive resistance.
CAUSE C - ENCODER FAULT
NOTE: Operate steer caster motor while performing this test.
1. Connect Breakout Kit #580002086 to the steer caster controller connector CPS082 and measure voltage be-
tween socket A3, A4 and B(-).
Does voltage signal relate to steer caster motor movement?
CAUSE D - FAULTY STEER CASTER CONTROLLER
END POSSIBLE CAUSES
9030-20-78
DTC 41062 (Cont)

DTC 41062 STEER CASTER - MOTOR - ENCODER DIAGRAMS
END FAULT
9030-20-79
DTC 41072
Steer Caster - Steer Angle - Mismatch
POSSIBLE CAUSE
A. STEER UNIT FAULT

B. ENCODER FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.41) and view target steer angle (D2.41.15) and actual steer angle (D2.41.16) to
verify angle rationality.
Does target steer angle and actual steering angle output agree?
CAUSE A - STEER UNIT FAULT
NOTE: Connect battery and turn key to ON position. Operate steering.
1. Connect Breakout Kit #580002086 to steer controller connector CPS059 and measure voltage between
Does voltage signal relate to steering input?
YES: Proceed to .
9030-20-80
DTC 41072 (Cont)

NOTE: Connect battery and turn key to ON position. Operate caster steer motor.
1. Connect Breakout Kit #580002086 to steer caster controller connector CPS082 and measure voltage be-
tween socket A3, A4 and B(-).
Does voltage signal relate to steer caster movement?
END POSSIBLE CAUSES
9030-20-81
DTC 41072 (Cont)

DTC 41072 STEER CASTER - STEER ANGLE - MISMATCH DIAGRAMS
END FAULT
9030-20-82
DTC 41073
Steer Caster - Steer Angle - Center Fault
POSSIBLE CAUSE
A. CENTER PROXIMITY SWITCH WIRING FAULT

B. CENTER PROXIMITY SWITCH FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.41) and view center proximity switch status (D2.41.14) to verify switch operation.
Does the center proximity switch display ON when the steering is turned right of center and OFF
when turned left of center?
CAUSE A - CENTER PROXIMITY SWITCH WIRING FAULT
1. Disconnect proximity switch connector CPS081 and measure between socket 1 and B(-).
NO: Inspect circuit 285-Z for open or short.
2. Disconnect the caster steer controller connector CPS082. Measure resistance between the controller connec-
tor CPS082, socket A13 and the caster center proximity switch connector CPS081, socket 2.
NO: Inspect ground circuit 107-C and 107-A for open or short.
9030-20-83
DTC 41073 (Cont)

Steer Caster - Steer Angle - Center Fault
3. Measure resistance between the caster steer controller connector CPS082, socket A12 and the caster center
proximity switch connector CPS081, socket 3.
YES: Connect battery and the caster center proximity switch connector CPS081. Proceed to Cause B.
NO: Inspect ground input circuit 515-B for open, short, or source of excessive resistance.
CAUSE B - CENTER PROXIMITY SWITCH FAULT
NOTE: Key in ON position and turn steer tiller right of center to provide sensor ground.
1. Connect Breakout Kit #580002086 to the steer caster controller connector CPS082 and measure continuity
between socket A12 and socket A13.
Is continuity present when steering is turned to right?
NO: Replace faulty caster center proximity switch.
END POSSIBLE CAUSES
DTC 41073 STEER CASTER - STEER ANGLE - CENTER FAULT DIAGRAMS
END FAULT
9030-20-84
DTC 41085
Steer Caster - Key Input - Voltage Low
POSSIBLE CAUSE

B. KEY INPUT WIRING
NOTE
System YRM.
3. Locate input diagnostics (D2.41) and view key input voltages (D2.41.10, D2.41.11) to verify key voltage and
minimum captured key voltage.
CAUSE B - KEY INPUT WIRING
1. Disconnect the steer caster controller connector CPS082 and measure voltage between socket A15 and B(-).
9030-20-85
DTC 41085 (Cont)

YES: Cause C.
NO: Inspect circuit 206-U for open, short, or source of excessive resistance.
END POSSIBLE CAUSES
9030-20-86
DTC 41085 (Cont)

DTC 41085 STEER CASTER - KEY INPUT - VOLTAGE LOW DIAGRAMS
END FAULT
9030-20-87
Steer Caster DC Bus Voltage

CODES
DTC 41086 - Steer Caster - DC Bus - Voltage Low

DTC 41087 - Steer Caster - DC Bus - Voltage High
POSSIBLE CAUSE

C. STEER CASTER CONTROLLER WIRING FAULT
D. FAULTY STEER CASTER CONTROLLER
NOTE
System YRM.
ing Step 3.
age.
9030-20-88
Steer Caster DC Bus Voltage (Cont)

CAUSE C - STEER CASTER CONTROLLER WIRING FAULT
1. Measure voltage between the steer caster controller B(+) terminal and B(-).
NO: Inspect steer caster controller B(+) cable for damage or loose connections.
CAUSE D - FAULTY STEER CASTER CONTROLLER
END POSSIBLE CAUSES
9030-20-89
Steer Caster DC Bus Voltage (Cont)

DIAGRAMS
Cause A and B Troubleshooting Scenes
END FAULT
9030-20-90
Lift Pump Motor

CODES
DTC 50060 - Pump - Motor - Circuit

DTC 50061 - Pump - Motor - Open
POSSIBLE CAUSE
A. HYDRAULIC MOTOR CABLE FAULT

B. HYDRAULIC MOTOR FAULT
C. FAULTY PUMP CONTROLLER
NOTE
System YRM.
CAUSE A - HYDRAULIC MOTOR CABLE FAULT
1. Disconnect the hydraulic motor cables from the pump controller and hydraulic motor. Measure continuity of
individual cables to isolate fault.
NO: Repair or replace faulty hydraulic motor cable.
9030-20-91
Lift Pump Motor (Cont)

CAUSE B - HYDRAULIC MOTOR FAULT
1. Measure resistance between the hydraulic motor terminals U and V.

