Mitsubishi FBC15/18/20/25KS Service Manual Messages, Codes, and Tests

Mitsubishi FBC15/18/20/25KS Service Manual Messages, Codes, and Tests
Messages, Codes, and Tests 6:
6-1
Messages, Codes, and Tests Mitsubishi FBC15/18/20/25KS Service Manual
List of Codes and Tests

Codes
Code 10 - Power ON; SelfTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 1H - Traction Power Amp #1 Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 1L - Interface Card Detected EPO Switch Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 1T - Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 28 - Excessive Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 29 - No Movement When Travel Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 2A - Traction Motor #1 (left) Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 2F - Regen Circuit #1 Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 2H - Speed Feedback Circuit #1 Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 2N - Brush Wear Indicator, Motor #1 (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 2M - Traction Power Amp #1 (left) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 42 - LPC Contactor Closed When Commanded Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 43 - LPC Contactor Open When Commanded Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 44 - TPC Contactor Closed When Commanded Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 45 - TPC Contactor Open When Commanded Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 4B - STR Contactor Closed When Commanded Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code 4C - STR Contactor Open When Commanded Closed. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 5F - No Comm. From Traction Power Amp #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code 5G - No Comm. From Traction Power Amp #1 (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Code 5H - No Communication From Translator Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code 5K - SPI Communication Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Code 6D - Pressure Sensor Out-Of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Code 6F - Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Code 6U - Lift Motor Brush Wear Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Code 80 - Throttle Controller Reading Out-Of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Code A0 - Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Code AG - Operator Display Comm. Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Code AH - Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Code AJ - Defective ROM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Code AK - Defective RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Code AL - Defective Battery Backed RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Code EC - Operating System Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Code F4 - System Card COP Time-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Code F5 - Bad Op Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Code F6 - Device Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Code F8 - COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Code FG - +12 Volt Power Supply Out-Of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Code FH - Battery Voltage Out-Of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Code G2 - No Steer Position Reference Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Code G7 - No Steer Sensor Signal Input While Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Code H6 - Traction Motor #2 (right) Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Code H9 - Regen Circuit #2 Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Code HB - Speed Feedback Circuit #2 Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Code HE - Brush Wear Indicator, Motor #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Code HF - Traction Power Amp #2 (right) Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Code HK - Traction Power Amp #2 (right) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Code L1 - Forward Direction Switch Closed at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Code L2 - Reverse Direction Switch Closed at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
6-2
Code L3 - Throttle Command With Deadman Input Not Selected . . . . . . . . . . . . . . . . . . . . . . . 6-61

Code L4 - Throttle Command With No Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Code L5 - Throttle Command Too High at Start-up (>4.2V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Code L6 - Throttle Command Too Low At Start-up (<3.0V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Code L7 - Both Forward And Reverse Direction Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Code L8 - Deadman Input On At Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Code L9 - Precharge Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Code LA - Overvoltage During Regen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Code LB - Low Battery Voltage Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
Code LC - Internal Fault, Power Amplifier #1 (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Code R1 - Forward Direction Switch Closed at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Code R2 - Reverse Direction Switch Closed at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Code R3 - Throttle Command With Deadman Input Not Selected . . . . . . . . . . . . . . . . . . . . . . . 6-73
Code R4 - Throttle Command With No Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Code R5 - Throttle Command Too High at Start-up (>4.2V). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Code R6 - Throttle Command Too Low At Start-up (<3.0V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Code R7 - Both Forward And Reverse Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Code R8 - Deadman Input On At Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Code R9 - Precharge Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Code RA - Overvoltage During Regen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Code RB - Low Battery Voltage Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Code RC - Internal Fault, Power Amplifier #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Code RR - Battery Disconnected During Regen/Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Code "Waiting for Precharge" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Analog Tests
Test A05 - Throttle Potentiometer Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Test A06 - Battery Discharge Indicator Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Test A07 - Power Supply +12VDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
Test A08 - FU2 Traction Fuse Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Test A09 - Weight Sensor Voltage (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Input Tests
Test I00 - Deadman Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Test I01 - EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Test I02 - High Speed Limit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
Test I03 - Tilt Up Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
Test I04 - Tilt Down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Test I05 - Sideshift Right Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Test I06 - Sideshift Left Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Test I07 - Lift Limit Mast Switch (optional) Switch 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99
Test I08 - Steer Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100
Test I09 - Spool Valve Switch (S17) (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Test I10 - Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102
Test I11 - FU1 Steering Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Test I12 - FU3 Lift Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
Test I13 - Traction Motor #1 (left) Brush Wear Indicator (both) . . . . . . . . . . . . . . . . . . . . . . . 6-105
Test I14 - Traction Motor #2 (right) Brush Wear Indicator (upper) . . . . . . . . . . . . . . . . . . . . . 6-106
Test I15 - Traction Motor #2 (right) Brush Wear Indicator (lower) . . . . . . . . . . . . . . . . . . . . . 6-107
Test I16 - Lift Motor Brush Wear Indicator (upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
6-3
Test I17 - Lift Motor Brush Wear Indicator (lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109

Test I18 - Traction Motor #1 (left) Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110
Test I19 - Traction Motor #2 (right) Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Test I20 - Traction Motor #1 (left) Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
Test I21 - Traction Motor #2 (right) Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
Test I22 - Lift Motor Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
Test I23 - Lift Switch (S13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115
Test I24 - Lower Switch (S14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116
Test I25 - Attachment Spool Valve Switch (S17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Test I26 - Tilt Limit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Test I27 - TPC_L Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Test I28 - TPC_R Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Test I29 - Left Power Amplifier Switch Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121
Test I30 - Right Power Amplifier Switch Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Output Tests
Test O01 - Toggle the Load Hold (SOL1) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-124
Test O02 - Toggle the Sideshift (SOL2) Solenoid (optional) . . . . . . . . . . . . . . . . . . . . . . .. . . 6-125
Test O04 - Toggle the Tilt (SOL4) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-126
Test O05 - Toggle the Aux PSI Select (SOL5) Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-127
Test O06 - Toggle the Auxiliary Direction A Solenoid (SOL6) . . . . . . . . . . . . . . . . . . . . . .. . . 6-128
Test O07 - Toggle the Equalization (SOL7) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-129
Test O08 - Toggle the Auxiliary Direction B (SOL8) Solenoid . . . . . . . . . . . . . . . . . . . . . .. . . 6-130
Test O09 - Toggle the High Flow Auxiliary (SOL9) Solenoid (Optional). . . . . . . . . . . . . . .. . . 6-131
Test O10 - Toggle the High Flow Attachment 1 (SOL10) Solenoid (Optional) . . . . . . . . . .. . . 6-132
Test O11 - Toggle the High Flow Attachment 2 (SOL11) Solenoid (Optional) . . . . . . . . . .. . . 6-133
Test O12 - Toggle the TPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-134
Test O13 - Toggle the LPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-135
Test O14 - Toggle the STR Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-136
Test O15 - Toggle the AUX Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-137
Test O16 - Ramp the #1 (left) Traction Power Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-138
Test O17 - Ramp the #2 (right) Traction Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-140
Test O18 - Toggle Traction Motor Brake #1 (left). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-142
Test O19 - Toggle Traction Motor Brake #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-143
Test O20 - Ramp the Frequency to the Operator Display Alarm . . . . . . . . . . . . . . . . . . .. . . 6-144
Test O21 - Toggle the Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-145
Test O22 - Toggle the Travel Alarm (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-146
6-4
Message and Code Summary Tables

6: Messages, Codes, and Tests

The following tables summarize informational, performance limiting, and fault codes.
NOTE: The following “Effect” designations are used throughout these tables:
“Effect” Designations
0 0 mph speed limit (coasts) H Load Handler Shutdown R Top Speed Minus 2 mph
1 1 mph speed limit (coasts) I Informational S Steer system shutdown
Acquire speed, configurable Lift system shutdown Traction system shutdown
A from 1.0 mph to max. L T w/o applying brake
speed
Hard Plug until <1 mph then Main lift system shutdown Lowering system shutdown
B M W
dump brake
Traction system derating 2nd stage lift pump Total shutdown
D N X
(Configure) inhibited
Decelerate to config. speed Speed limit Total shutdown w/o
E NI Y
(0 or 1.5 mph) applying brake
Decelerate to 0 speed Minimum Power (Traction Height detection shutdown
F P Z
System)
G Guidance Disabled Q Maximum weight assumed 2.5 2.5 mph speed limit
.
Informational/Performance Limiting Fault Codes

Traction Lift
Brushes Transistor Wrench Temp
Code Condition Effect Motor Motor
Icon Icon Icon Icon
Icon Icon
10 Power on SelfTest 0 On On On On On On
Traction power amp #1 On/
1H I On On
overheated Blink
Emergency power off
1L X Blink
switch detected down
Lift cutout point
configured for Battery
1T L On Blink
State-of-Charge (BSOC)
has been reached
6-5

.
Traction System Fault Codes (Apply to Left Traction Motor and Power Amp #1)
Traction Lift
Icon Icon Icon Icon
Icon Icon
28 Excessive acceleration P Blink
No movement detected
29 P Blink
when travel is requested
Traction Motor #1 On/
2A 2.5 On
overheated Blink
2F Regen Circuit Failure T On On Blink
Failure detected in speed
2H P Blink
feedback circuit #1
Brush Wear Indicator,
2N I/2.5 On On Blink
Motor #1
Traction Power Amplifier
2M T On On Blink
#1 Fault
.
Contactor Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
P (or LPC) contactor
42 detected closed when L On On Blink
commanded open
P (or LPC) contactor
43 detected open when I On On Blink
commanded closed
PC (or TPC) contactor
44 detected closed when T On On Blink
commanded open
PC (or TPC) contactor
45 detected closed when T On On Blink
commanded open
Steer contactor detected
4B closed when commanded I On Blink
open
Steer contactor detected
4C open when commanded T On On Blink
closed
6-6

.
Communications Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
No communications from
5F traction power amp #2 T On On Blink
(right)
5G traction power amp #1 T On On Blink
(left)
5H T On On Blink
translator card
SPI communication
5K X Blink
timeout
.
Lift System Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
Pressure sensor
6D H Blink
out-of-range
Lift motor overheated On/
6F I/L On
Blink
Brush wear indicator, lift
6U I/L On On Blink
motor
.
Operator’s Controls Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
Traction throttle reading
80 T On On Blink
out-of-range
6-7

