Codigos H35ZDR D264

CONTROLLER
DIAGNOSTICS
N35ZDR2, N45ZR2 [D264];N30ZDR2,
N35-40ZR2 [E470];N30ZDRS2, N35-40ZRS2 [B265]
This manual contains information that is confidential and/or proprietary to Hyster

Company, its subsidiaries and/or vendors. Copying or distribution of any sections
of this manual marked "Confidential/Proprietary" is prohibited.
PART NO. 4075036 9000 SRM 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 Hyster® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions
contained in the Service Manual could result in damage to the products, personal injury, property damage
or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove 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:
(N35ZDR2, N45ZR2) [D264];

(N30ZDR2, N35-40ZR2) [E470];
(N30ZDRS2, N35-40ZRS2) [B265]
©2019 HYSTER COMPANY i

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

GENERAL INSTRUCTIONS AND SAFETY GENERAL INSTRUCTIONS
INFORMATION
1 Become familiar with the content, layout, and
access provisions of data in this manual. This
WARNING will improve your efficiency and decrease the
DO NOT add to or modify the lift truck. Any modifi- time required to resolve the problems.
cation that affects the safe operation of the truck 2 Once you begin a troubleshooting procedure, do
cannot be undertaken without written authoriza- not skip steps.
tion of the Hyster company. 3 If you reach the end of a procedure without
Any change to the lift truck, the tires, or its equip- resolving the problem and you are not directed
ment can change the lifting capacity. The lift truck to another procedure contact Resident Service
must be rated as equipped and the nameplate Engineering through the Contact Management
must show the new rating capacity. System.
4 Do not limit yourself, remember to apply your
own experience and knowledge to assist in
WARNING resolving the problems, but do not compromise
The technician must be aware of, and follow, all safety in doing so.
general safety precautions that are published in 5 Most of the cross-reference data in the manual
the Operating Manual and that are posted as Safe- will be electronically linked for rapid and easy
ty Decals on and in the lift truck. access. Use the links wherever the cursor
highlights an item as a linkable option.
Before starting, the technician should be familiar with
certain policies, requirements, and instructions used in
the troubleshooting procedures. Using the
troubleshooting procedures correctly helps the
technician to perform the procedure safely and
prevents damage to the machine and support
equipment.
HOW TO USE DIAGNOSTIC