NO: Repair or replace faulty hydraulic motor.
2. Measure resistance between the hydraulic motor terminals U and W.
3. Measure resistance between the hydraulic motor terminals W and V.
CAUSE C - FAULTY PUMP CONTROLLER
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-92
DTC 50062
Pump - Motor - Encoder
POSSIBLE CAUSE

B. ENCODER FAULT
NOTE
System YRM.
Is encoder signal responding to pump speed?
1. Disconnect the pump encoder connector CPS016 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 280-A for open or short.
2. Measure voltage between the pump encoder connector CPS016, socket 1 and socket 4.
NO: Inspect ground circuits 103-B and 103-A for open or short.
3. Disconnect the pump controller connector CPS12. Measure resistance between socket A14 of the pump con-
9030-20-93
DTC 50062 (Cont)

4. Measure resistance between socket A7 of the pump controller connector and socket 3 of the encoder connec-
tor CPS016.
YES: Connect battery and pump encoder. Proceed to Cause B.
NOTE: Operate pump while performing this test.
1. Connect Breakout Kit #580002086 to the pump controller and measure voltage between socket A14, A7 and
B(-).
Does voltage signal relate to pump motor operation?
END POSSIBLE CAUSES
9030-20-94
DTC 50062 (Cont)

DTC 50062 PUMP - MOTOR - ENCODER DIAGRAMS
END FAULT
9030-20-95
DTC 50068
Pump - Main Contactor - Not Closed
POSSIBLE CAUSE

B. MAIN CONTACTOR STUCK OPEN
C. DC BUS CONNECTION FAULT
NOTE
System YRM.
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.
1. Disconnect the main contactor coil's positive socket terminal TS013. Measure voltage between the main con-
tactor coil's positive socket terminal TS013 and B(-).
2. Disconnect traction controller connector CPS11. Measure continuity between the main contactor coil's nega-
tive socket terminal TS012 and socket A16 of the traction controller connector CPS11.
9030-20-96
DTC 50068 (Cont)

YES: Reconnect battery and all connectors. Proceed to Cause B.
NO: Inspect ground control circuit 024-A for open or short.
CAUSE B - MAIN CONTACTOR STUCK OPEN
Is voltage present?
YES: Reconnect TS049 and proceed to Cause D.
NO: Replace faulty main contactor.
CAUSE C - DC BUS CONNECTION FAULT
1. Inspect pump controller B(+) bolt and main contactor studs for proper torque.
Are studs/bolts properly torqued?
NO: Repair connection and retest system.
2. Inspect contact surface between the following locations:
• Bus bar and pump B(+)
• Bus bar and main contactor stud
• Battery connector and battery
Are contact surfaces clean and free of damage?
NO: Clean or repair faulty connections.
1. Measure voltage between pump controller B(+) and B(-) and compare measurement with CAP voltage display
(D2.50.8).
Is measurement ± 2 volts compared to CAP voltage display?
YES: Replace controller only if no faults found while performing Cause C.
END POSSIBLE CAUSES
9030-20-97
DTC 50068 (Cont)

DIAGRAMS
END FAULT
9030-20-98
DTC 50069
Pump - Capacitor - Charge
POSSIBLE CAUSE

C. PUMP CONTROLLER WIRING FAULT
D. FAULTY PUMP CONTROLLER
NOTE
System YRM.
ing Step 3.
age.
YES: Verify battery state of charge and recheck condition. If actual voltage does not agree with display, pro-
ceed to Cause D.
9030-20-99
DTC 50069 (Cont)

YES: Connect connector CPS001 and proceed to Cause C.
CAUSE C - PUMP CONTROLLER WIRING FAULT
1. Measure voltage between the pump controller B(+) terminal and B(-).
NO: Inspect pump controller B(+) bus bar and cables for damage or loose connections.
CAUSE D - FAULTY PUMP CONTROLLER
END POSSIBLE CAUSES
9030-20-100
DTC 50069 (Cont)

DTC 50069 PUMP - CAPACITOR - CHARGE DIAGRAMS
END FAULT
9030-20-101
Auxiliary Pump Motor

CODES
DTC 51060 - Auxiliary Pump - Motor - Circuit

DTC 51061 - Auxiliary Pump - Motor - Open
POSSIBLE CAUSE
A. AUXILIARY HYDRAULIC MOTOR WIRING

B. AUXILIARY HYDRAULIC MOTOR FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.51) and view motor current (D2.51.7) to verify motor operation.
CAUSE A - AUXILIARY HYDRAULIC MOTOR WIRING
1. Measure voltage between the auxiliary motor B(+) terminal and known good B(-).
NO: Repair or replace faulty auxiliary motor power cable.
2. Measure voltage between the auxiliary motor B(+) and the auxiliary motor B(-).
NO: Repair or replace faulty auxiliary motor ground cable.
9030-20-102
Auxiliary Pump Motor (Cont)

CAUSE B - AUXILIARY HYDRAULIC MOTOR FAULT
1. Disconnect auxiliary motor cables and measure continuity between the auxiliary motor B(+) terminal and the
B(-) terminal.
NO: Replace faulty auxiliary motor.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-103
DTC 51062
Auxiliary Pump - Motor - Encoder
POSSIBLE CAUSE
A. AUXILIARY MOTOR ENCODER COMMUNICATION FAULT

B. FAULTY PUMP CONTROLLER
NOTE
System YRM.
3. Locate input diagnostics (D2.51) and view target speed (D2.51.1) and actual motor speed (D2.51.2) to verify
encoder operation.
Does target motor speed agree with actual motor speed?
CAUSE A - AUXILIARY MOTOR ENCODER COMMUNICATION FAULT
1. Disconnect the auxiliary motor connector CPS047 and measure voltage between socket 1 and B(-).
NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI is shorted to ground or open. If
voltage is above 5 volts, the CAN HI circuit is shorted to power.
2. Measure voltage between the auxiliary motor connector CPS047, socket 2 and B(-).
YES: Disconnect the battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If volage is 0 volts, the CAN LO circuit is shorted to ground or
3. Measure resistance between the auxiliary motor connector CPS047, socket 1 and socket 2.
9030-20-104
DTC 51062 (Cont)

Auxiliary Pump - Motor - Encoder
YES: No communication faults are present, suspect faulty encoder.
CAUSE B - FAULTY PUMP CONTROLLER
END POSSIBLE CAUSES
DTC 51062 AUXILIARY PUMP - MOTOR - ENCODER DIAGRAMS
END FAULT
9030-20-105
Auxiliary Pump DC Bus Voltage

CODES
DTC 51086 - Auxiliary Pump - DC Bus - Voltage Low

DTC 51087 - Auxiliary Pump - DC Bus - Voltage High
POSSIBLE CAUSE

C. AUXILIARY PUMP WIRING FAULT
D. FAULTY PUMP CONTROLLER
NOTE
System YRM.
ing Step 3.
age.
9030-20-106
Auxiliary Pump DC Bus Voltage (Cont)