.
System Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
Incorrect software for
A0 Y On Blink
proper vehicle operation
Communications to
AG 2.5 On Blink
operator display failed
Bad operator display
AH 2.5 On Blink
checksum
AJ Bad ROM checksum Y On Blink
AK Bad RAM checksum Y On Blink
AL Bad NV RAM checksum Y On Blink
.
MTX Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
EC Operating system error Y On Blink
.
Function Controller Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
F4 System card COP timeout Y On Blink
F5 Bad Op code Y On Blink
F6 Device reset Y On Blink
F8 System card COP timeout Y On Blink
+12V Power supply
FG Y On Blink
out-of-range
Battery voltage
FH Y Blink
out-of-range
.
Steering Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
No steer position reference
G2 2.5 Blink
input
Steer encoder-drive wheel
G7 2.5 Blink
speed mismatch
6-8

.
Traction System Fault Codes (Apply to Motor #2 (right) and Power Amp #2)
Traction Lift
Icon Icon Icon Icon
Icon Icon
Traction motor #2 On/
H6 2.5 On
overheated Blink
H9 Regen circuit #2 failure T On On Blink
Motor #2 velocity feedback
HB P Blink
error
Brush wear indicator,
HE I/2.5 On On Blink
motor #2
Power amp #2 overheated On/
HF I On On
Blink
Traction power amplifier
HK T On On Blink
#2 fault
.
Left Power Amp Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
Forward direction switch
L1 T On On On
closed at power-up
Reverse direction closed at
L2 T On On On
power-up
Throttle command with
L3 deadman input not T On On On
selected
Throttle command with no
L4 T On On On
direction selected
Throttle command too
L5 T On On On
high at start-up (>4.2V)
Throttle command too low
L6 T On On On
at start-up (<3.0V)
Both forward and reverse
L7 T On On On
direction selected
Deadman input on at
L8 T On On On
start-up
L9 Precharge failure T On On On
LA Overvoltage during regen T On On On
Low battery voltage
LB T On On On
detected
General fault, power
LC T On On On
amplifier #1
6-9

.
Right Side Power Amp Fault Codes

Traction Lift
Icon Icon Icon Icon
Icon Icon
Forward direction switch
R1 T On On On
closed at power-up
Reverse direction closed at
R2 T On On On
power-up
Throttle command with
R3 deadman input not T On On On
selected
Throttle command with no
R4 T On On On
direction selected
Throttle command too
R5 T On On On
high at start-up (>4.2V)
Throttle command too low
R6 T On On On
at start-up (<3.0V)
Both forward and reverse
R7 T On On On
direction selected
Deadman input on at
R8 T On On On
start-up
R9 Precharge failure T On On On
RA Overvoltage during regen T On On On
Low battery voltage
RB T On On On
detected
General fault, power
RC T On On On
amplifier #2
Battery disconnected
RR during Regen/plugging T On On On
(Battery voltage >45V)
6-10
Messages and Codes
Messages and Codes
6-11
Messages and Codes
Code 10 - Power ON; SelfTest
Code Title Power ON; SelfTest
During power-up, the truck will run through SelfTest to

Reason check internal circuits. After SelfTest is complete, all
systems should be functional.
System Response
Alarm Sounds No
Operator Display SelfTest
Travel PC Contactor Energized
Lift PC Contactor Energized
Performance Limits
Travel System Operational
Lift/Lower System Operational
Attachments Operational
How To Clear This is a status indication only; there is no need to clear.
Tests to Run None
6-12
Messages and Codes
Code 1H - Traction Power Amp #1 Overheated
Code Title Traction Power Amplifier #1 Overheated
Reason The traction power amplifier #1 has overheated.
System Response
Alarm Sounds Yes
Operator Display Code 1H. Overheated, Allow Time to Cool.
Performance Limits
Travel System 2.5 mph speed limit
How To Clear Allow time for power amplifier to cool. Self-resetting.
Tests to Run O14 - Ramp Command to Traction Power Amp #1
NOTE: Code 1H corresponds to GE Amplifier

Code 41.
6-13
Messages and Codes
Code 1L - Interface Card Detected EPO Switch Down
The Interface Card Detected The Emergency Power

Code Title
Off Switch As Down
Reason The emergency power off switch has been depressed.
System Response
Alarm Sounds Yes
Operator Display Code 1L. Lift Emergency Stop Button.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Performance Limits
Travel System Shutdown
Lift/Lower System Shutdown
Attachments Shutdown
Turn key switch OFF, lift emergency off button, then

How To Clear
turn key switch ON to resume operation.
Tests to Run I01 - Emergency Power Off Switch
6-14
Messages and Codes
Code 1T - Battery Low
Code Title Battery Low
Reason Lift cutout point configured for BSOC has been reached.
System Response
Alarm Sounds Yes
Operator Display Code 1T. Battery Low, No Lift.
Performance Limits
Lift/Lower System No lift
How To Clear Change battery. Self resetting.
Tests to Run A06 - Battery Discharge Indicator Voltage
6-15
Messages and Codes
Code 28 - Excessive Acceleration
Code Title Excessive Acceleration
Reason Excessive acceleration detected.
System Response
Alarm Sounds Yes
Operator Display Code 28. Speed limited.
Performance Limits
Travel System Speed limited
How To Clear Cycle the deadman switch.
Tests to Run I18 - Traction Motor #1 Speed Sensor
6-16
Messages and Codes
Code 29 - No Movement When Travel Requested
Code Title No Movement Detected When Travel Is Requested
This code is detected if the following four conditions

occur at the same time for more than two seconds:
• Speed request from throttle is greater than 25%.
Reason • Velocity from the left motor speed sensor is zero.
• The ramp command to the left power amplifier is
greater than 50%.
• No current limit detected from power amplifier #1.
System Response
Alarm Sounds Yes
Operator Display Code 29. Speed limited.
Performance Limits
I18 - Traction Motor #1 (left) Speed Sensor

Tests to Run
O16 - Ramp Command to Traction Power Amp #1 (left)
6-17
Messages and Codes
Code 2A - Traction Motor #1 (left) Overheated
Code Title Traction Motor #1 (left) Overheated
The Interface Card has detected the left traction motor

Reason
has overheated.
System Response
Alarm Sounds Yes
Operator Display Code 2A. Overheated, Allow Time to Cool.
Performance Limits
How To Clear Allow time for the motor to cool. Self resetting.
I20 - Traction Motor #1 (left) Thermostat

Tests to Run
I21 - Traction Motor #2 (right) Thermostat
6-18
Messages and Codes
Code 2F - Regen Circuit #1 Failure
Code Title Failure Detected in Regen Circuit #1
A fault has been detected in the regen circuit by the left

Reason
traction power amplifier.
System Response
Alarm Sounds Yes
Operator Display Code 2F. Not Slowing.
Performance Limits
Tests to Run O16 - Ramp Command to Traction Power Amp #1 (left)
6-19
Messages and Codes
Code 2H - Speed Feedback Circuit #1 Failure
Code Title Failure Detected In Speed Feedback Circuit #1
The speed feedback circuit is not communicating,

Reason
inoperative, or not installed in the truck.
System Response
Alarm Sounds Yes
Operator Display Code 2H. Speed limited.
Performance Limits
I18 - Traction Motor #1 (left) Speed Sensor

Tests to Run
A07 - Power Supply +12VDC
6-20
Messages and Codes
Code 2N - Brush Wear Indicator, Motor #1 (left)
Code Title Brush Wear Indicator, Motor #1 (left)
The switch on traction motor #1 (left) brush wear

Reason
indicator is closed indicating service is required.
System Response
Alarm Sounds Yes
Operator Display Code 2N. Schedule Service.
Performance Limits
How To Clear Replace brushes. Self resetting.
Tests to Run I13 - Traction Motor #1 (left) Brush Wear Indicator (both)
6-21
Messages and Codes
Code 2M - Traction Power Amp #1 (left) Fault
Code Title Traction Power Amplifier #1 (left) Fault
A fault has been detected by the left traction power

Reason
amplifier. TPC_L line at incorrect state.
System Response
Alarm Sounds Yes
Operator Display Code 2M. Traction Shutdown.
Performance Limits

O17 - Ramp Command to Traction Power Amp #2 (right)
Tests to Run
I27 - TPC_L Signal
I28 - TPC_R Signal
Corrective Action:
Reference “Power Amplifier Fault Codes” on
page 5-5.
6-22
Messages and Codes
Code 42 - LPC Contactor Closed When Commanded Open
P (or LPC) Contactor Detected Closed When

Code Title
Commanded Open
A voltage is detected after the pump contactor when it

Reason
was commanded open.
System Response
Alarm Sounds Yes
Operator Display Code 42. Lift Shutdown.
Performance Limits
How To Clear Cycle the key switch OFF/ON.
Tests to Run O13 - Toggle the LPC Contactor
6-23
Messages and Codes
Code 43 - LPC Contactor Open When Commanded Closed
P (or LPC) Contactor Detected Open When

Code Title
Commanded Closed
The correct voltage was not detected after the pump

Reason
contactor when it was commanded closed.
System Response
Alarm Sounds Yes
Operator Display Code 43. Lift Shutdown.
Performance Limits
Lift/Lower System Lift Shutdown
Tests to Run O13 - Toggle the LPC Contactor
6-24
Messages and Codes
Code 44 - TPC Contactor Closed When Commanded Open
PC (or TPC) Contactor Detected Closed When

Code Title
Commanded Open
A voltage is detected after the traction contactor when it

Reason
was commanded open.
System Response
Alarm Sounds Yes
Operator Display Code 44. Drive Shutdown.
Performance Limits
Tests to Run O12 - Toggle the TPC Contactor
NOTE: Code 44 corresponds to GE Amplifier

Code 52.
6-25
Messages and Codes
Code 45 - TPC Contactor Open When Commanded Closed
PC (or TPC) Contactor Detected Open When

Code Title
Commanded Closed
The correct voltage was not detected after the traction