TROUBLESHOOTING MANUAL
Manual Layout:
Section: This manual consists of one section which is
further divided into groups.
• 9030 – Electrical System
Groups: The 9030 Electrical System is divided into
two groups that identify specific electrical
troubleshooting procedures.
• 03 – General Maintenance/Diagnostic Data
The General Maintenance and Diagnostic Data
group includes general troubleshooting,
discharging the capacitors, basic electrical
troubleshooting, multiplexing, User Iterface, and
status codes and descriptions.
• 20 – Diagnostic Trouble Codes
The Diagnostic Trouble Codes group includes
all troubleshooting procedures for status codes
reported by a given Node or system.
For a listing of all Diagnostic Trouble Codes and
descriptions, see the Status Codes section of this
manual.
Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
Confidential/Proprietary - Do Not Copy or Duplicate iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
SECTION 9030
ELECTRICAL SYSTEM
TABLE OF CONTENTS
Group 03 General Maintenance and Diagnostic Data
General Troubleshooting ........................................................................................................................ 9030-03-1
Discharging the Capacitors .................................................................................................................9030-03-1
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 ................................................................................................................................ 9030-03-3
Voltage Checks ...............................................................................................................................9030-03-3
Amperage Checks .......................................................................................................................... 9030-03-4
Resistance Checks ......................................................................................................................... 9030-03-4
Contactor and Contactor Coil Checks ............................................................................................ 9030-03-4
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 ......................................................................................................................9030-03-6
Automatic Diagnostics .................................................................................................................... 9030-03-6
Status Code Indication ....................................................................................................................9030-03-6
Status Codes and Descriptions .............................................................................................................. 9030-03-7
Status Codes ...................................................................................................................................... 9030-03-7
Status Code Descriptions ................................................................................................................... 9030-03-7
Warning Codes ............................................................................................................................. 9030-03-11
Group 20 Diagnostic Trouble Codes
DTC xx099 - Internal - Fault............................................................................................................ 9030-20-1
DTC xx101 - CANBus Communications - Traction.......................................................................... 9030-20-2
DTC xx103 - CANBus Communications - Pump............................................................................. 9030-20-5
DTC xx104 - CANBus Communications - Steer.............................................................................. 9030-20-8
DTC xx105 - CANBus Communications - Caster Steer.................................................................9030-20-11
DTC xx106 - CANBus Communications - Handle......................................................................... 9030-20-14
DTC xx107 - CANBus Communications - CAN I/O....................................................................... 9030-20-17
DTC xx108 - CANBus Communications - Remote Module........................................................... 9030-20-20
DTC xx110 - CANBus Communications - Impact Module............................................................. 9030-20-23
DTC xx111 - CANBus Communciations - Auxiliary Pump............................................................. 9030-20-26
DTC 30033 - Traction - Main Cont Coil - Circuit............................................................................ 9030-20-28
DTC 30035 - Traction - Brake Coil - Circuit................................................................................... 9030-20-31
Main Contactor/Brake Coil Short:
Confidential/Proprietary - Do Not Copy or Duplicate 9030-1
TABLE OF CONTENTS
DTC 30034 - Traction - Main Cont Coil - Short
DTC 30036 - Traction - Brake Coil - Short.......................................................................................... 9030-20-34
DTC 30052 - Traction - Throttle - Sensor Fault............................................................................. 9030-20-37
DTC 90052 - CAN - Handle - Signal..............................................................................................9030-20-37
Traction Motor:
DTC 30060 - Traction - Motor - Circuit
DTC 30061 - Traction - Motor - Open................................................................................................. 9030-20-40
DTC 30062 - Traction - Motor - Encoder....................................................................................... 9030-20-43
Traction Main Contactor:
DTC 30067 - Traction - Main Contactor - Welded Tips
DTC 30068 - Traction - Main Contactor - Not Closed......................................................................... 9030-20-46
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.................................................................................. 9030-20-49
DTC 30085 - Traction - Key input - Voltage Low........................................................................... 9030-20-52
DTC 30116 - Traction - Height Encoder / Mast Proximity - Mismatch........................................... 9030-20-54
DTC 30117 - Traction - Height Encoder / Mast Proximity - Mismatch........................................... 9030-20-54
DTC 90117 - CAN I/O - Height Encoder / Mast Proximity - Mismatch........................................... 9030-20-54
Steer Motor:
DTC 40060 - Steer - Motor - Circuit
DTC 40061 - Steer - Motor - Open..................................................................................................... 9030-20-58
DTC 40062 - Steer - Motor - Encoder............................................................................................9030-20-60
DTC 40070 - Steer - Steer Request - MTS Sensor....................................................................... 9030-20-63
DTC 40072 - Steer - Steer Angle - Mismatch................................................................................ 9030-20-66
DTC 40073 - Steer - Steer Angle - Center Fault............................................................................9030-20-70
DTC 40085 - Steer - Key input - Voltage Low................................................................................9030-20-73
DTC 40074 - Steer - Motor - Stalled.............................................................................................. 9030-20-75
Steer DC Bus Voltage:
DTC 40086 - Steer - DC Bus - Voltage Low
DTC 40087 - Steer - DC Bus - Voltage High.......................................................................................9030-20-78
Steer Caster Motor:
DTC 41060 - Steer Caster - Motor - Circuit
DTC 41061 - Steer Caster - Motor - Open..........................................................................................9030-20-81
DTC 41062 - Steer Caster - Motor - Encoder................................................................................ 9030-20-83
DTC 41072 - Steer Caster - Steer Angle - Mismatch.................................................................... 9030-20-86
DTC 41073 - Steer Caster - Steer Angle - Center Fault................................................................ 9030-20-89
DTC 41085 - Steer Caster - Key Input - Voltage Low....................................................................9030-20-91
Steer Caster DC Bus Voltage:
DTC 41086 - Steer Caster - DC Bus - Voltage Low
DTC 41087 - Steer Caster - DC Bus - Voltage High........................................................................... 9030-20-93
Lift Pump Motor:
DTC 50060 - Pump - Motor - Circuit
DTC 50061 - Pump - Motor - Open.....................................................................................................9030-20-96
DTC 50062 - Pump - Motor - Encoder...........................................................................................9030-20-98
DTC 50068 - Pump - Main Contactor - Not Closed..................................................................... 9030-20-101
DTC 50069 - Pump - Capacitor - Charge.................................................................................... 9030-20-104
Auxiliary Pump Motor:
DTC 51060 - Auxiliary Pump - Motor - Circuit
DTC 51061 - Auxiliary Pump - Motor - Open.................................................................................... 9030-20-107
DTC 51062 - Auxiliary Pump - Motor - Encoder.......................................................................... 9030-20-109
9030-2 Confidential/Proprietary - Do Not Copy or Duplicate
TABLE OF CONTENTS
Auxiliary Pump DC Bus Voltage:
DTC 51086 - Auxiliary Pump - DC Bus - Voltage Low
DTC 51087 - Auxiliary Pump - DC Bus - Voltage High......................................................................9030-20-111
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................................................................................. 9030-20-114
Impact Module:
DTC 80065 - Impact Module - Soft Impact
DTC 80066 - Impact Module - Hard Impact ..................................................................................... 9030-20-117
CAN I/O Lift Coil:
DTC 90001 - CAN I/O - Lift Coil - Circuit
DTC 90002 - CAN I/O - Lift Coil - Short............................................................................................ 9030-20-120
CAN I/O Lower Coil:
DTC 90003 - CAN I/O - Lower Coil - Circuit
DTC 90004 - CAN I/O - Lower Coil - Short....................................................................................... 9030-20-123
CAN I/O Load Hold Coil:
DTC 90005 - CAN I/O - Load Hold - Circuit
DTC 90006 - CAN I/O - Load Hold - Short........................................................................................9030-20-126
CAN I/O Auxiliary Forward Coil:
DTC 90007 - CAN I/O - Auxiliary Forward Coil - Circuit
DTC 90008 - CAN I/O - Auxiliary Forward Coil - Short..................................................................... 9030-20-129
CAN I/O Auxiliary Reverse Coil:
DTC 90009 - CAN I/O - Auxiliary Reverse Coil - Circuit
DTC 90010 - CAN I/O - Auxiliary Reverse Coil - Short.....................................................................9030-20-131
CAN I/O Tilt Coil:
DTC 90011 - CAN I/O - Tilt Coil - Circuit
DTC 90012 - CAN I/O - Tilt Coil - Short............................................................................................ 9030-20-133
CAN I/O Side-Shift Coil:
DTC 90017 - CAN I/O - Side-Shift Coil - Circuit
DTC 90018 - CAN I/O - Side-Shift Coil - Short................................................................................. 9030-20-135
CAN I/O Extend/Retract Coil:
DTC 90023 - CAN I/O - Extend/Retract Coil - Circuit
DTC 90024 - CANI/O - Extend/Retract Coil - Short.......................................................................... 9030-20-137
CAN I/O Audible Alarm:
DTC 90037 - CAN I/O - Audible Alarm - Circuit
DTC 90038 - CAN I/O - Audible Alarm - Short..................................................................................9030-20-139
CAN I/O Visible Alarm:
DTC 90039 - CAN I/O - Visible Alarm - Circuit
DTC 90040 - CAN I/O - Visible Alarm - Short................................................................................... 9030-20-142
DTC 90043 - CAN I/O - TFD Coil - Circuit................................................................................... 9030-20-145
DTC 90053 - CAN I/O - Pressure - Sensor Fault.........................................................................9030-20-148
DTC 90075 - CAN I/O - Steer - Security Line.............................................................................. 9030-20-150
DTC 90076 - CAN I/O - Steer Caster - Security Line.................................................................. 9030-20-153
DTC 90085 - CAN I/O - Key input - Voltage Low.........................................................................9030-20-156
DTC 90253 - CAN I/O - Lost - Wire............................................................................................. 9030-20-158
DTC 40253 - Steer - Lost - Wire.................................................................................................. 9030-20-158
DTC 90087 - CAN I/O - BUS - Voltage High................................................................................9030-20-160
Remote Module Auxiliary Forward Coil:
DTC 91007 - Remote Module - Auxiliary Forward Coil - Circuit
Confidential/Proprietary - Do Not Copy or Duplicate 9030-3
TABLE OF CONTENTS
DTC 91008 - Remote Module - Auxiliary Forward Coil - Short......................................................... 9030-20-162
Remote Module Auxiliary Reverse Coil:
DTC 91009 - Remote Module - Auxiliary Reverse Coil - Circuit
DTC 91010 - Remote Module - Auxiliary Reverse Coil - Short.........................................................9030-20-164
Remote Module Tilt Coil:
DTC 91011 - Remote Module - Tilt Coil - Circuit
DTC 91012 - Remote Module - Tilt Coil - Short................................................................................ 9030-20-166
Remote Module Side-Shift Coil:
DTC 91017 - Remote Module - Side-Shift Coil - Circuit
DTC 91018 - Remote Module - Side-Shift Coil - Short..................................................................... 9030-20-168
Remote Module Extend/Retract Coil:
DTC 91023 - Remote Module - Extend/Retract Coil - Circuit
DTC 91024 - Remote Module - Extend/Retract Coil - Short............................................................. 9030-20-170
DTC 91049 - Remote Module - Tilt - Sensor fault........................................................................9030-20-172
DTC 91051 - Remote Module - Extend and Retract - Sensor Fault............................................ 9030-20-175
9030-4 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical System General Maintenance and Diagnostic Data
Group 03
General Maintenance and Diagnostic Data
General Troubleshooting
GENERAL TROUBLESHOOTING accessing status codes and following the diagnostic
procedure provided for each status code.
In the event the lift truck does not operate correctly, a
status code is displayed on the display panel. Once Use standard testing procedures to verify inputs and
the status code is obtained, follow the procedures outputs when necessary.
outlined in this manual only after reviewing the
following information regarding the truck’s unique
electrical system and troubleshooting procedures. CAUTION
Never attempt to probe through the back of the
NOTE: Due to the interaction of the CAN I/O control-
connector plugs of the motor controller. These
ler with all truck functions, almost any status code or
plugs are special sealed plugs. Probing through
controller fault could be caused by an internal failure of
the back of the plugs will destroy the seal and can
the CAN I/O controller. After all other status code pro-
cause a short circuit. If a circuit must be tested for
cedures have been followed and no problem is found,
voltage, check for voltage at an amp-type plug, a
the CAN I/O controller should be tested and replaced
switch, or component. If a circuit is suspect, check
as the last option to correct the problem.
the circuit for continuity by disconnecting the plug
The onboard diagnostic system employed on the and testing continuity from the front (pin end) of
vehicle can assist in the troubleshooting process. the plug.
Read and be familiar with the instructions for
Standard probes are too large to be inserted into
accessing and using the display's diagnostic system in
the center of female pins (sockets) of the special
2200 SRM 1614 .
sealed plugs and can damage or expand the pins.
Prior to troubleshooting systems and components on Expanded pins will not provide good connections
the vehicle, ensure the battery voltage is correct and once the plug is reconnected. The connectors are
within specifications. Make sure the battery connector shaped to allow the insertion of a small flat-blade
contacts are clean of corrosion and the battery polarity screwdriver into the connector. After inserting the
within the connector is correct. Inspect that all fuses screwdriver into the connector, attach probes with
are correct and are not the cause of component alligator clips to the shank of the screwdriver to
failure. Ensure the key switch is in the ON position obtain readings. An additional method would be to
when conducting voltage checks or verifying the use Breakout Kit #1397311 .
operation of a component. Make sure the brake switch
and the operator presence switch, if equipped, are Refer to 8000SRM 1619 for wiring diagrams and
functioning properly and are closed. additional circuit information.
Many faults noted by lift truck’s electrical system may DISCHARGING THE CAPACITORS
be the result of loose wiring connections and/or broken
or shorted wiring within the lift truck. Begin the When working with the electrical systems of the truck,
troubleshooting process by carefully inspecting the it is necessary to discharge the internal or external
wiring involving the device or devices noted by the capacitors of the controllers associated with each
onboard diagnostic system. Faults noted with circuit affected.
components located on the reach attachment may be
caused by broken or shorted wires in the mast cable.
Ensure the integrity of this cable before
troubleshooting attachment related faults .
The controllers are sealed units with no serviceable
components. Troubleshooting is usually limited to
Confidential/Proprietary - Do Not Copy or Duplicate 9030-03-1
General Maintenance and Diagnostic Data Electrical System
any controller terminal or motor terminal to the