CAUSE C - AUXILIARY PUMP WIRING FAULT
1. Measure voltage between the auxiliary motor B(+) terminal and B(-).
NO: Inspect auxiliary motor B(+) cable for damage or loose connections.
CAUSE D - FAULTY PUMP CONTROLLER
END POSSIBLE CAUSES
9030-20-107
Auxiliary Pump DC Bus Voltage (Cont)

DIAGRAMS
END FAULT
9030-20-108
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
POSSIBLE CAUSE
A. HANDLE WIRING FAULT

B. HANDLE COMMUNICATION FAULT
C. FAULTY HANDLE
NOTE
System YRM.
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 handle inputs:
• Traction (D2.60.19).
• Lift/Lower (D2.60.20).
• Side-shift and extend/retract (D2.60.21).
• Tilt (D2.60.23).
Does value follow handle input?
CAUSE A - HANDLE WIRING FAULT
9030-20-109
Handle (Cont)
1. Disconnect the appropriate handle connector CPS023/CPS023A. Measure voltage between the side-stance
handle connector CPS023, socket 6 and B(-) or measure voltage between the fore-aft handle connector
CPS023A, socket 1 and B(-).
Is voltage approximately 24 ± 2.5 Vdc / 36 ± 3.5 Vdc?
NO: Inspect circuit 201-B or 201-C for open or short.
2. Measure voltage between the side-stance handle connector CPS023, socket 6 and socket 2 or measure volt-
age between the fore-aft handle connector CPS023A, socket 1 and socket 4.
Is voltage approximately 24 ± 2.5 Vdc / 36 ± 3.5 Vdc?
NO: Inspect ground circuit 113-J or 113-T for open or short.
CAUSE B - HANDLE COMMUNICATION FAULT
and B(-).
and B(-).
3. Measure resistance between the handle connector CPS023/CPS023A, socket 4 and socket 5 (side-stance)
OR socket 2 and socket 3 (fore/aft).
YES: No communication faults are present, proceed to Cause C.
CAUSE C - FAULTY HANDLE
1. If no faults are found, replace handle.
END POSSIBLE CAUSES
9030-20-110
Handle (Cont)
DIAGRAMS
Side-Stance Handle Troubleshooting Scenes
Fore/Aft Handle Troubleshooting Scenes
END FAULT
9030-20-111
Impact Module
CODES
DTC 80065 - Impact Module - Soft Impact

DTC 80066 - Impact Module - Hard Impact
POSSIBLE CAUSE
A. IMPACT MODULE COMMUNICATION FAULT

B. FAULTY IMPACT MODULE
NOTE
System YRM.
3. Locate input diagnostics (D2.80) and verify if impact has been recorded (D2.80.1, D2.80.2).
Has the vehicle recorded an impact when impact has not occurred?
YES: Proceed only to Cause A if impact has not occured or been reported and status code is still present.
NO: See Owner's Manual for further information regarding impact parameters.
CAUSE A - IMPACT MODULE COMMUNICATION FAULT
1. Disconnect impact module connector CPS148 and measure voltage between socket 1 and B(-).
2. Measure voltage between the impact module connector CPS148, socket 2 and socket 3.
NO: Inspect ground circuit 113-C for open or short.
9030-20-112
Impact Module (Cont)

5. Measure resistance between the impact module connector CPS148, socket 2 and socket 4.
YES: No communication faults are present, proceed to Cause B.
CAUSE B - FAULTY IMPACT MODULE
1. If no faults are found, replace module. Make sure to indicate the DTC code(s) on the warranty claim to include
an accurate problem description leading to controller replacement.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-113
CAN I/O Lift Coil

CODES
DTC 90001 - CAN I/O - Lift Coil - Circuit

DTC 90002 - CAN I/O - Lift Coil - Short
POSSIBLE CAUSE
A. LIFT COIL WIRING FAULT

B. LIFT COIL FAULT
C. FAULTY CAN I/O CONTROLLER
NOTE
System YRM.
3. Locate status menu (D1) and verify that lift coil is enabled (D1.6).
Is lift enabled?
NO: Check that all interlocks have been met.
NOTE: Operate lift.
4. Locate input diagnostics (D2.90) and verify lift coil input is operating correctly (D2.90.52).
Does lift coil receive input?
5. Locate output diagnostics (D3.90) and actuate lift coil (D3.90.13).
Does coil energize when actuated?
CAUSE A - LIFT COIL WIRING FAULT
9030-20-114
CAN I/O Lift Coil (Cont)

1. Disconnect the hold/lift connector CPS052 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 206-S for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect the CAN I/O connector CPS031 and the hold/lift coil connector CPS052. Measure resistance be-
tween the CAN I/O connector CPS031, socket A34 and the hold/lift coil connector CPS052, socket 2.
NO: Inspect ground control circuit 811 for open or short.
CAUSE B - LIFT COIL FAULT
1. Measure resistance between the hold/lift coil positive and negative terminals.
NO: Replace faulty lift coil.
CAUSE C - FAULTY CAN I/O CONTROLLER
END POSSIBLE CAUSES
9030-20-115
CAN I/O Lift Coil (Cont)

DIAGRAMS
END FAULT
9030-20-116
CAN I/O Lower Coil

CODES
DTC 90003 - CAN I/O - Lower Coil - Circuit

DTC 90004 - CAN I/O - Lower Coil - Short
POSSIBLE CAUSE
A. LOWER COIL WIRING FAULT

B. LOWER COIL FAULT
NOTE
System YRM.
3. Locate status menu (D1) and verify that lower coil is enabled (D1.7).
Is lower enabled?
NO: Check that all interlocks have been met.
NOTE: Operate lower coil.
4. Locate input diagnostics (D2.90) and verify lower coil input is operating correctly (D2.90.42).
Does lower coil receive input?
5. Locate output diagnostics (D3.90) and actuate lower coil (D3.90.9).
CAUSE A - LOWER COIL WIRING FAULT
9030-20-117
CAN I/O Lower Coil (Cont)