Reason
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run O12 - Toggle the TPC Contactor
NOTE: The following description of fault code NOTE: The TPC contactor is supposed to be
45 applies to trucks using software open when this happens.
version VM 1.7.
A Code 45 means that the TPC contactor What Causes a Code 45:
and/or fuse FU2 is detected open when
The following list should help you identify
commanded closed.
possible error code sources should you
A code 45 is detected when; encounter a Code 45.
• the voltage at the output side of the TPC • The TPC contactor may have failed open.
contactor drops below 20V and the battery • Fuse FU2 may have failed open.
voltage is greater than 22V when the
contactor is supposed to be closed • The Translator Card has failed so that the
amplifiers will not turn off when the TPC
• the voltage at the output side of the TPC contactor is opened.
contactor is 3 or more volts above the
battery voltage and the battery voltage is • The Interface Card has failed so that it
greater than 30V when the contactor is cannot properly read the voltages at the
supposed to be closed TPC contactor.
• the voltage at the output side of the TPC

contactor drops below 20V when the power
amplifiers are first turned on or when they
are being restarted from idle.
6-26
Messages and Codes
Corrective Action:
It is important to determine what conditions
existed when this code occurred.
1. Did the code occur during Regen/plugging?
• Check the battery condition.
• Check Fuse FU2 for continuity.
• Check operation of the TPC contactor to
verify that it remained closed until the
error code was displayed.
NOTE: The TPC contactor will be opened when
the error is detected.
2. Did the error code occur while the truck
was standing idle?
• Check the LEDs on the Translator Card
to verify that the amplifiers are being
told to turn off. After 30 seconds of
inactivity, the TPC contactor should
open. At the same time, the KEY, EPO,
DM, FWD_L, REV_L, FWD_R, and
REV_R LEDs on the Translator Card
should all turn off. If the LEDs do not
turn off, the Translator Card is bad.
• Check the voltage at the output side of
the TPC contactor. It should be approx.
B+. If not, one or more of the power
amplifiers may be bad. Turn the key
switch OFF and disconnect both
amplifiers from the TPC contactor and
place the disconnected leads so that
they will not touch anything. Turn the
truck ON and measure voltage at the
disconnected leads. They should both be
within 2V of B+. Turn the key switch
OFF and time how long it takes for the
voltage at each lead to drop to 5V. It
must take at least 5 seconds for this to
occur.
3. Did the code occur when the deadman
pedal was depressed after the amplifiers
were idle for a significant time period?
• Check the operation of the TPC
contactor to verify that it closed.
• Check Fuse FU2 for continuity.
6-27
Messages and Codes
Code 4B - STR Contactor Closed When Commanded Open
Steer Contactor Detected Closed When Commanded

Code Title
Open
A voltage is detected after the steer contactor when it

Reason
was commanded open.
System Response
Alarm Sounds Yes
Operator Display Code 4B. Schedule Service.
Performance Limits
How To Clear Self resetting.
I11 - FU1 Steering Fuse

Tests to Run
O14 - Toggle the STR Contactor
6-28
Messages and Codes
Code 4C - STR Contactor Open When Commanded Closed
Steer Contactor Detected Open When Commanded

Code Title
Closed
The correct voltage was not detected after the steer

Reason
System Response
Alarm Sounds Yes
Operator Display Code 4C. Drive Shutdown.
Performance Limits
I11 - FU1 Steering Fuse

Tests to Run
O14 - Toggle the STR Contactor
6-29
Messages and Codes
Code 5F - No Comm. From Traction Power Amp #2 (right)
No Communication Received From Traction Power

Code Title
Amplifier #2 (right)
The communication bus signal from traction power

Reason
amplifier #2 (right) is missing or incorrect.
System Response
Alarm Sounds Yes
Operator Display Code 5F. Drive Shutdown.
Performance Limits
Tests to Run None
Corrective Action:
1. Turn the key switch OFF and disconnect
the battery.
2. Check the wiring from the Translator Card
to power amplifier #1 and power amplifier
#2. Then, check the wiring from the
Translator Card to the Interface Card.
Repair as necessary.
3. Swap traction power amplifier #1 and #2. If
the code changes, replace the bad power
amplifier.
4. Replace the Translator Card.
5. If no wiring faults are found, replace the
Interface Card.
6-30
Messages and Codes
Code 5G - No Comm. From Traction Power Amp #1 (left)
No Communications Received From Traction Power

Code Title
Amplifier #1 (left)
The communication bus signal from traction power

Reason
amplifier #1 (left) is missing or incorrect.
System Response
Alarm Sounds Yes
Operator Display Code 5G. Drive Shutdown.
Performance Limits
Tests to Run None
Corrective Action:
1. Turn the key switch OFF and disconnect
the battery.
2. Check the wiring from the Translator Card
to the Interface Card. Then, check the
wiring from the Translator Card to power
amplifier #1 and power amplifier #2.
3. Swap traction power amplifier #1 and #2. If
the code changes, replace the power
amplifier.
4. Replace the Translator Card,
5. If no wiring faults are found, replace the
Interface Card.
6-31
Messages and Codes
Code 5H - No Communication From Translator Card
Code Title No Communication From Translator Card
The communication signal from the Translator Card is

Reason
missing or incorrect.
System Response
Alarm Sounds Yes
Operator Display Code 5H. Drive Shutdown.
Performance Limits
Tests to Run None
Corrective Action:
Check the wiring from the Translator Card to
the Interface Card. Repair or replace as
necessary.
6-32
Messages and Codes
Code 5K - SPI Communication Timeout
Code Title SPI Communication Timeout
A fault has been detected by the right traction power

Reason
amplifier.
System Response
Alarm Sounds Yes
Operator Display Code 5K. Shutdown.
Performance Limits
Tests to Run None
6-33
Messages and Codes
Code 6D - Pressure Sensor Out-Of-Range
Code Title Pressure Sensor Out-Of-Range
Reason The pressure sensor out-of-range.
System Response
Alarm Sounds Yes
Operator Display Code 6D. Aux Shutdown.
Performance Limits
A07 - Power Supply +12 VDC

Tests to Run
A09 - Weight Sensor Voltage
6-34
Messages and Codes
Code 6F - Lift Motor Overheated
Code Title Lift Motor Overheated
The Interface Card has detected that the lift motor has
Reason
overheated.
System Response
Alarm Sounds Yes
Operator Display Code 6F. Lift Shutdown.
Performance Limits
Lift/Lower System Lift system shutdown, Lower only
How To Clear Allow time to cool. Self resetting.
Tests to Run I22 - Lift Motor Thermostat
6-35
Messages and Codes
Code 6U - Lift Motor Brush Wear Indicator
Code Title Brush Wear Indicator, Lift Motor
The switch on the lift motor brush wear indicator is

Reason
closed, indicating service is required.
System Response
Alarm Sounds Yes
Operator Display Code 6U. Schedule Service.
Performance Limits
I16 - Lift Motor Brush Wear Indicator (upper)

Tests to Run
I17 - Lift Motor Brush Wear Indicator (lower)
6-36
Messages and Codes
Code 80 - Throttle Controller Reading Out-Of-Range
Code Title Traction Throttle Reading Out-Of-Range
Throttle potentiometer voltage is out-of-range. Results in

Reason
total shutdown without applying the brake.
System Response
Alarm Sounds Yes
Performance Limits
The control potentiometer needs to be returned to within

How To Clear
its limits. Self resetting.
A05 - Throttle Potentiometer Voltage

Tests to Run
6-37
Messages and Codes
Code A0 - Incorrect Software
Code Title Incorrect Software For Proper Vehicle Operation
Software has been detected that is not correct for this

Reason
vehicle.
System Response
Alarm Sounds Yes
Operator Display Code A0. Shutdown.
Performance Limits
Tests to Run None
Corrective Action:
1. Check the Firmware version by using the
operator display. If the display shows 0.0 or
the incorrect version, obtain new Firmware
from Mitsubishi Caterpillar Forklift America
Inc.
2. If the proper Firmware version appears on
the operator display, replace the Interface
Card.
6-38
Messages and Codes
Code AG - Operator Display Comm. Failure
Code Title Communications To/From Operator’s Display Failed
Serial communications from the operator display has

Reason
failed or is incorrect.
System Response
Alarm Sounds Yes
Operator Display Code AG. Speed limited.
Performance Limits
Tests to Run None
Corrective Action:
1. Check the continuity of the cable from the
Interface Card (JC5) to the operator display
(JD1). Repair or replace as necessary.
2. The operator display may be bad.
3. The Interface Card may be bad.
6-39
Messages and Codes
Code AH - Bad Operator Display Checksum
Code Title Bad Operator Display Checksum
The software checksum in the display does not match

Reason
the one in the Interface Card.
System Response
Alarm Sounds Yes
Operator Display Code AH. Speed limited.
Performance Limits
Tests to Run None
Corrective Action:
1. Check the Firmware version by using the
operator display. If the display shows 0.0 or
an incorrect version, obtain new Firmware
from Mitsubishi Caterpillar Forklift America
Inc.
2. If the proper firmware version appears on
the operator display, replace the operator
display.
6-40
Messages and Codes
Code AJ - Defective ROM Memory
Code Title Bad ROM Checksum
Reason The ROM memory test during start-up has failed.
System Response
Alarm Sounds Yes
Operator Display Code AJ. ROM check failure.
Performance Limits
Tests to Run A07 - Power Supply +12 VDC
Corrective Action:
If the power supply voltage is correct, replace
the Interface Card.
6-41
Messages and Codes
Code AK - Defective RAM Memory
Code Title Bad RAM Checksum
Reason The RAM memory test during start-up has failed.
System Response
Alarm Sounds Yes
Operator Display Code AK. RAM check failure.
Performance Limits
Tests to Run A07 - Power Supply +12 VDC
Corrective Action:
If the power supply voltage is correct, replace
the Interface Card.
6-42
Messages and Codes
Code AL - Defective Battery Backed RAM Memory
Code Title Bad Non-Volatile RAM Checksum
The Non-Volatile (NV) RAM memory test during start-up

Reason
has failed.
System Response
Alarm Sounds Yes
Operator Display Code AL. NV RAM check failure.
Performance Limits
Tests to Run None
Corrective Action:
Replace the Interface Card.
6-43
Messages and Codes
Code EC - Operating System Error
Code Title Operating System Error
Reason A fault has been detected in the operating system.
System Response
Alarm Sounds Yes
Operator Display Code EC. Shutdown.
Performance Limits
Tests to Run None
Corrective Action:
6-44
Messages and Codes
Code F4 - System Card COP Time-Out
Code Title System Card COP Time-out
The COP circuit has timed out before a reset was