WARNING battery. Make sure to use proper procedure when
DO NOT make repairs or adjustments unless you servicing the controller.
have been properly trained and authorized to do
1. Move the lift truck to a safe, level area and
so. Improper repairs and adjustments can create
completely lower the mast. Turn the key switch to
dangerous operating conditions. DO NOT operate
the OFF position and attach a DO NOT
a lift truck that needs repairs. Report the need for
OPERATE tag to the control handle. Block the
repairs to your supervisor immediately. If repair is
drive wheel to prevent unexpected movement.
necessary, attach a DO NOT OPERATE tag to the
control handle and disconnect the battery.
2. Disconnect the battery power cable connector
Disconnect the battery and discharge the internal from the truck connector located on the right side
or external capacitors before opening any com- of the frame. Pull the battery cable connector
partment covers or inspecting or repairing the handle to separate the battery connector from the
electrical system. DO NOT place tools on top of truck connector.
the battery. If a tool causes a short circuit, the high
current flow from the battery can cause personal 3. Remove the operator compartment cover.
injury or property damage.
4. Discharge the internal or external capacitors in
Some checks and adjustments are performed with the controllers by connecting a 200-ohm, 2-watt
the battery connected. DO NOT connect the bat- resistor across the controller B(+) and B(-)
tery until the procedure instructs you to do so. terminals of the motor controller. Remove the
Never wear jewelry or other metallic items on your resistor after discharging the capacitors. See and
fingers, arms, or neck when working near electri- Figure 9030-03-1.
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 per-
sonal injury, discharge the internal or external ca-
pacitors before inspecting or repairing any compo-
nent 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-
troller and prevent the capacitors from discharging
properly. The proper way to disconnect the battery
is by separating the battery connectors.
1. POSITIVE CONNECTION B(+)

CAUTION 2. NEGATIVE CONNECTION B(-)
3. INSULATED JUMPER WIRES
To avoid controller damage, always disconnect the 4. 200-OHM, 2-WATT RESISTOR
battery, discharge the internal or external capaci-
tors, and never put power to the controller while Figure 9030-03-1. Discharging the Internal
any power wires are disconnected. Never short Capacitors
9030-03-2 Confidential/Proprietary - Do Not Copy or Duplicate
Electrical Test Equipment

ELECTRICAL TEST EQUIPMENT test leads do not have excessive resistance. A faulty
meter or damaged test leads will cause inaccurate
Before beginning intrusive circuit checks, verify the
readings and incorrect electrical diagnoses.
vehicle battery state of charge. Visually inspect
suspected connectors for loose, damaged, or corroded
Jumper Wires, Test Leads, and Test Lights
terminals. Check for blown fuses and inspect circuits
for cause of overcurrent conditions. Physically check When using jumper wires, test leads, and test lights,
mechanical operation to ensure a switch, relay, or take care not to force tips into connector sockets. Use
solenoid is not sticking or damaged. appropriate clips and adapters to prevent damage to
connectors. Expanded or damaged sockets can cause
NOTE: Measuring continuity between two terminals of
poor continuity between connections.
a switch while operating the switch will determine its
functionality. Jumper wires allow testing across a suspected open in
the circuit. Jumper wires can be used for located
opens, shorts, and performing voltage drops. If a
PC Service Tool
circuit operates correctly with the jumper wire in place,
The PC Service Tool is a Windows based service and is faulty when the jumper wire is removed, a fault
application that is used to communicate with the can be found in the bypassed location.
truck’s electrical control system. It can be used to
Jumper wires can also be used to eliminate sections of
monitor the status and condition of various systems.
the circuit to diagnose either power or grounds. Using
With this capability, the PC Service Tool can be used
the jumper wire to provide a component a known good
to monitor component operation, or determine if
ground can help reduce the amount of checks needed
abnormal events have occurred in the truck, and assist
to diagnose a circuit.
with diagnostics and troubleshooting.
Jumper wires can be used to bypass components
Breakout Kit #1397311 such as switches. If a faulty switch is suspected,
The Breakout Kit allows the technician to perform removing it from the circuit with a jumper wire can
circuit input and output checks at the controllers’ determine if a switch or component is at fault.
connectors. The Breakout kits primary function allows Jumper wires can be used to check for open or faulty
the technician to diagnose circuit faults while the relay contacts which are often sealed and can take
vehicle’s circuits are connected and operating. This is additional steps to properly diagnose.
done by installing the breakout kit in series with the
Test lights can be used when quick voltage or ground
controller and its circuits.
checks are necessary. Many features operate on
Digital Multimeter (DMM) switched voltage, and using a test light as a load
device may be helpful. The test light may also be used
Digital multimeters provide several measurement to verify continuity to B-. Discretion should be used
functions in one tool. A DMM should be capable of when troubleshooting a circuit using a test light, as the
accurately measuring voltage, amperage, and light may illuminate even though there may be an
resistance. Ensure that the multimeter used in excessive amount of resistance on the ground circuit
troubleshooting procedures is accurate and that the or when a low voltage or amperage situation exists.
Basic Electrical Troubleshooting