1. Disconnect the lower coil connector CPS141 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 206-AB for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect the CAN I/O connector CPS031 and the lower coil connector CPS141. Measure resistance be-
tween the CAN I/O connector CPS031, socket A35 and the lower coil connector CPS141, socket 2.
CAUSE B - LOWER COIL FAULT
1. Measure resistance between the lower coil's positive and negative terminals.
NO: Replace faulty lower coil.
END POSSIBLE CAUSES
9030-20-118
CAN I/O Lower Coil (Cont)

DIAGRAMS
END FAULT
9030-20-119
CAN I/O Load Hold Coil

CODES
DTC 90005 - CAN I/O - Load Hold - Circuit

DTC 90006 - CAN I/O - Load Hold - Short
POSSIBLE CAUSE
A. LOAD HOLD COIL WIRING FAULT

B. LOAD HOLD COIL FAULT
NOTE
System YRM.
NOTE: Operate load hold coil.
3. Locate input diagnostics (D2.90) and verify load hold coil input is operating correctly (D2.90.52).
Does load hold coil receive input?
4. Locate output diagnostics (D3.90) and actuate load hold coil (D3.90.12).
CAUSE A - LOAD HOLD COIL WIRING FAULT
1. Disconnect load hold coil connector CPS052 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 206-S for open or short. Inspect for loose or damaged coil terminals.
9030-20-120
CAN I/O Load Hold Coil (Cont)

2. Disconnect the CAN I/O connector CPS031 and the load hold/lift coil connector CPS052. Measure resistance
between the CAN I/O connector CPS031, socket A34 and the load hold/lift coil connector CPS052, socket 2.
CAUSE B - LOAD HOLD COIL FAULT
1. Measure resistance between the load hold coil's positive and negative terminals.
NO: Replace faulty load hold coil.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-121
CAN I/O Auxiliary Forward Coil

CODES
DTC 90007 - CAN I/O - Auxiliary Forward Coil - Circuit

DTC 90008 - CAN I/O - Auxiliary Forward Coil - Short
POSSIBLE CAUSE
A. AUXILIARY FORWARD COIL WIRING FAULT

B. AUXILIARY FORWARD COIL FAULT
C. FAULTY CAN I/O
NOTE
System YRM.
3. Locate input diagnostics (D2.90) and verify auxiliary forward coil input is connected (D2.90.40).
Is the auxiliary forward coil circuit connected?
4. Locate output diagnostics (D3.90) and actuate auxiliary forward coil (D3.90.4).
CAUSE A - AUXILIARY FORWARD COIL WIRING FAULT
1. Disconnect auxiliary forward coil connector CPS138 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 206-AA for open or short. Inspect for loose or damaged coil terminals.
9030-20-122
CAN I/O Auxiliary Forward Coil (Cont)

2. Disconnect the CAN I/O connector CPS031 and the auxiliary forward coil connector CPS138. Measure resist-
ance between the CAN I/O connector CPS031, socket A28 and the auxiliary forward coil connector CPS138.
socket 2.
CAUSE B - AUXILIARY FORWARD COIL FAULT
1. Measure resistance between the auxiliary forward coil's positive and negative terminals.
CAUSE C - FAULTY CAN I/O
END POSSIBLE CAUSES
9030-20-123
CAN I/O Auxiliary Forward Coil (Cont)

DIAGRAMS
CAN I/O Troubleshooting Scenes
END FAULT
9030-20-124
CAN I/O Auxiliary Reverse Coil

CODES
DTC 90009 - CAN I/O - Auxiliary Reverse Coil - Circuit

DTC 90010 - CAN I/O - Auxiliary Reverse Coil - Short
POSSIBLE CAUSE
A. AUXILIARY REVERSE COIL WIRING FAULT

B. AUXILIARY REVERSE COIL FAULT
C. FAULTY CAN I/O
NOTE
System YRM.
3. Locate input diagnostics (D2.90) and verify auxiliary reverse coil input is connected (D2.90.38).
Is the auxiliary reverse coil connected?
4. Locate output diagnostics (D3.90) and actuate auxiliary reverse coil (D3.90.3).
CAUSE A - AUXILIARY REVERSE COIL WIRING FAULT
1. Disconnect auxiliary reverse coil connector CPS139 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 206-AC for open or short. Inspect for loose or damaged coil terminals.
9030-20-125
CAN I/O Auxiliary Reverse Coil (Cont)

2. Disconnect the CAN I/O connector CPS031 and the auxiliary reverse coil connector CPS139. Measure resist-
ance between the CAN I/O connector CPS031, socket A29 and the auxiliary reverse coil connector CPS139,
socket 2.
CAUSE B - AUXILIARY REVERSE COIL FAULT
1. Measure resistance between the auxiliary reverse coil's positive and negative terminals.
NO: Replace faulty auxiliary reverse coil.
END POSSIBLE CAUSES
9030-20-126
CAN I/O Auxiliary Reverse Coil (Cont)

DIAGRAMS
END FAULT
9030-20-127
CAN I/O Tilt Coil

CODES
DTC 90011 - CAN I/O - Tilt Coil - Circuit

DTC 90012 - CAN I/O - Tilt Coil - Short
POSSIBLE CAUSE
A. TILT COIL WIRING FAULT

B. TILT COIL FAULT
C. FAULTY CAN I/O
NOTE
System YRM.
3. Locate input diagnostics (D2.90) and verify tilt coil input is connected (D2.90.46).
Is the tilt coil circuit connected?
4. Locate output diagnostics (D3.90) and actuate tilt coil (D3.90.11).
CAUSE A - TILT COIL WIRING FAULT
1. Disconnect the tilt coil connector CPS68 and measure voltage between socket 1 and B(-).
NO: Inspect power supply circuit 151MG for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect the CAN I/O connector CPS031 and the tilt coil connector CPS68. Measure resistance between
the CAN I/O connector CPS031, socket A2 and the tilt coil connector CPS68, socket 2.
9030-20-128
CAN I/O Tilt Coil (Cont)

CAUSE B - TILT COIL FAULT
1. Measure resistance between the tilt coil's positive and negative terminals.
NO: Replace faulty tilt coil.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-129
CAN I/O Side-Shift Coil

CODES
DTC 90017 - CAN I/O - Side-Shift Coil - Circuit

DTC 90018 - CAN I/O - Side-Shift Coil - Short
POSSIBLE CAUSE
A. SIDE-SHIFT COIL WIRING FAULT