Reason
generated.
System Response
Alarm Sounds Yes
Operator Display Code F4. Shutdown.
Performance Limits
Tests to Run None
Corrective Action:
6-45
Messages and Codes
Code F5 - Bad Op Code
Code Title Bad Op Code
Bad code was detected during SelfTest. Results in total

Reason
shutdown without applying the brake.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None
Corrective Action:
6-46
Messages and Codes
Code F6 - Device Reset
Code Title Device Reset
Reason An Interface Card reset has occurred.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run A07 - Power Supply +12VDC
Corrective Action:
If the power supply test shows the correct
voltage, replace the Interface Card.
6-47
Messages and Codes
Code F8 - COP Not Enabled
Code Title System Card COP Time-0ut
Reason Interface Card COP not enabled.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None
Corrective Action:
6-48
Messages and Codes
Code FG - +12 Volt Power Supply Out-Of-Range
Code Title +12 Volt Power Supply Out-Of-Range
Reason The +12V power supply voltage is out-of-range.
System Response
Alarm Sounds Yes
Operator Display Code FG. Shutdown.
Performance Limits
Tests to Run A07 - Power Supply +12VDC
6-49
Messages and Codes
Code FH - Battery Voltage Out-Of-Range
Code Title Battery Voltage Out-Of-Range
Reason Battery voltage was detected out-of-range.
System Response
Alarm Sounds Yes
Operator Display Code FH. Check Battery.
Performance Limits
Tests to Run A06 - Battery Discharge Indicator Voltage
6-50
Messages and Codes
Code G2 - No Steer Position Reference Input
Code Title No Steer Position Reference Input
Reason No steer position reference input was detected.
System Response
Alarm Sounds Yes
Operator Display Code G2. Speed limited.
Performance Limits
Tests to Run I08 - Steer Position Sensor
6-51
Messages and Codes
Code G7 - No Steer Sensor Signal Input While Driving
Code Title No Steer Sensor Signal Input While Driving
No pulses are being sent from the steer position sensor

Reason to the Interface Card when there are large differences
in the traction motor speeds.
System Response
Alarm Sounds Yes
Operator Display Code G3. Speed limited.
Performance Limits
I08 - Steer Position Sensor

Tests to Run I18 - Traction Motor #1 (left) Speed Sensor
I19 - Traction Motor #2 (right) Speed Sensor
6-52
Messages and Codes
Code H6 - Traction Motor #2 (right) Overheated
Code Title Traction Motor #2 (right) Overheated
The Interface Card has detected that the right traction

Reason
motor has overheated.
System Response
Alarm Sounds Yes
Operator Display Code H6. Overheated, Allow time to cool.
Performance Limits
How To Clear Allow time to cool. Self resetting.
I21 - Traction Motor #2 (right) Thermostat

Tests to Run
I20 - Traction Motor #1 (left) Thermostat
6-53
Messages and Codes
Code H9 - Regen Circuit #2 Failure
Code Title Regen Circuit #2 Failure
Reason A failure has been detected in regen circuit #2.
System Response
Alarm Sounds Yes
Operator Display Code H9. Drive Shutdown.
Performance Limits
How To Clear Cycle key switch ON/OFF.
Tests to Run O17 - Ramp Command to Traction Power Amp #2 (Right)
6-54
Messages and Codes
Code HB - Speed Feedback Circuit #2 Failure
Code Title Failure Detected In Speed Feedback Circuit #2
The speed feedback circuit is not communicating, is

Reason
inoperative, or not installed in the truck.
System Response
Alarm Sounds Yes
Operator Display Code HB. Speed limited.
Performance Limits
I19 - Traction Motor #2 (right) Speed Sensor

Tests to Run
6-55
Messages and Codes
Code HE - Brush Wear Indicator, Motor #2 (right)
Code Title Brush Wear Indicator, Traction Motor #2 (right)
The switch on traction motor #2 (right) brush wear

Reason
indicator is closed indicating service is required.
System Response
Alarm Sounds Yes
Operator Display Code HE. Schedule Service.
Performance Limits
How To Clear Replace brushes. Self resetting.
I14 - Traction Motor #2 Brush Wear Indicator (upper)

Tests to Run
I15 - Traction Motor #2 Brush Wear Indicator (lower)
6-56
Messages and Codes
Code HF - Traction Power Amp #2 (right) Overheated
Code Title Traction Power Amplifier #2 (right) Overheated
The temperature reading from power amplifier #2

Reason
indicates overheating.
System Response
Alarm Sounds Yes
Operator Display Code HF. Speed limited.
Performance Limits
How To Clear Allow time for the power amplifier to cool. Self resetting.
Tests to Run None
NOTE: Code HF corresponds to GE Amplifier

Code 41.
6-57
Messages and Codes
Code HK - Traction Power Amp #2 (right) Fault
Code Title Traction Power Amplifier #2 (right) Fault
Reason A fault has been detected by the power amplifier.
System Response
Alarm Sounds Yes
Operator Display Code HK. Traction Shutdown.
Performance Limits

Tests to Run
I28 - TPC_R Signal
I27 - TPC_L Signal
Corrective Action:
Reference “Power Amplifier Fault Codes” on
page 5-5.
6-58
Messages and Codes
Code L1 - Forward Direction Switch Closed at Power-up
Code Title Forward Direction Switch Closed at Power-up
The switch for forward direction was detected closed

Reason
during power-up.
System Response
Alarm Sounds Yes
Operator Display Code L1. Drive Shutdown.
Performance Limits
Tests to Run I29 - Left Power Amp Switch Inputs
NOTE: Code L1 corresponds to GE Amplifier

Code 2.
6-59
Messages and Codes
Code L2 - Reverse Direction Switch Closed at Power-up
Code Title Reverse Direction Switch Closed at Power-up
The switch for reverse direction was detected closed

Reason
during power-up.
System Response
Alarm Sounds Yes
Performance Limits

Code 3.
6-60
Messages and Codes
Code L3 - Throttle Command With Deadman Input Not Selected
Throttle Command With Deadman Input Not

Code Title
Selected
A throttle command was detected without a deadman

Reason
input.
System Response
Alarm Sounds Yes
Performance Limits

Code 5.
6-61
Messages and Codes
Code L4 - Throttle Command With No Direction Selected
Code Title Throttle Command With No Direction Selected
A throttle command was detected with no direction

Reason
selected.
System Response
Alarm Sounds Yes
Performance Limits

Code 6.
6-62
Messages and Codes
Code L5 - Throttle Command Too High at Start-up (>4.2V)
Code Title Throttle Command Too High At Start-up (>4.2V)
The throttle command was out-of-range (>4.2V) during

Reason
start-up.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None

Code 7.
6-63
Messages and Codes
Code L6 - Throttle Command Too Low At Start-up (<3.0V)
Code Title Throttle Command Too Low At Start-up (<3.0V)
The throttle command was out-of-range (<3.0V) during

Reason
start-up.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None

Code 8.
6-64
Messages and Codes
Code L7 - Both Forward And Reverse Direction Selected
Code Title Both Forward And Reverse Directions Selected
Reason Forward and reverse travel has been requested.
System Response
Alarm Sounds Yes
Performance Limits

Code 9.
6-65
Messages and Codes
Code L8 - Deadman Input On At Start-up
Code Title Deadman Input ON At Start-up
Reason The deadman input was detected ON at start-up.
System Response
Alarm Sounds Yes
Performance Limits

Code 11.
6-66
Messages and Codes
Code L9 - Precharge Failure
Code Title Precharge Failure
Reason The power amplifier failed to precharge.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None

Code 51.
6-67
Messages and Codes
Code LA - Overvoltage During Regen
Code Title Overvoltage During Regen
Reason Voltage was detected out-of-range during regen.
System Response
Alarm Sounds Yes
Operator Display Code LA. Drive Shutdown.
Performance Limits
Tests to Run Check battery condition and connections.
NOTE: Code LA corresponds to GE Amplifier

Code 76.
6-68
Messages and Codes
Code LB - Low Battery Voltage Detected
Code Title Low Battery Voltage Detected
Reason Low battery voltage has been detected.
System Response
Alarm Sounds Yes
Operator Display Code LB. Drive Shutdown.
Performance Limits
Tests to Run Check battery condition.
NOTE: Code LB corresponds to GE Amplifier

Code 81.
6-69
Messages and Codes
Code LC - Internal Fault, Power Amplifier #1 (left)
Code Title Internal Fault
Reason A general fault has occurred in power amplifier #1 (left).
System Response
Alarm Sounds Yes
Operator Display Code LC. Drive Shutdown.
Performance Limits

Tests to Run
NOTE: Code LC corresponds to GE Amplifier

Codes 10, 12, 15, 16, 17, 23, 24, 27, 28,
42, 43, 44, 45, 46, 57, 77, and 80.
6-70
Messages and Codes
Code R1 - Forward Direction Switch Closed at Power-up
Code Title Forward Direction Switch Closed at Power-up
The switch for forward direction was detected closed

Reason
during power-up.
System Response
Alarm Sounds Yes
Operator Display Code R1. Drive Shutdown.
Performance Limits
Tests to Run I30 - Right Power Amplifier Switch Inputs
NOTE: Code R1 corresponds to GE Amplifier

Code 2.
6-71
Messages and Codes
Code R2 - Reverse Direction Switch Closed at Power-up
Code Title Reverse Direction Switch Closed at Power-up
The switch for reverse direction was detected closed

Reason
during power-up.
System Response
Alarm Sounds Yes
Performance Limits

Code 3.
6-72
Messages and Codes
Code R3 - Throttle Command With Deadman Input Not Selected
Throttle Command With Deadman Input Not

Code Title
Selected
A throttle command was detected without a deadman

Reason
input.
System Response
Alarm Sounds Yes
Performance Limits

Code 5.
6-73
Messages and Codes
Code R4 - Throttle Command With No Direction Selected
Code Title Throttle Command With No Direction Selected
A throttle command was detected with no direction

Reason
selected.
System Response
Alarm Sounds Yes
Performance Limits

Code 6.
6-74
Messages and Codes
Code R5 - Throttle Command Too High at Start-up (>4.2V)
Code Title Throttle Command Too High At Start-up (>4.2V)
The throttle command was out-of-range (>4.2V) during