ELECTRICAL CHECKS Voltage Checks
The following electrical checks are used to diagnose Voltage is electrical pressure or force that pushes
circuit and component faults on trucks. Review the current through a circuit. The force is measured in
following information so that it may be applied when volts.
diagnosing a fault or status code.
Low voltage to a load device will cause the device to
be inoperative or operate poorly. This can be caused
by a low battery source, high circuit resistance, poor Resistance Checks

connections, or an open circuit; the resistance of poor
The ohmmeter is used to measure a circuit or device's
connections or poor ground acts as an additional load
resistance in ohms. Ohmmeters use low internal
in the circuit, causing low voltage pushing current, or
voltage and current which flow through an isolated
amperage, through a device.
circuit or device being tested. The voltage of the meter
A voltmeter is used to perform: battery and the amount of current flow in the circuit are
Measurement of force used to calculate the circuit’s resistance. It is
•
necessary to disconnect or isolate the circuit being test
• Presence of voltage so not to damage the vehicle’s electrical system or the
• Voltage drops ohmmeter.
When using a voltmeter to determine if voltage is An ohmmeter is used to perform:
present and capable of operating a device, connect • Resistance of a load device
the positive meter lead to the power circuit of a
device’s connector and connect the negative meter • Resistance of conductors
lead to the negative battery terminal. • Value of resistors
Measuring the voltage drop is performed by • Operation of variable resistors
connecting the positive test lead to the positive side of • CANbus termination resistors
the device while simultaneously connecting the
• Continuity
negative meter lead to the negative side of the device.
The test can also be performed across a section of Contactor and Contactor Coil Checks
wire that is faulty and suspected of having excessive
resistance. A voltage drop must be performed while 1. Navigate to the Battery Type menu and verify the
the device is operating. In a circuit with a single load selected battery type.
device, the device will drop the total voltage of the
circuit. If the device drops less than battery voltage, it Does the battery type setting on the display match
can be assumed that the circuits are using the battery type installed on truck?
remaining voltage as a source of excessive resistance YES- Proceed to Step 2.
or a poor connection exists, assuming the battery
NO-Change the Battery Type setting to match the
state-of-charge is correct.
battery installed in the truck.
Amperage Checks
2. Measure voltage between the coil's positive
An ammeter is used to measure amperage or current terminal and B(-).
flow through a circuit. An ampere is the measurement
of electron flow, which can be used to measure the NOTE: Key in ON position.
amount of electrons that are flowing through a circuit.
Is voltage same as truck's battery voltage?
Ohm’s Law states that current flow in a circuit is equal
to the circuit voltage divided by total circuit resistance, YES- Proceed to Step 3.
known as the potential difference. Since amperage is NO- Inspect the Coil's battery B(+) input circuit for
the current in the circuit, increasing voltage also open or short.
increases the current, or amperage levels.
Measuring amperage is always performed by placing 3. Disconnect coil's ground control circuit. Measure
the ammeter in series with the device or circuit. This resistance between ground circuit terminal and
will cause all current to flow through the protected B(-).
meter. The circuit must be operating in order to
measure amperage. Never measure amperage on NOTE: Actuate coil ground control.
high amperage circuits or in parallel to a circuit, this Is resistance <1 ohm?
can result in the damage of the meter and the
YES- Proceed to Step 4.
electrical system.
NO- Inspect ground control circuit. Verify that controller
is receiving device input signal.
4. Measure battery voltage between main YES- Repair or replace faulty contactor.
contactor's battery B(+) terminal and B(-).
NO- Inspect main contactor battery cable for loose,
damaged, or corroded connections.
NOTE: Key in ON position.
Is voltage same as truck's battery voltage?
Multiplexing
MULTIPLEXING AND THE CANBUS. If CANbus resistance is 120 ohms, there is an open
circuit or a termination resistor is missing.
Controller Area Network (CAN) Bus communication
allows multiple modules to communicate with each If resistance is 0 ohms, the two circuits are shorted
other using the same digital data on a shared network, together.
this method of communication is known as
multiplexing. The CANbus is a pair of twisted insulated 1. Measure voltage between the diagnostic
wires that interconnect all the modules on the network. connector, socket A and B(-).
The data transmitted is a digital encoded format. NOTE: Key in ON position.
Digital means only two states are used to transmit
data, High/On and Low/Off. This eliminates the need Is voltage approximately 2.5 volts?
for each module to be hard wired to each sensor. YES- Proceed to Step 2.
Using Multiplexing, sensor information that may be
NO- Inspect CAN HI circuit for open or short; if
received by one module, can then be shared with all
voltage is 0 volts, the CAN HI circuit is shorted to
other modules. The information is sent out over the
B(-) or open. If voltage is above 5 volts, the CAN
CANbus in an encoded form and any other module
HI is shorted to power.
that requires the information can pick it out from the
data stream.
2. Measure voltage between the diagnostic
connector, socket B and B(-).
Troubleshooting the CANbus
NOTE: Refer to the latest Diagram SRM for the most
current circuit information. Is voltage approximately 2.5 volts?
When the CANbus is active and modules are YES- Disconnect the battery and proceed Step 3.
communicating, CAN HI and CAN LO voltage will be
NO- Inspect the CAN LO circuit for open or short;
approximately 5 volts when added together. If both
If voltage is 0 volts, the CAN LO circuit is shorted
CAN HI and CAN LO have consistent 2.5 volt, there is
to B(-) or open. If voltage is above 5 volts, the
no communication on the CANbus.
CAN LO is shorted to power.
If CAN HI is shorted to B(-) or CAN LO is shorted to
battery voltage, network communication will stop. 3. Measure resistance between the diagnostic
connector, socket A and socket B.
If you measure battery voltage on the data link, there
is a short to power in the circuit. Is resistance 60 ± 6 ohms?
If you measure 0 volts while the CANBus is active, YES- CANbus communication is operating
there is a short to B(-) or an open in the circuit. correctly.
Internal control module failures can stop the entire NO- If resistance is 120 ohms; the CANbus has
network from communicating. If there are no harness an open circuit, missing, or damaged termination
problems, disconnect control modules one at a time resistor. If resistance is 0 ohms, the CANbus
until CANbus communication returns. circuits are shorted together. If resistance is open;
the CAN HI and/or CAN LO connection to the
With both 120 ohm termination resistors connected to
diagnostic port may be open. Use the wiring
the CANbus, resistance between the two circuits
diagrams to detect and correct open circuit.
should read 60 ohms.
User Interface
USER INTERFACE, SETUP, AND 7. Truck hours will be displayed.
TROUBLESHOOTING
Dash Display Access
The dash display has a LCD screen for displaying
truck system information. The display has five indicator The operator passwords are a series of five-digit
lights for truck function status. There are five number numbers. Each of the five number digits can be the
keys for password. Number keys 1-4 are also used for numbers 1 through 5. If enabled, the password
navigating the on-board setup and service menus. The number series must be entered into the memory by a
dash display also contains a battery state-of-charge technician or supervisor and assigned to an operator.
indicator and is equipped to allow operator selectable A certified dealer technician can use a personal
drive modes. computer (PC), connected to the lift truck, to check
and assign passwords.
Button Keypad
After the key is moved to the ON position, the LCD
The button keypad is located on the right side of the screen will show ENTER PASSWORD, if this function
display. It consists of four buttons arranged in a circle is enabled. Use the numbered push buttons to enter
with a fifth button in the center. The buttons are the five-digit password. The password can be entered
numbered 1 through 5, starting with button 1 at the top as many times as needed. If the password is entered
and continuing clockwise and ending with button 5 incorrectly, the message PASSWORD ERROR will
situated in the center of the keypad. appear and the operator will be prompted to ENTER
PASSWORD again.
LED Indicator Lights
Refer to User Interface manual User Interface
The LED indicator lights are located on the display Service Technician 2200SRM1614 for further
below the LCD screen and to the left of the button information regarding the User Interface for either
keypad. The lights illuminate to notify the operator of Supervisor or Technician application.
certain conditions. The function of each light (in order
from left to right) is as follows: Status Code Toggling
• Battery Indicator This feature allows the operator to toggle the display
• Wrench Indicator from the normal screen display to the status code
screen. Pressing the 2 button will cause the display to
• Temperature Indicator
switch from the normal display screen to the status
• Operator Symbol code screen. Pressing the 4 button will cause the
• Warning Indicator display to return from the status code screen to the
normal display.
LCD Screen
Automatic Diagnostics
The LCD screen displays the following when the key is
in the ON position: This feature allows for immediate access to
diagnostics associated with status codes. To use this
1. Indicator symbols will illuminate from left to feature, press the 5 button while viewing the status
right.
code screen. If diagnostics are available with the code,
2. The truck horn will beep. the diagnostics will be immediately entered.
3. The battery state-of-charge will illuminate.
Status Code Indication
4. Performance mode will be displayed.
5. Steer angle indicator will be displayed. This feature indicates if a status code is available
when in the normal screen. If a status code is present,
6. Truck speed indicator will be displayed. the mode indicator will display “!”.
Status Codes and Descriptions