B. SIDE SHIFT COIL FAULT
C. FAULTY CAN I/O
NOTE
System YRM.
3. Locate input diagnostics (D2.90) and verify side-shift coil input is connected (D2.90.36).
Is the side-shift coil circuit connected?
4. Locate output diagnostics (D3.90) and actuate side-shift coil (D3.90.2).
CAUSE A - SIDE-SHIFT COIL WIRING FAULT
1. Disconnect side-shift coil connector CPS67 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 285-MH for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect the CAN I/O connector CPS031 and the side-shift coil connector CPS67. Measure resistance be-
tween the CAN I/O connector CPS031, socket A4 and the side-shift coil connector CPS67, socket 2.
9030-20-130
CAN I/O Side-Shift Coil (Cont)

CAUSE B - SIDE SHIFT COIL FAULT
1. Measure resistance between the side-shift coil positive and negative terminals.
NO: Replace faulty side-shift coil.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-131
CAN I/O Extend/Retract Coil

CODES
DTC 90023 - CAN I/O - Extend/Retract Coil - Circuit

DTC 90024 - CANI/O - Extend/Retract Coil - Short
POSSIBLE CAUSE
A. EXTEND/RETRACT COIL CIRCUIT FAULT

B. EXTEND/RETRACT COIL FAULT
C. FAULTY CAN I/O
NOTE
System YRM.
3. Locate input diagnostics (D2.90) and verify extend/retract coil input is connected (D2.90.34).
Is the extend/retract coil circuit connected?
4. Locate output diagnostics (D3.90) and actuate extend/retract coil (D3.90.1).
CAUSE A - EXTEND/RETRACT COIL CIRCUIT FAULT
1. Disconnect extend/retract coil connector CPS69 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 285MB for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect the CAN I/O connector CPS031 and the extend/retract coil connector CPS69. Measure resistance
between the CAN I/O connector CPS031, socket A24 and the extend/retract coil connector CPS69, socket 2.
9030-20-132
CAN I/O Extend/Retract Coil (Cont)

CAUSE B - EXTEND/RETRACT COIL FAULT
1. Measure resistance between the extend/retract coil positive and negative terminals.
YES: Suspect faulty CAN I/O controller or Remote CAN module.
NO: Replace faulty extend/retract coil.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-133
CAN I/O Audible Alarm

CODES
DTC 90037 - CAN I/O - Audible Alarm - Circuit

DTC 90038 - CAN I/O - Audible Alarm - Short
POSSIBLE CAUSE
A. BACKUP ALARM WIRING FAULT

B. BACKUP ALARM FAULT
NOTE
System YRM.
NOTE: Operate audible alarm.
3. Locate input diagnostics (D2.90) and verify that audible alarm input is operating correctly (D2.90.44).
Does alarm receive backup input?
4. Locate output diagnostics (D3.90) and actuate audible alarm (D3.90.10).
Does alarm sound when actuated?
CAUSE A - BACKUP ALARM WIRING FAULT
1. Disconnect backup alarm connector CPS042 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 206-D for open or short.
9030-20-134
CAN I/O Audible Alarm (Cont)

2. Disconnect the CAN I/O connector CPS031. Measure resistance between the CAN I/O connector CPS031,
socket A33 and the backup alarm connector CPS042, socket 2.
YES: Connect CAN I/O connector CPS031 and proceed to Cause B.
CAUSE B - BACKUP ALARM FAULT
NOTE: Operate backup alarm.
1. Measure continuity between the backup alarm connector CPS042, socket 2 and B(-).
YES: Replace faulty backup alarm.
NO: Proceed to Cause C.
END POSSIBLE CAUSES
9030-20-135
CAN I/O Audible Alarm (Cont)

DIAGRAMS
END FAULT
9030-20-136
CAN I/O Visible Alarm

CODES
DTC 90039 - CAN I/O - Visible Alarm - Circuit

DTC 90040 - CAN I/O - Visible Alarm - Short
POSSIBLE CAUSE
A. STROBE WIRING FAULT

B. STROBE LIGHT FAULT
C. STROBE RELAY FAULT
D. FAULTY CAN I/O CONTROLLER
NOTE
System YRM.
NOTE: Operate strobe.
3. Locate input diagnostics (D2.90) and verify that strobe input is operating correctly (D2.90.54).
Does strobe receive input?
4. Locate output diagnostics (D3.90) and actuate strobe (D3.90.6).
Does strobe illuminate when actuated?
CAUSE A - STROBE WIRING FAULT
1. Disconnect strobe light connector TBF10 and measure voltage between socket TBF10 and B(-).
NO: Inspect circuit A206-LA for open or short.
9030-20-137
CAN I/O Visible Alarm (Cont)

NOTE: Actuate strobe light.
2. Disconnect strobe light connector TBF11. Measure voltage between the strobe light connector sockets TBF10
and TBF11.
NO: Inspect circuit A13-LC for open or short. If no circuit faults are found, proceed to Cause C.
CAUSE B - STROBE LIGHT FAULT
1. Replace strobe light.
CAUSE C - STROBE RELAY FAULT
1. Remove strobe light relay CPS049 and measure voltage between socket 86 and B(-).
NO: Inspect relay coil power circuit 285-C for open or short.
2. Measure voltage between the strobe light relay CPS049, socket 86 and socket 30.
NO: Inspect relay ground circuit 013-R for open or short.
3. Place jumper wire between the strobe light connector CPS049, socket 30 and socket 87.
Does strobe light operate?
YES: Replace faulty strobe light relay.
NO: Proceed to Cause D.
CAUSE D - FAULTY CAN I/O CONTROLLER
END POSSIBLE CAUSES
9030-20-138
CAN I/O Visible Alarm (Cont)

DIAGRAMS
END FAULT
9030-20-139
DTC 90043
CAN I/O - TFD Coil - Circuit
POSSIBLE CAUSE
A. TFD COIL WIRING FAULT

B. TFD COIL FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.90) and verify TFD coil is connected (D2.90.32).
Is TFD coil connected?
4. Locate output diagnostics (D3.90) and actuate TFD coil (D3.90.5).
CAUSE A - TFD COIL WIRING FAULT
1. Disconnect battery, discharge CAP bank, disconnect CAN I/O connector CPS031 and measure resistance
between pin 31 and pin 27.
Is resistance ≤ 30 ohms?
2. Measure continuity between the following:
• CPS031, pin 31 and CPS045, pin 5
• CPS031, pin 27, and CPS045, pin 6
• CPS001, pin 1, and COS045, pin 5
9030-20-140
DTC 90043 (Cont)

YES: Connect battery and proceed to Step 3.
NO: Inspect applicable circuits for open, short, or source of excessive resistance.
3. Measure voltage between CPS045, pin 5 and battery (-).