Reason
start-up.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None

Code 7.
6-75
Messages and Codes
Code R6 - Throttle Command Too Low At Start-up (<3.0V)
Code Title Throttle Command Too Low At Start-up (<3.0V)
The throttle command was out-of-range (<3.0V) during

Reason
start-up.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None

Code 8.
6-76
Messages and Codes
Code R7 - Both Forward And Reverse Direction Selected
Code Title Both Forward And Reverse Directions Selected
Reason Forward and reverse travel has been requested.
System Response
Alarm Sounds Yes
Performance Limits

Code 9.
6-77
Messages and Codes
Code R8 - Deadman Input On At Start-up
Code Title Deadman Input ON At Start-up
Reason The deadman input was detected ON at start-up.
System Response
Alarm Sounds Yes
Performance Limits

Code 11.
6-78
Messages and Codes
Code R9 - Precharge Failure
Code Title Precharge Failure
Reason The power amplifier failed to precharge.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None

Code 51.
6-79
Messages and Codes
Code RA - Overvoltage During Regen
Code Title Overvoltage During Regen
Reason Voltage was detected out-of-range during Regen.
System Response
Alarm Sounds Yes
Operator Display Code RA. Drive Shutdown.
Performance Limits
Tests to Run Check battery condition and connections.
NOTE: Code RA corresponds to GE Amplifier

Code 76.
6-80
Messages and Codes
Code RB - Low Battery Voltage Detected
Code Title Low Battery Voltage Detected
Reason Low battery voltage has been detected.
System Response
Alarm Sounds Yes
Operator Display Code RB. Drive Shutdown.
Performance Limits
Check battery condition.

Tests to Run
A06 - Battery Discharge Indicator Voltage
NOTE: Code RB corresponds to GE Amplifier

Code 81.
6-81
Messages and Codes
Code RC - Internal Fault, Power Amplifier #2 (right)
Code Title Internal Fault
A general fault has occurred in power amplifier #2

Reason
(right).
System Response
Alarm Sounds Yes
Operator Display Code RC. Drive Shutdown.
Performance Limits

Tests to Run
NOTE: Code LC corresponds to GE Amplifier

Codes 10, 12, 15, 16, 17, 23, 24, 27, 28,
42, 43, 44, 45, 46, 57, 77, and 80.
6-82
Messages and Codes
Code RR - Battery Disconnected During Regen/Plugging
Code Title Battery Disconnected During Regen/Plugging
The Battery was disconnected during Regen/plugging.

Reason
Battery voltage was detected at 45V or higher.
System Response
Alarm Sounds Yes
Operator Display Code RR. Drive Shutdown.
Performance Limits
Check battery connector.

Tests to Run
A06 - Battery Discharge Indicator Voltage
6-83
Messages and Codes
Code "Waiting for Precharge"
Code Title Waiting for Precharge
The capacitor charge voltage in the power amplifier has

Reason
not reached a minimum of 32V during start-up.
System Response
Alarm Sounds No
Operator Display Waiting for Precharge
Performance Limits
Troubleshoot the problem. Cycle the key switch

How To Clear
ON/OFF.
Tests to Run A08 - FU2 Traction Fuse Voltage
6-84
Analog Tests
6:snMessages, Codes, and Tests
Analog Tests
! WARNING
Do not disconnect energized circuits
while running the following tests. If the
circuits are disconnected while
energized, permanent damage to the
electrical system could occur.
6-85
Analog Tests
Test A05 - Throttle Press Enter to run test:

Potentiometer Voltage 1. Running Learn for the controls may make
the code disappear.
This test measures the voltage from the
forward/reverse throttle potentiometer in the 2. Move the control handle into the different
control handle. positions listed in the table above and
check the operator display for the correct
voltage. When observing the voltage on the
Related messages, codes, and tests operator display, the values should change
• Code 80 - Traction Throttle Reading smoothly and evenly as the control handle
Out-of-Range is moved from full forks-first position to full
tractor-first position.
3. If the readings on the operator display are
! WARNING outside of the voltage range listed in the
table, the test has failed.
Jack the drive tires off the floor before
conducting this test. See Jacking Safety Diagnosis and Repair
on page 2-14.
! CAUTION
! CAUTION Observe proper ESD precautions. See
The current in the armature should not Static Precautions on page 2-12.
exceed 50A for more than 10 seconds or
100A for more than 5 seconds without NOTE: If the throttle potentiometer is replaced,
field excitation. Learn will need to be run on the truck
for controls.
Limits: 1. Check connection JPC6. It may be loose or
disconnected from the Interface Card.
• The following table displays the voltage
range that should be present on the 2. The throttle potentiometer may be bad.
operator display at corresponding control Using an ohmmeter, the potentiometer
handle positions. should read approx. 2000 ohms from
PC6-15 to PC6-13 when the handle is in the
neutral position.
Control Handle
Voltage Range
Position 3. The Interface Card may be bad. Replace as
Full forks-first 1.1 to 2.0V necessary.
Neutral 2.0 to 3.0V

Full tractor-first 3.0 to 3.9V
• When JPC6 is disconnected, 5.0V should be

present on the operator display.
6-86
Analog Tests
Test A06 - Battery Discharge

Indicator Voltage
This test measures the voltage used to calculate
the battery state of charge.
Related messages, codes, and tests

• Code 1T - Lift Cutout Point Configured For
BSOC Has Been Reached.
Press Enter to run test:

1. The battery voltage as shown on the
operator display should be 32 to 39VDC.
2. If the numbers displayed are not in this
range, the test has failed.
Diagnosis and Repair

1. If the voltage is steady, but out-of-range,
check the battery with a voltmeter. The
battery may need servicing.
2. The wiring from the key switch may need
servicing. Repair or replace as necessary.
3. The key switch may be bad. Replace as
necessary.
4. The Interface Card may be bad. Replace as
necessary.
6-87
Analog Tests
Test A07 - Power Supply

+12VDC
This test measures the +12V Power Supply
Voltage.

• Code FG - +12V Power Supply
Out-of-Range.
Limits:
• +11 ±0.5V. If the operator display does not
read within these limits, the test has failed.

The operator display will show voltage
measured.
! CAUTION
Observe proper ESD precautions. See
Static Precautions on page 2-12.
1. Connect the (+) lead of a voltmeter to

JPC5-1 and the (-) lead to TP4 (B-). With the
key ON, the meter should show approx.
10.5V.
If it does not, or the operator display is
dark, turn the key switch OFF, disconnect
all connectors from the Interface Card
except the operator display (JPC5) and
B+Key (JPC8).
If the display lights up, then one of the
disconnected components is dragging the
12V supply down.
2. The cable from the Interface Card to the
operator display may be bad. Repair or
replace as necessary.
3. The power supply in the Interface Card may
be bad. Replace the Interface Card as
necessary.
6-88
Analog Tests
Test A08 - FU2 Traction Fuse

Voltage
This test measures voltage at Fuse FU2.

None.

1. If FU2 is visually good and the TPC
contactor is closed then the operator
display should read battery voltage when
run.
2. If the operator display shows 0V then either
the TPC contactor is open or Fuse FU2 is
bad.
3. If the operator display shows 0V and the
TPC contactor is closed, then Fuse FU2 is
bad.
6-89
Analog Tests
Test A09 - Weight Sensor 2. As weight is added to the forks, the voltage
should increase and the value indicated on
Voltage (optional) the operator display should also increase. If
the voltage increases on the voltmeter but
This test measures the voltage from the
not on the Operator Display, replace the
pressure sensor used for load weight sensing.
Interface Card.
3. If neither the meter nor the display value
changes, replace the pressure sensor.
• Code A07 - Power Supply +12VDC 4. If the weight and voltage indicated are both
low, the 12V supply to the sensor may be
low. Connect a voltmeter to JPC11-4 (+) and
! CAUTION JPC11-2 (-). If it is less than 11.5V,
Use extreme caution when working troubleshoot using Test A07.
near the elevated forks.
Limits:
• The operator display shows the voltage
present with various load weights.
Load Weight Voltage

0 (no load) 1V
5000 lb. 5V
• If the weight sensor is disconnected at the

Interface Card, the operator display will
show 0V.

The voltage shown on the operator display
should increase and decrease linearly as the
load weight is either increased or decreased. If it
does not, the test has failed.
! CAUTION
1. Connect a voltmeter to JPC11-3 (+) and

JPC11-2 (-). With no weight on the forks,
the voltmeter should indicate approx. 1.0V.
6-90
Input Tests
Input Tests
! WARNING
Do not disconnect energized circuits
while running the following tests. If the
circuits are disconnected while
energized, permanent damage to the
electrical system could occur.
6-91
Input Tests
Test I00 - Deadman Switch Diagnosis and Repair
This test is used to observe the ON/OFF signal

from the deadman switch. ! CAUTION
Related messages, codes, and tests Static Precautions on page 2-12.
None.
1. Verify proper operation of the deadman
switch (S2) by removing the pedal
assembly.
! WARNING
2. The cable from the Interface Card to the
Do not conduct this test on a ramp. deadman switch (JPC7-S2) may not be
working properly. Check it for continuity.
Press Enter to run test: 3. The switch may not be working properly.
The following table indicates the correct 4. Carefully jumper pins JPC7-16 and
message that should appear on the operator JPC7-5. If the display changes, the switch
display during this test. or circuit is bad. Remove the jumper when
the test is complete.
Operator Operator 5. If the display does not change, replace the
Action Display Message Interface Card.
Off deadman OFF
On deadman ON
If the display does not change when the pedal is

depressed, the test has failed.
6-92
Input Tests
Test I01 - EPO Switch Diagnosis and Repair
This test is to observe the ON/OFF signal from

the EPO switch. ! CAUTION
• Code 1L - Emergency Power Off (EPO)

Switch Detected Down. 1. Turn the key switch OFF and disconnect
the battery.
2. Check continuity of switch S21.
! CAUTION
3. Check continuity of the wiring from S21-2
Opening the EPO switch will open the to JC8-6 and from S21-1 to JC8-11. Repair
TPC and LPC contactors. All traction and or replace wiring as necessary.
lift control will cease.
4. Contactor fuse panel may be bad. Repair or
Press Enter to run test: 5. Interface Card may be bad. Repair or
Use the following table as a guideline for this replace as necessary.
test.
Operator Switch EPO

EPO
Display S21 Switch
Button
Message Position Resistance
Up
Out OFF <0.5 ohms
(closed)
Down
In ON Infinite
(open)
If the display does not change when the switch

is depressed, the test has failed.
6-93
Input Tests
Test I02 - High Speed Limit Diagnosis and Repair

Switch (optional)
This test is to observe ON/OFF signal from the
! CAUTION
high speed limit switch (if installed). Observe proper ESD precautions. See
1. Check the mechanical operation of the
• Code A07- Power Supply +12VDC switch (S11).
Interface Card (JC12) to the switch (JS5).
! WARNING Repair or replace as necessary.
Do not attempt high speeds during this 3. Using a voltmeter, measure the 12V supply
test. Speed limiting while elevated may to the switch (+) JS5-1, (-) JS5-3. If the 12V
be defeated during this test. supply is out-of-range (>11.5V), run the
12V power supply test (Test A07).
4. Jumper from JS5-2 to JS5-3. If the display
! CAUTION changes, replace the switch. If the display
Use extreme caution when working does not change, replace the Interface
around an elevated mast. Card.