STATUS CODES NODE 40: STEER
Status codes give an indication to the operator that a NODE 41: STEER CASTER (Optional)
possible malfunction or incorrect truck use has NODE 50: PUMP
occurred. Status codes are a code number of a NODE 51: AUXILIARY PUMP (Americas Only)
symptom or malfunction. The wrench symbol will flash NODE 60: HANDLE
and the status code number will be shown on the LCD
screen if an incorrect truck use or malfunction occurs NODE 80: IMPACT MODULE (Optional)
during operation. Have an authorized service person NODE 90: CAN I/O
check and repair the lift truck if a status code number NODE 91: REMOTE MODULE (Americas Only)
appears. The symptoms for each status code are
Status Codes are displayed as four lines. Line one
show in this manual. This manual also provides in-
consist of the Node and Code number. The second
depth troubleshooting procedures for each fault broken
line consists of the Node name while lines three and
down into the following system or node:
four contain code descriptions. For example, Status
NODE 10: DISPLAY Code 90106 is shown in the Status Code Structure
NODE 30: TRACTION Table 9030-03-1:
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
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 Control-
ler.
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 Con-
troller.
10 105 The Display has detected a loss of CAN communication with the Caster Steer
Controller.
10 106 The Display has detected a loss of CAN communication with the Handle.
*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.
Table 9030-03-2. Node 10 Status Codes (Continued)

10 107 The Display has detected a loss of CAN communication with the CAN I/O Control-
ler.
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 in-
put circuit.
30 086 The Traction Controller has detected low DC Bus voltage or a fault in the DC Bus
circuit.
30 087 The Traction Controller has detected high DC Bus voltage or a fault in the DC Bus
circuit.

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
circuit.
40 086 The Steer Controller has detected low DC Bus voltage or a fault in the DC Bus cir-
cuit.
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 cir-
cuit.
41 062 The Steer Caster Controller has detected a fault in the Steer Caster Motor Encod-
er.
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.

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 cir-
cuit.
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.

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
Sensor 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 in-
put circuit.
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.
Warning Codes electrical diagnosis. The following table of warning

codes and descriptions may assist in troubleshooting
This section contains Status Codes that may not
other faults the truck may encounter.
require 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
XX 080 Motor Cutback* 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
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.
XX 081 Motor Overheated* Motor cutback (XX080) was unsuccessful. Motor cutback
is initiated at 160°C (320°F). The truck will severely limit
performance until the motor temperature returns to nor-
mal. Motor temperature input can be monitored in menu
D2.32.6.
XX 082 Controller Cutback* A controller has begun to reduce power in attempt to
Thermal manage increased temperatures that may damage inter-
nal components. Controller cutback is initiated at
90°C (194°F). Truck performance will be reduced until
temperature lowers to an acceptable level. Controller
temperature input can be monitored in menu D2.32.5.
XX 083 Controller Overhea- Controller cutback (XX082) was unsuccessful. Controller
ted* cutback is initiated at 110°C (230°F). The truck will se-
verely limit performance until the motor temperature re-
turns to normal. Motor temperature input can be moni-
tored in menu D2.32.5.
XX 248 Low Temp* A controller has detected low temperature conditions.
Move truck to a warmer ambient condition an allow suffi-
cient time to warm.
*Any Node or system that detects a thermal fault is capable of reporting a Status Code.
Electrical System Diagnostic Trouble Codes
Group 20
Diagnostic Trouble Codes
DTC xx099
Internal - Fault
POSSIBLE CAUSE
A. INTERNAL FAULT
COMPONENT OPERATIONAL CHECK
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
SystemSRM.
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
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.
SystemSRM.
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
connector 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?
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
DIAGRAMS
Troubleshooting Scenes
END FAULT
DTC xx103
CANBus Communications - Pump
POSSIBLE CAUSE

B. PUMP CONTROLLER WIRING FAULT
NOTE
SystemSRM.
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(-).
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
DIAGRAMS
END FAULT
DTC xx104
CANBus Communications - Steer
POSSIBLE CAUSE

B. STEER CONTROLLER WIRING FAULT
NOTE
SystemSRM.
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
2. Measure voltage between the steer controller connector CPS059, socket A22 and B(-).
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
DIAGRAMS
END FAULT
DTC xx105
CANBus Communications - Caster Steer
POSSIBLE CAUSE

B. CASTER STEER CONTROLLER WIRING FAULT
NOTE
SystemSRM.
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
controller connector CPS082, socket A23 and B(-).
2. Measure voltage between the caster steer controller connector CPS082, socket A22 and B(-).
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
DIAGRAMS
END FAULT
DTC xx106
CANBus Communications - Handle
POSSIBLE CAUSE

B. HANDLE WIRING FAULT
NOTE
SystemSRM.
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(-).
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
NO: Inspect ground circuit 113-J/113-T for open or short.
END POSSIBLE CAUSES
DIAGRAMS
Side-Stance Handle Troubleshooting Scenes
Fore-Aft Handle Troubleshooting Scenes
END FAULT
DTC xx107
CANBus Communications - CAN I/O
POSSIBLE CAUSE

B. CAN I/O WIRING FAULT
NOTE
SystemSRM.
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(-).
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
DIAGRAMS
END FAULT
DTC xx108
CANBus Communications - Remote Module
POSSIBLE CAUSE

B. REMOTE MODULE WIRING FAULT
NOTE
SystemSRM.
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(-).
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
DIAGRAMS
END FAULT
DTC xx110
CANBus Communications - Impact Module
POSSIBLE CAUSE

B. IMPACT MODULE WIRING FAULT
NOTE
SystemSRM.
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(-).
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
DIAGRAMS
END FAULT
DTC xx111
CANBus Communciations - Auxiliary Pump
POSSIBLE CAUSE

B. FAULTY AUXILIARY PUMP
NOTE
SystemSRM.
3. Locate input diagnostics (D2.10) and verify auxiliary pump communication (D2.10.51).
Is auxiliary pump online?