Is voltage same as battery voltage?
YES: Disconnect battery and proceed to Cause B.
NO: Fault may be intermittent, clear 90043 code and troubleshoot existing codes.
CAUSE B - TFD COIL FAULT
1. Disconnect CPS045 and measure resistance between sensor side pins 5 and 6.
NO: Replace faulty lower coil.
1. Disconnect battery, discharge CAP bank, disconnect CAN I/O connector CPS031 and measure resistance
between the following locations:
• Pin 12 and pin 27
• Pin 13 and pin 27
Is resistance ≥ 30 ohms?
NO: Replace CAN I/O controller.
END POSSIBLE CAUSES
9030-20-141
DTC 90043 (Cont)

DIAGRAMS
END FAULT
9030-20-142
DTC 90053
CAN I/O - Pressure - Sensor Fault
POSSIBLE CAUSE
A. PRESSURE SENSOR WIRING FAULT

B. PRESSURE SENSOR FAULT
NOTE
System YRM.
NOTE: When the forks are placed on the ground, sensor voltage should be 2.5 volts. Operating lift with load will
increase sensor voltage.
3. Locate input diagnostics (D2.90) and view pressure sensor voltage (D2.90.25).
Does voltage follow lift operation?
CAUSE A - PRESSURE SENSOR WIRING FAULT
1. Disconnect the pressure sensor connector CPS034 and measure voltage between socket 3 and B(-).
NO: Inspect circuit 251 for open or short.
2. Measure voltage between the pressure sensor connector CPS034, socket 1 and socket 3.
9030-20-143
DTC 90053 (Cont)

3. Disconnect the CAN I/O controller connector CPS031. Measure resistance between the CAN I/O controller
connector CPS031, socket A7 and the pressure sensor connector CPS034, socket 2.
NO: Inspect signal circuit 062 for open, short, or source of excessive resistance.
CAUSE B - PRESSURE SENSOR FAULT
NOTE: Reconnect battery and operate lift.
1. Connect Breakout Kit #580002086 to the CAN I/O controller connector CPS031 and measure voltage be-
tween socket A7 and B(-).
Does voltage relate to lift pressure?
NO: Replace faulty pressure sensor.
END POSSIBLE CAUSES
9030-20-144
DTC 90053 (Cont)

DTC 90053 CAN I/O - PRESSURE - SENSOR FAULT DIAGRAMS
END FAULT
9030-20-145
DTC 90075
CAN I/O - Steer - Security Line
POSSIBLE CAUSE
A. STEERING FAULT
B. STEER CALIBRATION REQUIRED
C. STEER CONTROLLER WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.90) and verify steer status (D2.90.23).
Is the steer ON?
4. Locate output diagnostics (D3.40) and verify status line operation (D3.40.6).
Is the status line ON?
YES: Suspect short to frame. Inspect frame grounds using approved meter or test light. Repair any shorts to
the truck frame or battery leakage to frame.
CAUSE A - STEERING FAULT
1. Verify if any steering fault codes (Node 40) have been set.
Using the Error Log E1-E16 or PC Service Tool, verify if any steering fault codes are present at this
time?
YES: Proceed to appropriate steering fault troubleshooting procedures prior to diagnosing 90075.
NO: Proceed to Cause B
9030-20-146
DTC 90075 (Cont)

CAUSE B - STEER CALIBRATION REQUIRED
1. Calibrate the Steer Wheel (C1). For complete calibration procedures, refer to the User Interface Service
Technician 2200YRM1614 manual.
Was Steer Wheel calibration successful?
YES: Clear status code and retest operation.
CAUSE C - STEER CONTROLLER WIRING FAULT
1. Disconnect the steer controller and CAN I/O controller. Measure resistance between the steer controller con-
nector CPS059, socket A9 and the CAN I/O connector CPS031, socket A14.
Is resistance ≤1 ohm?
YES: Proceed to NOTE.
NO: Inspect circuit 600 (white) for open, short, or source of excessive resistance.
2. Measure voltage between the steer controller B(+) terminal and B(-).
END POSSIBLE CAUSES
9030-20-147
DTC 90075 (Cont)

DTC 90075 CAN I/O - STEER - SECURITY LINE DIAGRAMS
END FAULT
9030-20-148
DTC 90076
CAN I/O - Steer Caster - Security Line
POSSIBLE CAUSE
A. STEER CASTER FAULT

B. STEER CASTER CALIBRATION REQUIRED
C. STEER CASTER CONTROLLER WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.90) and verify caster steer status (D2.90.24).
Is the caster steer ON?
CAUSE A - STEER CASTER FAULT
1. Verify if any steer caster fault codes (Node 41) have been set.
Using the Error Log E1-E16 or PC service tool, determine if any steer caster fault codes are present at
this time?
YES: Proceed to appropriate steering fault troubleshooting procedures prior to diagnosing 90076.
NO: Proceed to Cause B
9030-20-149
DTC 90076 (Cont)

CAUSE B - STEER CASTER CALIBRATION REQUIRED
1. Calibrate the Caster Wheel (C26). For complete calibration procedures, refer to the User Interface Service
Technician 2200YRM1614 manual.
Was Caster Wheel calibration successful?
YES: Clear status code and retest operation.
CAUSE C - STEER CASTER CONTROLLER WIRING FAULT
1. Disconnect the steer controller and CAN I/O controller. Measure resistance between the steer caster control-
ler connector CPS082, socket A9 and the CAN I/O connector CPS031, socket A15.
Is resistance ≤1 ohm?
NO: Inspect circuit 601 (white) for open, short, or source of excessive resistance.
2. Measure voltage between the caster controller B(+) terminal and B(-).
END POSSIBLE CAUSES
9030-20-150
DTC 90076 (Cont)

DTC 90076 CAN I/O - STEER CASTER - SECURITY LINE DIAGRAMS
END FAULT
9030-20-151
DTC 90085
CAN I/O - Key input - Voltage Low
POSSIBLE CAUSE

B. KEY INPUT WIRING FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.30) and view key input voltages (D2.90.11, D2.90.13) to verify actual key voltage
and minimum captured key voltage.
CAUSE B - KEY INPUT WIRING FAULT
1. Disconnect the CAN I/O controller connector CPS031 and measure voltage between socket A11 and B(-).
9030-20-152
DTC 90085 (Cont)