The following table indicates the correct
messages on the operator display for this test.
Operator Display
Mast Position
Message
Lowered ON
Raised OFF
6-94
Input Tests
Test I03 - Tilt Up Switch

the tilt up switch in the control handle.

• Test O06 - Toggle the Tilt Solenoid (SOL4)

If the display does not change when the tilt up
switch is depressed, the test has failed.
! CAUTION
1. Carefully jumper from connection JC6-3 to

JC6-14 on the Interface Card. If the display
changes, the switch or wiring is bad. If the
display does not change, replace the
Interface Card.
2. Use an ohmmeter to check for continuity at
PC6-3 and PC6-14. With the switch closed,
the meter should show 0 ohms. With the
switch open, the meter should show infinite
resistance. If the meter reads out-of-range,
repair or replace the switch or wiring as
necessary.
6-95
Input Tests
Test I04 - Tilt Down Switch

the tilt down switch in the control handle.

• Test O06 - Toggle the Tilt Solenoid (SOL4)

If the display does not change when the tilt
down switch is depressed, the test has failed.
! CAUTION

changes, then the switch or wiring is bad. If
the display does not change, replace the
Interface Card.
necessary.
6-96
Input Tests
Test I05 - Sideshift Right Switch

(optional)
the sideshift right switch in the control handle.
NOTE: This option must be configured on the
truck for this test to work.

• O05 - Toggle the Sideshift (SOL2) Solenoid

If the display does not change when the
sideshift right switch is depressed, the test has
failed.
! CAUTION

changes, the switch or wiring is bad. If the
display does not change, replace the
Interface Card.
2. Check for continuity with an ohmmeter at
necessary.
6-97
Input Tests
Test I06 - Sideshift Left Switch

(optional)
the sideshift left switch in the control handle.

• O05 - Toggle the Sideshift (SOL2) Solenoid

If the display does not change when the
sideshift left switch is depressed, the test has
failed.
! CAUTION

changes, then the switch or wiring is bad. If
Interface Card.
necessary.
6-98
Input Tests
Test I07 - Lift Limit Mast Switch Diagnosis and Repair

(optional) Switch 12
! CAUTION
the lift limit mast switch. Observe proper ESD precautions. See
1. Using an ohmmeter, check the cable from
the Interface Card (JC12) to the lift limit
Related messages, codes, and tests switch (JS6) for continuity. Repair or
None. replace as necessary.
2. Using a voltmeter, check for approx. 11.5V
at JPC12-4 (+) and JPC12-2 (-). If approx.
! WARNING 11.5V is not seen, troubleshoot the power
supply using Test A07.
Lifting should only be done in an area
with a ceiling height greater than the 3. Carefully connect a jumper from JPC12-5
to JPC12-2. If the display changes, replace
truck’s maximum elevated height.
the switch. If the display does not change,
replace the Interface Card.
! CAUTION
Use extreme caution when working
around an elevated mast.

messages on the operator display for this test.
Operator Display
Mast Position
Message
Lowered ON
Raised OFF
If the display does not change when the lift limit

switch is closed, the test has failed.
NOTE: This test will only show on the display if
the option is turned ON.
6-99
Input Tests
Test I08 - Steer Position Sensor Diagnosis and Repair
This test is to observe the binary signal (BCD)

from the steer position sensor. ! CAUTION
• Code G2 - No Steer Position Reference

Input 1. The cable from the Interface Card to the
steer position sensor (JC7 to JS2) may be
• Code G3 - No Steer Sensor Signal While bad. Check for shorts and continuity.
Driving Repair or replace the cable as necessary.
2. To see if the steer position prox switch is
working properly, check the switch to make
! WARNING sure it shows no visible signs of damage.
Jack the steer tire off the floor before Replace any damaged components.
conducting this test. See Jacking Safety 3. Hook the (+) lead of a voltmeter to JPC7-17
on page 2-14. and the (-) lead to TP4 (B-).
4. Place a steel object such as a screwdriver
over the bottom of the prox switch.
! CAUTION
When the metal object is over the bottom of
Steer tire rotation is opposite that of the
the prox switch, the voltmeter should read
steer tiller. less than 2V.
When the metal object is taken away from
Press Enter to run test: the bottom of the prox switch, the voltmeter
should read more than 7V.
Press Enter on the operator display and step on
the deadman pedal. As the steer tire rotates, the If the above two conditions are not met,
numbers listed below appear on the display. If replace the prox switch.
they do not change or are erratic, the test has 5. Now connect the (+) lead of the voltmeter to
failed. JPC7-18 and repeat step 4. The results
should be the same.
Steer Tire Position Operator Display 6. Now connect the (+) lead of the voltmeter to
(±2°) Message JPC7-8 and repeat step 4. The results
90° (full clockwise) to should be the same.
101
66°
7. If steps 5 and 6 pass, replace the Interface
65° to 40° 100 Card.
39° to 14° 000
13° to -15°
001
(wheels centered)
-16° to -45° 011
-46° to -76° 010
-90°
(counterclockwise) 110
to -77°
Error Condition 111
6-100
Input Tests
Test I09 - Spool Valve Switch

(S17) (optional)
the attachment control lever switch that is
mounted on the top of the auxiliary manifold.

None.

1. Use the following table as a guideline.
Switch Operator Display

Position Message
Depressed ON
Released OFF
2. If the display does not change when the


1. Check to make sure that switch S17 is
mechanically functioning.
2. Replace the suspect switch with a new
switch and repeat this test.
3. If test fails, troubleshoot wiring.
6-101
Input Tests
Test I10 - Horn Switch

Horn switch in the operator’s control handle.

None.

Horn Switch Operator Display

Position Message
Depressed ON
Released OFF

NOTE: When connecting jumpers, use caution
and connect correct pins.

mechanically functioning. Replace as
necessary or repair wiring.
2. Remove connector JPC6 from the Interface
Card. With an ohmmeter, check the
continuity from PC6-7 to PC6-14. When the
switch is depressed, the ohmmeter should
show 0 ohms. When the switch is released,
the meter should show infinite resistance.
3. Carefully connect a jumper from JC6-7 to
JC6-14. With the jumper installed, the
display should indicate ON. With the
jumper removed, the display should show
OFF. If this is not observed, replace the
Interface Card.
6-102
Input Tests
Test I11 - FU1 Steering Fuse 3. FU1 sense may be disconnected or broken.
Check continuity from JC8-9 to STR-2 and
This test is to measure the absence or presence repair or replace as necessary.
of B+ voltage at the load side of the Steer Motor 4. The deadman switch may not be working
(STR) contactor. properly. Run test I00.
5. The STR contactor tips may be burned or
Related messages, codes, and tests open.
• Test O02 - Toggle the STR Contactor 6. The Interface Card may be bad. Replace as
• Code G2 - No Steer Position Reference necessary.
Input
• Test I00 - Deadman Switch
! CAUTION
When this test is activated and the
deadman pedal is depressed, the steer
motor/pump will activate.

NOTE: The deadman pedal must be depressed
for this test to function.
Use the following table as a guideline.
B+ Voltage Operator Display

Status Message
B+ present ON
B+ absent OFF
If the display message does not change when

the test is activated, the test has failed.
! CAUTION
1. FU1 may be bad. Remove and test. Replace

as necessary.
2. The connections at FU1 may be corroded or
loose. Clean and retighten as necessary.
6-103
Input Tests
Test I12 - FU3 Lift Fuse Diagnosis and Repair
This test is to measure the absence or presence

of B+ voltage at the load side of the lift motor ! CAUTION
(LPC) contactor. Observe proper ESD precautions. See
• Test O13 - Toggle the LPC Contactor 1. FU3 may be bad. Remove and test. Replace
as necessary.
• Test I00 - Deadman Switch
2. The connections at FU3 may be corroded or
loose. Clean and retighten as necessary.
! WARNING 3. FU3 sense may be disconnected or broken.
Check continuity from JC8-8 to TPC-2 and
Jack the drive tires off the floor before repair or replace as necessary.
conducting this test. See Jacking Safety
on page 2-14. 4. The deadman switch may not be working
properly. Run test I00.
! CAUTION necessary.
When this test is activated and the
deadman pedal is depressed, the
Traction motors will activate.