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(-).
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
DIAGRAMS
END FAULT
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
SystemSRM.
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
terminal TS013 and B(-).
NO: Inspect circuit 245-A and 245-B for open or short.
NOTE: Key in OFF position.
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
connector 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
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 30035
Traction - Brake Coil - Circuit
POSSIBLE CAUSE
A. ELECTRIC BRAKE COIL WIRING FAULT

B. ELECTRIC BRAKE COIL FAILURE
NOTE
SystemSRM.
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.
2. Disconnect traction controller connector CPS11. Measure resistance between the electric brake coil
connector 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
DIAGRAMS
END FAULT
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
SystemSRM.
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(-).
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 2.
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
DIAGRAMS
END FAULT
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
SystemSRM.
3. Locate input diagnostics (D2.30) and view the aft enable switch (D2.30.34) to ensure the aft handle is
enabled.
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.
NOTE: Hold aft handle to actuate optic sensor.
2. Connect Breakout Kit #1397311 to the traction controller and measure voltage between the traction controller
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 #1397311 , 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
DIAGRAMS
END FAULT
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
SystemSRM.
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.
4. Locate and run Motor Open Test (D3.30.4) to isolate open.
Was the Motor Open Test successful?
NOTE: Disconnect battery and disconnect cables from controller as noted on the display. Reconnect battery and
perform test.
5. Locate and run Motor Current Test (D3.30.5) to isolate circuit fault.
Was the Motor Current Test successful?
NO: Proceed to CAUSE C.
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
individual cables to isolate fault.
Is continuity present?
NO: Repair or replace faulty phase cable.
CAUSE B - TRACTION MOTOR FAULT
1. Traction motor may require replacment. Contact Hyster service for authorization.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 30062
Traction - Motor - Encoder
POSSIBLE CAUSE
A. ENCODER WIRING FAULT

B. ENCODER FAULT
NOTE
SystemSRM.
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.
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
encoder 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 #1397311 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
DIAGRAMS
END FAULT
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
SystemSRM.
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
contactor coil's positive socket terminal TS013 and B(-).
2. Disconnect traction controller connector CPS11. Measure continuity between the main contactor coil's
negative 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
DIAGRAMS
END FAULT
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
SystemSRM.
YES: Disconnect battery and discharge the capacitor. Connect battery and re-key the vehicle prior to
performing Step 3.
3. Locate input diagnostics (D2.30) and view CAP voltages (D2.30.8, D2.30.9, D2.30.10) to verify capacitor
voltage.
Is CAP voltage same as battery voltage?
YES: Verify battery state of charge and recheck condition. If actual voltage does not agree with display,
proceed to CAUSE D.
CAUSE A - INTEGRATED FUSE BOARD WIRING FAULT

1. Disconnect the main contactor precharge terminal TS049 from main contactor. Measure voltage between
precharge 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.
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
DIAGRAMS
Cause A and Cause C Troubleshooting Scenes
Cause D Troubleshooting Scenes
END FAULT
DTC 30085
Traction - Key input - Voltage Low
POSSIBLE CAUSE
A. FAULTY INTEGRATED FUSE BOARD

B. KEY INPUT WIRING FAULT
NOTE
SystemSRM.
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

CAUSE B - KEY INPUT WIRING FAULT

1. Disconnect the traction controller connector CPS11. Measure voltage between the traction controller
NO: Inspect circuit 206-G for open, short, or source of excessive resistance.
END POSSIBLE CAUSES
DIAGRAMS
Cause A Troubleshooting Scenes
Cause B Troubleshooting Scenes
END FAULT
CODES
DTC 30116 - Traction - Height Encoder / Mast Proximity - Mismatch

DTC 30117 - Traction - Height Encoder / Mast Proximity - Mismatch
DTC 90117 - CAN I/O - Height Encoder / Mast Proximity - Mismatch
POSSIBLE CAUSE
A. MAST PROXIMITY SENSOR FAULT

B. HOIST ENCODER FAULT
NOTE
SystemSRM.
3. Locate input diagnostics (D2.50) and view motor encoder count (D2.50.3) while operating pump.
Does encoder relate to actual motor operation?
YES: Proceed to .
NO: Proceed to CAUSE B
4. Locate input diagnostics (D2.30) and view mast proximity sensor (D2.30.22) while lifting and lowering the
mast.
Does proximity sensor relate to actual mast movement?
CAUSE A - MAST PROXIMITY SENSOR FAULT
NOTE: Perform Step 1 and Step 2 with key in the ON position.

1. Disconnect the mast proximity sensor connector CPS90 and measure voltage between socket 2 and B(-).
NO: Inspect sensor input circuit W010-D for open or short.
2. Measure voltage between the mast proximity sensor connector CPS90, socket 2 and socket 3.
NO: Inspect ground circuit W113-D for open or short.
3. Disconnect the traction controller connector CPS100 and measure resistance between socket 6 and the mast
proximity sensor connector CPS90, socket 1.
NO: Inspect circuit 571 for open or source of excessive resistance. If no circuit faults are found, replace faulty
proximity sensor.
CAUSE B - HOIST ENCODER FAULT
NOTE: Perform Step 1 and Step 2 with key in ON position.

1. Disconnect the hoist motor encoder connector CPS151 and measure voltage between socket 1 and B(-).
NO: Inspect circuit 283 for open or short.
NO: Inspect ground circuit 114 for open or short.
3. Disconnect the hoist motor controller connector CPS150. Measure resistance between socket 7 of the hoist
NO: Inspect signal circuit 575 for open or source of excessive resistance.
4. Measure resistance between socket 14 of the hoist motor controller connector CPS150 and socket 3 of the
encoder connector CPS151.
YES: Reconnect the encoder connector CPS151 and proceed to Step 5.
NO: Inspect signal circuit 576 for open or source of excessive resistance.
NOTE: Connect Breakout Kit #1397311 , connect battery, and perform Step 5 with key in ON position.
5. Measure voltage between the hoist motor controller connector CPS150, socket 7/14 and B(-).
Does voltage signal relate to pump operation?
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
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
SystemSRM.
perform test.
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.
CAUSE B - STEER MOTOR FAULT
1. Steer motor may require replacement. Contact Hyster service for authorization.
CAUSE C - FAULTY STEER CONTROLLER
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 40062
Steer - Motor - Encoder
POSSIBLE CAUSE
A. FAULTY BATTERY
B. ENCODER WIRING FAULT
C. ENCODER FAULT
D. FAULTY STEER CONTROLLER
NOTE
SystemSRM.
Is encoder signal responding to actual traction motor speed?
CAUSE A - FAULTY BATTERY
1. Check battery state of charge.