NO: Inspect circuit 206-H for open, short, or source of excessive resistance.
END POSSIBLE CAUSES
9030-20-153
DTC 90085 (Cont)

DTC 90085 CAN I/O - KEY INPUT - VOLTAGE LOW DIAGRAMS
END FAULT
9030-20-154
CODES
DTC 90253 - CAN I/O - Lost - Wire

DTC 40253 - Steer - Lost - Wire
POSSIBLE CAUSE
A. STEER STATUS WIRING FAULT

B. FAULTY CAN I/O CONTROLLER
NOTE
System YRM.
3. Locate input diagnostics (D2.90) and view steer status (D2.90.23).
Is steer status input received by CAN I/O controller?
YES: Suspect short to frame. Inspect frame grounds using approved meter or test light. Repair any shorts to
the truck frame or battery leakage to frame.
NO: Disconnect battery and proceed to Cause A.
CAUSE A - STEER STATUS WIRING FAULT
1. Disconnect the CAN I/O controller connector CPS031 and the steer motor controller connector CPS059.
Measure continuity between the CAN I/O controller, socket A14 and the steer controller CPS059, socket A9.
NO: Inspect circuit 600 for open, short, or source of excessive resistance.
9030-20-155
(Cont)
CAUSE B - FAULTY CAN I/O CONTROLLER
END POSSIBLE CAUSES
DTC 90253 CAN I/O - LOST - WIRE DIAGRAMS
END FAULT
9030-20-156
Remote Module Auxiliary Forward Coil

CODES
DTC 91007 - Remote Module - Auxiliary Forward Coil - Circuit

DTC 91008 - Remote Module - Auxiliary Forward Coil - Short
POSSIBLE CAUSE
A. AUXILIARY FORWARD COIL WIRING FAULT

B. AUXILIARY FORWARD COIL FAULT
C. FAULTY REMOTE MODULE
NOTE
System YRM.
3. Locate input diagnostics (D2.91) and verify auxiliary forward coil input is connected (D2.91.7).
Is the auxiliary forward coil circuit connected?
4. Locate output diagnostics (D3.91) and actuate auxiliary forward coil (D3.91.4).
CAUSE A - AUXILIARY FORWARD COIL WIRING FAULT
1. Disconnect auxiliary forward coil connector CPS78 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 285MD for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect the remote module connector CPS85 and measure resistance between socket 9 and the auxiliary
forward coil connector CPS78, socket 2.
9030-20-157
Remote Module Auxiliary Forward Coil (Cont)

NO: Inspect mast cable and circuit 11B/Orange for damage.
CAUSE B - AUXILIARY FORWARD COIL FAULT
1. Measure resistance between the auxiliary forward coil's positive and negative terminals.
CAUSE C - FAULTY REMOTE MODULE
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-158
Remote Module Auxiliary Reverse Coil

CODES
DTC 91009 - Remote Module - Auxiliary Reverse Coil - Circuit

DTC 91010 - Remote Module - Auxiliary Reverse Coil - Short
POSSIBLE CAUSE
A. AUXILIARY REVERSE COIL WIRING FAULT

B. AUXILIARY REVERSE COIL FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.91) and verify auxiliary reverse coil input is connected (D2.91.8).
Is auxiliary reverse coil circuit connected?
4. Locate output diagnostics (D3.91) and actuate auxiliary reverse coil (D3.91.3).
CAUSE A - AUXILIARY REVERSE COIL WIRING FAULT
1. Disconnect auxiliary reverse coil connector CPS71 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 285MC for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect remote CAN module connector CPS85 and measure resistance between socket 3 and the auxili-
ary reverse coil connector CPS71, socket 2.
9030-20-159
Remote Module Auxiliary Reverse Coil (Cont)

NO: Inspect mast cable and circuit 11B/Violet for damage.
CAUSE B - AUXILIARY REVERSE COIL FAULT
1. Measure resistance between the auxiliary reverse coil's positive and negative terminals.
NO: Replace faulty auxiliary reverse coil.
END POSSIBLE CAUSES
DIAGRAMS
Remote Module Troubleshooting Scenes
END FAULT
9030-20-160
Remote Module Tilt Coil

CODES
DTC 91011 - Remote Module - Tilt Coil - Circuit

DTC 91012 - Remote Module - Tilt Coil - Short
POSSIBLE CAUSE
A. TILT COIL WIRING FAULT

B. TILT COIL FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.91) and verify tilt coil input is connected (D2.91.4).
Is the tilt coil input circuit connected?
4. Locate output diagnostics (D3.91) and actuate tilt coil (D3.91.11).
CAUSE A - TILT COIL WIRING FAULT
1. Disconnect the tilt coil connector CPS68 and measure voltage between socket 1 and B(-).
NO: Inspect power supply circuit 285MG for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect the remote module connector CPS85 and measure resistance between socket 4 and the tilt coil
connector CPS68, socket 2.
9030-20-161
Remote Module Tilt Coil (Cont)

NO: Inspect mast cable and circuit 10B/Black for damage.
CAUSE B - TILT COIL FAULT
1. Measure resistance between the tilt coil's positive and negative terminals.
NO: Replace faulty tilt coil.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-162
Remote Module Side-Shift Coil

CODES
DTC 91017 - Remote Module - Side-Shift Coil - Circuit

DTC 91018 - Remote Module - Side-Shift Coil - Short
POSSIBLE CAUSE
A. SIDE-SHIFT COIL WIRING FAULT

B. SIDE SHIFT COIL FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.91) and verify side-shift coil input is connected (D2.91.5).
Is the side shift coil circuit connected?
4. Locate output diagnostics (D3.91) and actuate side-shift coil (D3.91.2).
CAUSE A - SIDE-SHIFT COIL WIRING FAULT
1. Disconnect side-shift coil connector CPS67 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 285MH for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect the remote CAN module connector CPS85 and measure resistance between socket 7 and the
side-shift coil connector CPS67, socket 2.
9030-20-163
Remote Module Side-Shift Coil (Cont)

NO: Inspect ground control circuit 152MH for open or short.
CAUSE B - SIDE SHIFT COIL FAULT
1. Measure resistance between the side-shift coil positive and negative terminals.
NO: Replace faulty side-shift coil.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-164
Remote Module Extend/Retract Coil