B+ Voltage Operator Display

Status Message
B+ present ON
B+ absent OFF
If the display message does not change when

the test is activated, the test has failed.
6-104
Input Tests
Test I13 - Traction Motor #1 Diagnosis and Repair

(left) Brush Wear Indicator NOTE: If the test will not show ON, go to step 1.
(both) If the test will not show OFF and the
brushes are OK, go to step 4.
This test is used to observe the composite signal
from the two brush wear indicator switches in
traction motor #1 (left). ! CAUTION
• Code 2N - Brush Wear Indicator, Motor #1

1. Carefully attach a jumper from the brush
wear indicator to the brush spring of the
! CAUTION motor. If the display shows ON now, clean
the brush wear indicator connection. If it
When working around the motors, does not show ON, go to step 2.
extreme caution should be taken to
prevent small parts from falling into 2. Depending on which brushes are worn,
them. attach the jumper from JPS11-2 or
JPS11-4 to the brush spring. If it shows ON
now, repair or replace the wiring. If it does
Press Enter to run test: not show ON, go to step 3.
Use the following table as a guideline. 3. Depending on which brushes are worn,
attach the jumper from JPC10-8 or
JPC10-9 to the brush spring. If the display
Operator shows ON, repair or replace the wiring. If it
Brush Status
Display Message does not show ON with the jumper in place
Worn, needs and the connector attached to the Interface
ON
replacing Card, then replace the Interface Card.
OK OFF NOTE: A dirty motor or battery may make the
brush wear indicator always show ON.
• Model FBC25KS: When the brush wear 4. Remove the wire from the brush wear
indicator touches the brush rigging, the indicator at the brush rigging. If it shows
operator display should show ON. OFF now, clean the motor. If it does not
• Models FBC15/18/20KS: When the wire show OFF, go to step 5.
in the brush touches the commutator 5. Remove JS11-2 and JS11-4 from the
surface, the operator display should show connector. If the operator display shows
ON. OFF, locate which wire is shorted to the
vehicle. If it does not show OFF, go to
step 6.
6. Remove JC10-8 and JC10-9 from the
Interface Card. If the display shows OFF
now, look for a wire shorted to the vehicle.
If it still will not show OFF, replace the
Interface Card.
6-105
Input Tests

(right) Brush Wear Indicator NOTE: If the test will not show ON, go to step 1.
(upper) If the test will not show OFF and the
from the upper brush wear indicator switch in
traction motor #2 (right). ! CAUTION
• Code HE - Brush Wear Indicator, Motor #2

prevent small parts from falling into 2. Attach the jumper from JPS12-2 to the
them. brush spring. If it shows ON now, repair or
replace the wiring. If it does not show ON,
go to step 3.
Press Enter to run test: 3. Attach the jumper from JPC10-13 to the
Use the following table as a guideline. brush spring. If the display shows ON,
repair or replace the wiring. If it does not
show ON with the jumper in place and the
Operator connector attached to the Interface Card,
Brush Status
Display Message replace the Interface Card.
Worn, needs
ON NOTE: A dirty motor or battery may make the
replacing
OK OFF
4. Remove the wire from the brush wear
indicator at the brush rigging. If it shows
• Model FBC25KS: When the brush wear OFF now, clean the motor. If it does not
indicator touches the brush rigging, the show OFF, go to step 5.
operator display should show ON. 5. Remove JS12-2 from the connector. If the
• Models FBC15/18/20KS: When the wire operator display shows OFF, locate which
in the brush touches the commutator wire is shorted to the vehicle. If it does not
surface, the operator display should show show OFF, go to step 6.
ON.
6. Remove JC10-13 from the Interface Card. If
the display shows OFF now, look for a wire
shorted to the vehicle. If it still will not show
OFF, replace the Interface Card.
6-106
Input Tests

(right) Brush Wear Indicator NOTE: If the test will not show ON, go to step 1.
(lower) If the test will not show OFF and the
from the lower brush wear indicator switch in
traction motor #2 (right). ! CAUTION
• Code HE - Brush Wear Indicator, Motor #2

prevent small parts from falling into 2. Attach the jumper from JPS12-4 to the
them. brush spring. If it shows ON now, repair or
go to step 3.
Press Enter to run test: 3. Attach the jumper from JPC10-10 to the
Use the following table as a guideline. brush spring. If the display shows ON,
repair or replace the wiring. If it does not
show ON with the jumper in place and the
Operator connector attached to the Interface Card,
Brush Status
Display Message replace the Interface Card.
Worn, needs
ON NOTE: A dirty motor or battery may make the
replacing
OK OFF
indicator at the brush rigging. If it shows
• Model FBC25KS: When the brush wear OFF now, clean the motor. If it does not
indicator touches the brush rigging, the show OFF, go to step 5.
operator display should show ON. 5. Remove JS12-4 from the connector. If the
• Models FBC15/18/20KS: When the wire operator display shows OFF, locate which
in the brush touches the commutator wire is shorted to the vehicle. If it does not
surface, the operator display should show show OFF, go to step 6.
ON.
6-107
Input Tests
Test I16 - Lift Motor Brush Wear Diagnosis and Repair

Indicator (upper) NOTE: If the test will not show ON, go to step 1.
If the test will not show OFF and the
This test is used to observe the composite signal brushes are OK, go to step 4.
from the upper brush wear indicator switch in
lift motor.
! CAUTION
Related messages, codes, and tests Observe proper ESD precautions. See
• Code 6U - Brush Wear Indicator, Lift Motor

! CAUTION wear indicator to the brush spring of the
When working around the motors, motor. If the display shows ON now, clean
extreme caution should be taken to the brush wear indicator connection. If it
prevent small parts from falling into does not show ON, go to step 2.
them. 2. Attach the jumper from JPS8-2 to the
brush spring. If it shows ON now, repair or
Press Enter to run test: go to step 3.
Use the following table as a guideline. 3. Attach the jumper from JPC10-14 to the
brush spring. If the display shows ON,
Operator repair or replace the wiring. If it does not
Brush Status show ON with the jumper in place and the
Display Message
connector attached to the Interface Card,
Worn, needs then replace the Interface Card.
ON
replacing
NOTE: A dirty motor or battery may make the
OK OFF
• Model FBC25KS: When the brush wear indicator at the brush rigging. If it shows
indicator touches the brush rigging, the OFF now, clean the motor. If it does not
operator display should show ON. show OFF, go to step 5.
• Models FBC15/18/20KS: When the wire
5. Remove JS8-2 from the connector. If the
in the brush touches the commutator
operator display shows OFF, locate which
surface, the operator display should show
wire is shorted to the vehicle. If it does not
ON.
show OFF, go to step 6.
6-108
Input Tests
Test I17 - Lift Motor Brush Wear Diagnosis and Repair

Indicator (lower) NOTE: If the test will not show ON, go to step 1.
If the test will not show OFF and the
This test is used to observe the composite signal brushes are OK, go to step 4.
from the lower brush wear indicator switch in
lift motor.
! CAUTION
Related messages, codes, and tests Observe proper ESD precautions. See
• Code 6U - Brush Wear Indicator, Lift Motor

! CAUTION wear indicator to the brush spring of the
When working around the motors, motor. If the display shows ON now, clean
extreme caution should be taken to the brush wear indicator connection. If it
prevent small parts from falling into does not show ON, go to step 2.
them. 2. Attach the jumper from JPS8-4 to the
brush spring. If it shows ON now, repair or
Press Enter to run test: go to step 3.
Use the following table as a guideline. 3. Attach the jumper from JPC10-15 to the
brush spring. If the display shows ON,
Operator repair or replace the wiring. If it does not
Brush Status show ON with the jumper in place and the
Display Message
connector attached to the Interface Card,
Worn, needs then replace the Interface Card.
ON
replacing
NOTE: A dirty motor or battery may make the
OK OFF
• Model FBC25KS: When the brush wear indicator at the brush rigging. If it shows
indicator touches the brush rigging, the OFF now, clean the motor. If it does not
operator display should show ON. show OFF, go to step 5.
• Models FBC15/18/20KS: When the wire
5. Remove JS8-4 from the connector. If the
in the brush touches the commutator
operator display shows OFF, locate which
surface, the operator display should show
wire is shorted to the vehicle. If it does not
ON.
show OFF, go to step 6.
6-109
Input Tests

(left) Speed Sensor 1. The cable from JPS3 to the Interface Card
may be bad. Check for continuity. Repair or
This test is to observe the signal from the speed replace as necessary.
sensor on traction motor #1 in mph.
2. Measure the voltage from JPS3-1 (+) to
JPS3-3 (-). The meter should show approx.
Related messages, codes, and tests 10.9V. If it does not, run the +12V test (Test
• Code 2H - Failure Detected in Speed A07).
Feedback Circuit #1 3. Connect a voltmeter from JPS3-2 (+) to
JPS3-3 (-) with no metal over the sensor.
The meter should show approx. 5V.
! WARNING With a flat metal object over the sensor, the
This test should be conducted in an area meter should show approx. 0V. If these
figures are not seen, replace the speed
free of obstructions with ample room for
sensor.
maneuvering.
The clearance from the sensor to the
impeller is 0.050 to 0.080 in. (0.127 to
Press Enter to run test: 0.203 mm).
1. Use the following table as a guideline. 4. The Interface Card may be bad.
Sensor Signal Operator Display

Status Message
Present 0.0 MPH
Absent OFF
The operator display will show speed as

seen by the velocity sensor.
2. The speed and direction of each drive motor
will depend on the position of the steer tire.
For best results, the steer tire should be in
the straight ahead position.
6-110
Input Tests

(right) Speed Sensor 1. The cable from JPS4 to the Interface Card
may be bad. Check for continuity. Repair or
This test is to observe the signal from the speed replace as necessary.
sensor on traction motor #2 in mph.
2. Measure the voltage from JPS4-1 (+) to
JPS4-3 (-). The meter should show approx.
Related messages, codes, and tests 11.5V. If it does not, run the +12V test (Test
• Code HB - Motor #2 Speed Feedback Error A07).
3. Connect a voltmeter from JPS4-2 (+) to
JPS4-3 (-) with no metal over the sensor.
! WARNING The meter should show approx. 5V.
This test should be conducted in an area With a flat metal object over the sensor, the
meter should show approx. 0V. If these
free of obstructions with ample room for
figures are not seen, replace the speed
maneuvering.
sensor.
The clearance from the sensor to the
Press Enter to run test: impeller is 0.050 to 0.080 in. (0.127 to
0.203 mm).
Sensor Signal Operator Display
Status Message
Present 0.0 MPH
Absent OFF
The operator display will show speed as

seen by the speed sensor.
2. The speed and direction of each drive motor
will depend on the position of the steer tire.
For best results, the steer tire should be in
the straight ahead position.
6-111
Input Tests