Is battery voltage within specifications?
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(-).
3. Disconnect the steer controller connector CPS059. Measure resistance between socket A4 of the steer
4. Measure resistance between socket A3 of the steer controller connector and socket 2 of the encoder
connector 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 #1397311 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
DIAGRAMS
END FAULT
DTC 40070
Steer - Steer Request - MTS Sensor
POSSIBLE CAUSE
A. STEER UNIT WIRING FAULT

B. STEER UNIT FAULT
NOTE
SystemSRM.
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
connector CPS059, socket A20 and the steer unit connector CPS045, socket 3.
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
DIAGRAMS
END FAULT
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.
SystemSRM.
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?
NOTE: Operate steer motor while performing this test.

1. With Breakout Kit #1397311 connected, measure voltage between socket A3, A4 and B(-).
Does voltage signal relate to steer motor movement?
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 40073
Steer - Steer Angle - Center Fault
POSSIBLE CAUSE
A. CENTER PROXIMITY SWITCH WIRING FAULT

B. CENTER PROXIMITY SWITCH FAULT
NOTE
SystemSRM.
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
connector CPS059, socket A13 and the center proximity switch connector CPS051, socket 3.
3. Measure resistance between the main steer controller connector CPS059, socket A12 and the center
proximity 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 #1397311 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
DIAGRAMS
END FAULT
DTC 40085
Steer - Key input - Voltage Low
POSSIBLE CAUSE

B. KEY INPUT WIRING
NOTE
SystemSRM.
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.

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
DIAGRAMS
END FAULT
DTC 40074
Steer - Motor - Stalled
POSSIBLE CAUSE

B. FAULTY STEER MOTOR
NOTE
SystemSRM.
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(-).
3. Disconnect the steer controller connector CPS059. Measure resistance between socket A4 of the steer
4. Measure resistance between socket A3 of the steer controller connector and socket 2 of the encoder
connector 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?
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.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
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
SystemSRM.
performing Step 3.
voltage.
YES: Verify battery state of charge and recheck condition. If capacitor voltage is within specifications after
retest and code remains, proceed to CAUSE D.


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
DIAGRAMS
Cause A and Cause B Troubleshooting Scenes
Cause C Troubleshooting Scenes
END FAULT
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
SystemSRM.
CAUSE A - STEER CASTER MOTOR CABLE FAULT

1. Disconnect the caster motor cables from the caster controller and caster motor. Measure continuity of
CAUSE B - STEER CASTER MOTOR FAULT

1. Measure resistance between the caster motor terminals U and V.
Is resistance between .322 and .383 ohms?
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
DTC 41062
Steer Caster - Motor - Encoder
POSSIBLE CAUSE
A. FAULTY BATTERY
B. ENCODER WIRING FAULT
C. ENCODER FAULT
D. FAULTY STEER CASTER CONTROLLER
NOTE
SystemSRM.
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?
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(-).
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 #1397311 to the steer caster controller connector CPS082 and measure voltage
between socket A3, A4 and B(-).
Does voltage signal relate to steer caster motor movement?
CAUSE D - FAULTY STEER CASTER CONTROLLER
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 41072
Steer Caster - Steer Angle - Mismatch
POSSIBLE CAUSE
A. STEER UNIT FAULT

B. ENCODER FAULT
NOTE
SystemSRM.
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 #1397311 to steer controller connector CPS059 and measure voltage between socket
A17, A20 and B(-).
Does voltage signal relate to steering input?

NOTE: Connect battery and turn key to ON position. Operate caster steer motor.
1. Connect Breakout Kit #1397311 to steer caster controller connector CPS082 and measure voltage between
Does voltage signal relate to steer caster movement?
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 41073
Steer Caster - Steer Angle - Center Fault
POSSIBLE CAUSE
A. CENTER PROXIMITY SWITCH WIRING FAULT

B. CENTER PROXIMITY SWITCH FAULT
NOTE
SystemSRM.
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
connector 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.
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 #1397311 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
DIAGRAMS
END FAULT
DTC 41085
Steer Caster - Key Input - Voltage Low
POSSIBLE CAUSE

B. KEY INPUT WIRING
NOTE
SystemSRM.
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(-).
YES: CAUSE C.
NO: Inspect circuit 206-U for open, short, or source of excessive resistance.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
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
SystemSRM.
performing Step 3.
voltage.


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
DIAGRAMS
Cause A and B Troubleshooting Scenes
END FAULT
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
SystemSRM.
perform test.
CAUSE A - HYDRAULIC MOTOR CABLE FAULT

1. Disconnect the hydraulic motor cables from the pump controller and hydraulic motor. Measure continuity of
NO: Repair or replace faulty hydraulic motor cable.
CAUSE B - HYDRAULIC MOTOR FAULT
1. Pump motor may require replacement. Contact Hyster service for authorization.
CAUSE C - FAULTY PUMP CONTROLLER
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 50062
Pump - Motor - Encoder
POSSIBLE CAUSE

B. ENCODER FAULT
NOTE
SystemSRM.
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
4. Measure resistance between socket A7 of the pump controller connector and socket 3 of the encoder
connector CPS016.
YES: Connect battery and pump encoder. Proceed to CAUSE B.
NOTE: Operate pump while performing this test.

1. Connect Breakout Kit #1397311 to the pump controller and measure voltage between socket A14, A7 and
B(-).
Does voltage signal relate to pump motor operation?
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 50068
Pump - Main Contactor - Not Closed
POSSIBLE CAUSE

B. MAIN CONTACTOR STUCK OPEN
C. DC BUS CONNECTION FAULT
NOTE
SystemSRM.
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
contactor coil's positive socket terminal TS013 and B(-).
2. Disconnect traction controller connector CPS11. Measure continuity between the main contactor coil's
negative socket terminal TS012 and socket A16 of the traction controller connector CPS11.
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
DIAGRAMS
END FAULT
DTC 50069
Pump - Capacitor - Charge
POSSIBLE CAUSE

C. PUMP CONTROLLER WIRING FAULT
D. FAULTY PUMP CONTROLLER
NOTE
SystemSRM.
performing Step 3.
voltage.
YES: Verify battery state of charge and recheck condition. If actual voltage does not agree with display,
proceed to CAUSE D.


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
DIAGRAMS
END FAULT
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
SystemSRM.
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.
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
DTC 51062
Auxiliary Pump - Motor - Encoder
POSSIBLE CAUSE
A. AUXILIARY MOTOR ENCODER COMMUNICATION FAULT

B. FAULTY PUMP CONTROLLER
NOTE
SystemSRM.
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.
YES: No communication faults are present, suspect faulty encoder.
CAUSE B - FAULTY PUMP CONTROLLER
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
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
SystemSRM.
performing Step 3.
voltage.