CODES
DTC 91023 - Remote Module - Extend/Retract Coil - Circuit

DTC 91024 - Remote Module - Extend/Retract Coil - Short
POSSIBLE CAUSE
A. EXTEND/RETRACT COIL CIRCUIT FAULT

B. EXTEND/RETRACT COIL FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.91) and verify extend/retract coil input connected (D2.91.6).
Is the extend/retract coil circuit connected?
4. Locate output diagnostics (D3.91) and actuate extend/retract coil (D3.91.1).
CAUSE A - EXTEND/RETRACT COIL CIRCUIT FAULT
1. Disconnect extend/retract coil connector CPS69 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 285MB for open or short. Inspect for loose or damaged coil terminals.
2. Disconnect the remote CAN module connector CPS85 and measure resistance between socket 8 and the ex-
tend/retract coil connector CPS69, socket 2.
9030-20-165
Remote Module Extend/Retract Coil (Cont)

NO: Inspect mast cable and circuit 11B/Orange for damage.
CAUSE B - EXTEND/RETRACT COIL FAULT
1. Measure resistance between the extend/retract coil positive and negative terminals.
YES: Suspect faulty CAN I/O controller or Remote CAN module.
NO: Replace faulty extend/retract coil.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
9030-20-166
DTC 91049
Remote Module - Tilt - Sensor fault
POSSIBLE CAUSE
A. TILT SENSOR WIRING FAULT

B. TILT SENSOR FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.91) and verify that tilt sensor is ON (D2.91.3).
Is the tilt sensor operational?
CAUSE A - TILT SENSOR WIRING FAULT
1. Disconnect the tilt sensor connector CRP75 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 5 volt supply circuit for open or short.
2. Measure voltage between the tilt sensor connector CRP75, socket 3 and socket 1.
NO: Inspect ground circuit for open, short, or source of excessive resistance.
3. Disconnect the option module connector CRP84. Measure resistance between socket C2 and the tilt sensor
connector CRP75, socket 2.
NO: Inspect signal circuit for open, short, or source of excessive resistance.
9030-20-167
DTC 91049 (Cont)

CAUSE B - TILT SENSOR FAULT
NOTE: Connect battery, turn key to ON position, and operate tilt functions.
1. Connect Breakout Kit #580002086 to the remote CAN module connector CPS85 and measure voltage be-
tween socket 12 and B(-).
Does voltage signal follow fork position?
NO: Inspect circuit 302-A between option module and remote CAN module for open or short. If no faults are
found, replace tilt sensor.
1. If no faults are found, replace module Make sure to indicate the DTC code(s) on the warranty claim to include
END POSSIBLE CAUSES
9030-20-168
DTC 91049 (Cont)

DTC 91049 REMOTE MODULE - TILT - SENSOR FAULT DIAGRAMS
END FAULT
9030-20-169
DTC 91051
Remote Module - Extend and Retract - Sensor Fault
POSSIBLE CAUSE
A. REACH POSITION SENSOR WIRING FAULT

B. REACH POSITION SENSOR FAULT
NOTE
System YRM.
3. Locate input diagnostics (D2.91) and verify that reach sensor is ON (D2.91.2).
Is the reach sensor operational?
CAUSE A - REACH POSITION SENSOR WIRING FAULT
1. Disconnect the reach sensor connector CPS73 and measure voltage between socket 3 and B(-).
NO: Inspect circuit 285ME for open or short.
2. Measure continuity between the reach sensor connector CPS73, socket 1 and B(-).
NO: Inspect ground circuit CBL-11B/Blue for open, short, or source of excessive resistance.
3. Disconnect the remote CAN module connector CPS85. Measure resistance between socket 11 of the remote
CAN module and socket 2 of the reach position sensor connector CPS73.
9030-20-170
DTC 91051 (Cont)

YES: Reconnect the reach position sensor CPS73 and proceed to Cause B.
NO: Inspect signal circuit CBL-11B/Red for open, short, or source of excessive resistance.
CAUSE B - REACH POSITION SENSOR FAULT
NOTE: Connect battery, turn key to ON position, and operate extend/retract functions.
1. Connect Breakout Kit #580002086 to the remote CAN module connector CPS85 and measure voltage be-
tween socket A11 and B(-).
Does voltage signal follow fork position?
NO: Replace faulty position sensor.
1. If no faults are found, replace module Make sure to indicate the DTC code(s) on the warranty claim to include
END POSSIBLE CAUSES
9030-20-171
DTC 91051 (Cont)

DTC 91051 REMOTE MODULE - EXTEND AND RETRACT - SENSOR FAULT DIAGRAMS
END FAULT
9030-20-172
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
9000 YRM 1622 1/15 (11/14)(1/14)(9/13)(8/13)

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Maintenance

PART NO. 550073171 9000 YRM 1622

SECTION 9030 - ELECTRICAL SYSTEM

This section is for the following models:

(NDR035EB, NR045EB) [D861];

©2015 Yale Materials Handling Corp. i

How To Use This Troubleshooting Manual

For a listing of all Diagnostic Trouble Codes and de-

Group 03 - General Maintenance and Diagnostic Data

General Maintenance and Diagnostic Data

GENERAL TROUBLESHOOTING nents located on the reach attachment may be

DISCHARGING THE CAPACITORS

Before performing any tests or adjustments, block

The capacitors in the transistor controllers can

DO NOT short across the motor controller termi-

Make certain the Emergency Disconnect Switch

Figure 9030-03-1. Discharging the Internal

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 Codes and Descriptions

Table 9030-03-1. Status Code Structure

LINE NUMBER LINE DESCRIPTION

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 40 Status Codes

NODE STATUS DESCRIPTION

Table 9030-03-5. Node 41 Status Codes (Optional)

NODE STATUS DESCRIPTION

Table 9030-03-6. Node 50 Status Codes

NODE STATUS DESCRIPTION

Table 9030-03-7. Node 51 Status Codes (Americas Only)

NODE STATUS DESCRIPTION

Table 9030-03-8. Node 60 Status Codes

NODE STATUS DESCRIPTION

Table 9030-03-9. Node 80 Status Codes (Optional)

NODE STATUS DESCRIPTION

Table 9030-03-10. Node 90 Status Codes

NODE STATUS DESCRIPTION

Table 9030-03-11. Node 91 Status Codes (Americas Only)

NODE STATUS DESCRIPTION

Warning Codes electrical diagnosis. The following table of warning co-

Table 9030-03-12. Warning Codes

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