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
DIAGRAMS
END FAULT
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
SystemSRM.
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

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
voltage 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
DIAGRAMS
Side-Stance Handle Troubleshooting Scenes
Fore/Aft Handle Troubleshooting Scenes
END FAULT
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
SystemSRM.
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.
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
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
SystemSRM.
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

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
between 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
DIAGRAMS
END FAULT
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
SystemSRM.
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

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
between 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
DIAGRAMS
END FAULT
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
SystemSRM.
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.
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
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
SystemSRM.
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.
2. Disconnect the CAN I/O connector CPS031 and the auxiliary forward coil connector CPS138. Measure
resistance 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
DIAGRAMS
CAN I/O Troubleshooting Scenes
END FAULT
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
SystemSRM.
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.
2. Disconnect the CAN I/O connector CPS031 and the auxiliary reverse coil connector CPS139. Measure
resistance 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
DIAGRAMS
END FAULT
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
SystemSRM.
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.
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
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
SystemSRM.
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
between the CAN I/O connector CPS031, socket A4 and the side-shift coil connector CPS67, socket 2.
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
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
SystemSRM.
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.
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
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
SystemSRM.
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.
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.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
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
SystemSRM.
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.
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
DIAGRAMS
END FAULT
DTC 90043
CAN I/O - TFD Coil - Circuit
POSSIBLE CAUSE
A. TFD COIL WIRING FAULT

B. TFD COIL FAULT
NOTE
SystemSRM.
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
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
DIAGRAMS
END FAULT
DTC 90053
CAN I/O - Pressure - Sensor Fault
POSSIBLE CAUSE
A. PRESSURE SENSOR WIRING FAULT

B. PRESSURE SENSOR FAULT
NOTE
SystemSRM.
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.
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 #1397311 to the CAN I/O controller connector CPS031 and measure voltage between
socket A7 and B(-).
Does voltage relate to lift pressure?
NO: Replace faulty pressure sensor.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 90075
CAN I/O - Steer - Security Line
POSSIBLE CAUSE
A. STEERING FAULT
B. STEER CALIBRATION REQUIRED
C. STEER CONTROLLER WIRING FAULT
NOTE
SystemSRM.
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.
CAUSE B - STEER CALIBRATION REQUIRED
1. Calibrate the Steer Wheel (C1). For complete calibration procedures, refer to the User Interface Service
Technician 2200SRM1614 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
connector 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
DIAGRAMS
END FAULT
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
SystemSRM.
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.
CAUSE B - STEER CASTER CALIBRATION REQUIRED
1. Calibrate the Caster Wheel (C26). For complete calibration procedures, refer to the User Interface Service
Technician 2200SRM1614 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
controller 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
DIAGRAMS
END FAULT
DTC 90085
CAN I/O - Key input - Voltage Low
POSSIBLE CAUSE

NOTE
SystemSRM.


1. Disconnect the CAN I/O controller connector CPS031 and measure voltage between socket A11 and B(-).
NO: Inspect circuit 206-H for open, short, or source of excessive resistance.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
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
SystemSRM.
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.
CAUSE B - FAULTY CAN I/O CONTROLLER
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
DTC 90087
CAN I/O - BUS - Voltage High
POSSIBLE CAUSE

NOTE
SystemSRM.


1. Disconnect the CAN I/O controller connector CPS031 and measure voltage between socket A11 and B(-).
NO: Inspect circuit 206-H for open, short, or source of excessive resistance.
END POSSIBLE CAUSES
DIAGRAMS
END FAULT
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
SystemSRM.
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.
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
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
SystemSRM.
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
auxiliary reverse coil connector CPS71, socket 2.
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
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
SystemSRM.
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.
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
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
SystemSRM.
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.
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
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
SystemSRM.
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
extend/retract coil connector CPS69, socket 2.
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
DTC 91049
Remote Module - Tilt - Sensor fault
POSSIBLE CAUSE
A. TILT SENSOR WIRING FAULT

B. TILT SENSOR FAULT
NOTE
SystemSRM.
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.
CAUSE B - TILT SENSOR FAULT
NOTE: Connect battery, turn key to ON position, and operate tilt functions.
1. Connect Breakout Kit #1397311 to the remote CAN module connector CPS85 and measure voltage between
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
DIAGRAMS
END FAULT
DTC 91051
Remote Module - Extend and Retract - Sensor Fault
POSSIBLE CAUSE
A. REACH POSITION SENSOR WIRING FAULT

B. REACH POSITION SENSOR FAULT
NOTE
SystemSRM.
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.
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 #1397311 to the remote CAN module connector CPS85 and measure voltage between
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
DIAGRAMS
END FAULT
TECHNICAL PUBLICATIONS
9000 SRM 1622 10/19 (1/16)(1/15)(11/14)(1/14)(9/13)

Codigos H35ZDR D264

Uploaded by

Document Informationclick to expand document information

Document Informationclick to expand document information

Copyright:

Available Formats

Codigos H35ZDR D264

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Codigos H35ZDR D264

Uploaded by

Copyright:

Available Formats

CONTROLLER

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

PART NO. 4075036 9000 SRM 1622

This section is for the following models:

(N35ZDR2, N45ZR2) [D264];

©2019 HYSTER COMPANY i

How To Use This Troubleshooting Manual

HOW TO USE DIAGNOSTIC

any controller terminal or motor terminal to the

1. POSITIVE CONNECTION B(+)

Electrical Test Equipment

Basic Electrical Troubleshooting

by a low battery source, high circuit resistance, poor Resistance Checks

Status Codes and Descriptions

Table 9030-03-1. Status Code Structure

STATUS CODE DESCRIPTIONS

Table 9030-03-2. Node 10 Status Codes

Table 9030-03-2. Node 10 Status Codes (Continued)

Table 9030-03-3. Node 30 Status Codes

Table 9030-03-4. Node 40 Status Codes

Table 9030-03-4. Node 40 Status Codes (Continued)

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

Table 9030-03-6. Node 50 Status Codes

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

Table 9030-03-8. Node 60 Status Codes

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

Table 9030-03-10. Node 90 Status Codes

Table 9030-03-10. Node 90 Status Codes (Continued)

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

Warning Codes electrical diagnosis. The following table of warning

Table 9030-03-12. Warning Codes

COMPONENT OPERATIONAL CHECK

CAUSE A - INTERNAL FAULT

END POSSIBLE CAUSES

A. CANBUS COMMUNICATION FAULT

COMPONENT OPERATIONAL CHECK

CAUSE A - CANBUS COMMUNICATION FAULT

NOTE: Key in ON position

CAUSE B - TRACTION CONTROLLER WIRING FAULT

NOTE: Key in ON position

END POSSIBLE CAUSES

A. CANBUS COMMUNICATION FAULT

COMPONENT OPERATIONAL CHECK

CAUSE A - CANBUS COMMUNICATION FAULT

NOTE: Key in ON position

CAUSE B - PUMP CONTROLLER WIRING FAULT

NOTE: Key in ON position

END POSSIBLE CAUSES

A. CANBUS COMMUNICATION FAULT

COMPONENT OPERATIONAL CHECK

CAUSE A - CANBUS COMMUNICATION FAULT

NOTE: Key in ON position

CAUSE B - STEER CONTROLLER WIRING FAULT

NOTE: Key in ON position

END POSSIBLE CAUSES

A. CANBUS COMMUNICATION FAULT

COMPONENT OPERATIONAL CHECK

CAUSE A - CANBUS COMMUNICATION FAULT