(left) Thermostat
This test measures the temperature of the left
! CAUTION
traction motor. Observe proper ESD precautions. See
1. Disconnect JPS11 from the motor.
• Code 2A - Traction Motor #1 Overheated
2. With an ohmmeter, check resistance of the
• Code H6 - Traction Motor #2 Overheated temperature switch at JPS11-3 and
JPS11-1. Use the following table as a
Limits: guideline (all values are approximate).
• Ambient to +145°C (293°F) normal
operation Motor Switch
Resistance
Temperature Position
• Operation cutback at 145 to 155°C
(293 to 311°F) °C °F
<145 <293 Closed 0 ohms
Press Enter to run test: >145 >293 Open Infinite
1. With the truck at rest and at ambient
temperature, observe the operator display. If the resistance measured does not match
It should show “I20 CLSD”. the values listed above, replace the
2. If the message on the operator display is temperature sensor.
different, the test has failed. 3. Check for continuity of JPS11 to JC10.
Repair or replace the cable as required.
6-112
Input Tests

(right) Thermostat
This test measures the temperature of the right
! CAUTION
traction motor. Observe proper ESD precautions. See
• Code H6 - Traction Motor #2 Overheated
2. With an ohmmeter, check resistance of the
• Code 2A - Traction Motor #1 Overheated temperature switch at JPS12-3 and
JPS12-1. Use the following table as a
Limits: guideline (all values are approximate).
Resistance
Temperature Position
• Operation cutback at 145 to 155°C
(293 to 311°F) °C °F
Press Enter to run test: >145 >293 Open Infinite
temperature, observe the operator display. If the resistance measured does not match
It should show “I21 CLSD”. the values listed above, replace the
different, the test has failed. 3. Check for continuity of JPS12 to JC10.
6-113
Input Tests
Test I22 - Lift Motor Thermostat Diagnosis and Repair
This test measures the temperature of the lift

motor. ! CAUTION
• Code 6F - Lift Motor Overheated

• Code 6G - Lift Motor Temperature
Out-of-Range 2. With an ohmmeter, check resistance of the
temperature switch at JPS8-3 and JPS8-1.
Use the following table as a guideline (all
Limits: values are approximate).
Resistance
• Operation cutback at 145 to 155°C Temperature Position
(293 to 311°F) °C °F
>145 >293 Open Infinite
temperature, observe the operator display.
If the resistance measured does not match
It should show “I22 CLSD”.
the values listed above, replace the
different, the test has failed.
3. Check for continuity of JPS8 to JC10.
6-114
Input Tests
Test I23 - Lift Switch (S13)

lift switch in the operator’s control handle/lift
linkage assembly.

None.

Lift Switch Operator Display

Position Message
Depressed ON
Released OFF


functioning mechanically.
3. If test fails, troubleshoot wiring.
6-115
Input Tests
Test I24 - Lower Switch (S14)

lower switch in the operator’s control handle/
lift linkage assembly.

None.

Lower Switch Operator Display

Position Message
Depressed ON
Released OFF


functioning mechanically.
If test fails, troubleshoot wiring.
6-116
Input Tests
Test I25 - Attachment Spool

Valve Switch (S17)
the attachment spool valve switch (if installed).

None.
! CAUTION
Use extreme caution when working
around an elevated mast.

messages on the operator display for this test:
Switch Button Operator Display

Position Message
Depressed ON
Raised OFF
If the message does not match, the test has

failed.
! CAUTION

switch (S17).
2. Check the continuity of the cable from JPA3
on the Attachment Card to the switch (S17)
through JPA4. Repair or replace as
necessary.
3. Carefully jumper from JPA3-6 to JPA3-2. If
the display changes, replace the switch. If
Attachment Card.
4. If the problem still exists, replace the
Interface Card.
6-117
Input Tests
Test I26 - Tilt Limit Switch Diagnosis and Repair

(optional)
! CAUTION
the tilt limit switch (if installed). Observe proper ESD precautions. See
• Test A07 - Power Supply +12 VDC switches (S11 and S18).
Interface Card (JC12) to the switch (JS5).
! WARNING Repair or replace as necessary.
Do not attempt high speeds during this 3. Check the clearance from the sensor head
test. Speed limiting while elevated may to the adjacent metal switch actuator. The
be defeated during this test. clearance should be 0.050 to 0.100 in.
(1.27 to 2.54 mm) when the mast is tilted
back and the carriage is lowered.
! CAUTION 4. Using a voltmeter, measure the +12V
Use extreme caution when working supply to the switch (+) JS5-1, (-) JS5-3. If
around an elevated mast. the +12V supply is out-of-range, run the
+12V Power Supply Test (Test A07).
Press Enter to run test: 5. Carefully jumper from JS5-2 to JS5-3. If

the display changes, replace the switch. If
The following table indicates the correct the display does not change, replace the
messages on the operator display in relation to Interface Card.
the mast and tilt position:
NOTE: This option uses two switches (S11 and
S18) working together to operate.
Mast Operator
Mast Tilt
Elevated Display
Position
Position Message
Within
<3° Forward OFF
Free-Lift
Above
>3° Forward ON
Free-Lift
Above
<3° Forward OFF
Free-Lift
Within
>3° Forward OFF
Free-Lift
If the message does not match the above

conditions, the test has failed.
6-118
Input Tests
Test I27 - TPC_L Signal

This test is used to observe the command from
the left power amplifier to either energize or
de-energize the TPC contactor. The command is
sent from JPTL1-17 to JPX2-13.

• Code 2M - Power Amplifier #1 (left) Fault
• Code HK - Power Amplifier #2 (right) Fault

Key and
Operator
Deadman Deadman
Display
Pedal Outputs From
Message
Translator Card
Down On ON
Up Off OFF

Check the TPC Contactor to verify that it is
either energized (closed) or de-energized (open)
in accordance with the input to the Translator
Card.
NOTE: It may be helpful to run Test I28 and
compare the results to this test. Check
to see that the left and right power
amplifiers are not sending conflicting
commands to the Translator Card.
6-119
Input Tests
Test I28 - TPC_R Signal

This test is used to observe the command from
the right power amplifier to either energize or
de-energize the TPC contactor. The command is
sent from JPTR1-17 to JPX1-13.

• Code HK - Power Amplifier #2 (right) Fault
• Code 2M - Power Amplifier #1 (left) Fault
• Test I27 - TPC_L Signal

Key and
Operator
Deadman Deadman
Display
Pedal Outputs From
Message
Translator Card
Down On ON
Up Off OFF

Check the TPC Contactor to verify that it is
either energized (closed) or de-energized (open)
in accordance with the input to the Translator
Card.
NOTE: It may be helpful to run Test I27 and
compare the results to this test. Check
to see that the left and right power
amplifiers are not sending conflicting
commands to the Translator Card.
6-120
Input Tests
Test I29 - Left Power Amplifier 2. The Interface Card will then change the
outputs to the power amplifier sequentially
Switch Inputs that will operate all of the switch inputs to
the amplifier. The correct sequence that
The left power amplifier requires five (5) digital
should be displayed on the operator display
input signals to operate: KEY, EPO, DM
during this test is as follows:.
(deadman), FWD directional signal, and REV
directional signal. These signals are created by
the Interface Card and sent to the power Sequence of
Condition Message
amplifiers via the Translator Card. The Operator Display
Represents
amplifiers read these inputs and communicate Message
what has been read back to the Translator Card XXX Test not started yet.
using communication lines TXD_L and RXD_L.
EPO off; DM off; both
This test displays what is being communicated
00B forward and reverse
back to the Translator Card from the left power
inputs on.
amplifier.
EPO off; DM on; both
inputs on.
• Code HK - Power Amplifier #2 (right) Fault EPO on; DM off; both
• Code 2M - Power Amplifier #1 (left) Fault 10B forward and reverse
inputs on.
• Test I30 - Right Power Amp Switch Inputs
EPO off; DM off;
00F forward direction on,
reverse direction off.
1. The Interface Card will generate a test EPO off; DM off;
pattern that will be monitored by the 00R forward direction off,
Operator Display during this test. The reverse direction on.
display will show a three-character code.
EPO off; DM off;
The first character represents the EPO
00N forward direction off,
switch input status, the second represents
the deadman switch input status, and the
third represents the directional input
status. If "XXX" is displayed while the test is
For the first two characters, a "1" indicates running, then communication shutdown
that the input is being read as "on" and a has occurred.
"0" indicates that the input is being read as If "OFF" is displayed when this test is run,
"off." then the key switch input is detected as
For the directional, or third, character, a OFF.
"B" indicates that both directional inputs If "---" is displayed when this test is run,
are being read as "on," an "F" indicates that then the voltage output of the TPC
only the forward directional is "on," an "R" Contactor has dropped below 16V. The
indicates that only the reverse directional is amplifiers require at least 16V to turn on.
"on," and an "N" indicates that neither
directional is "on." Diagnosis and Repair
NOTE: The signals that are sent to the
amplifiers are not physically connected It may be helpful to compare the results of this
to the key, deadman, and EPO switches. test with the Translator Card LEDs while the
test is running. Troubleshoot deviations
accordingly.
6-121
Input Tests
Test I30 - Right Power Amplifier 2. The Interface Card will then change the
outputs to the power amplifier sequentially
Switch Inputs that will operate all of the switch inputs to
the amplifier. The correct sequence that
The right power amplifier requires five digital
should be displayed on the operator display
input signals to operate: KEY, EPO, DM
during this test is as follows:.
(deadman), FWD directional signal, and REV
directional signal. These signals are created by
the Interface Card and sent to the power Sequence of
Condition Message
amplifiers via the Translator Card. The Operator Display
Represents
amplifiers read these inputs and communicate Message
what has been read back to the Translator Card XXX Test not started yet.
using communication lines TXD_R and RXD_R.
EPO off; DM off; both
This test displays what is being communicated
back to the Translator Card from the right
inputs on.
power amplifier.
EPO off; DM on; both
inputs on.
• Code HK - Power Amplifier #2 (right) Fault EPO on; DM off; both
• Code 2M - Power Amplifier #1 (left) Fault 10B forward and reverse
inputs on.
• Test I29 - Left Power Amp Switch Inputs
EPO off; DM off;
00F forward direction on,
1. The Interface Card will generate a test EPO off; DM off;
pattern that will be monitored by the 00R forward direction off,
Operator Display during this test. The reverse direction on.
display will show a three-character code.
EPO off; DM off;
The first character represents the EPO
00N forward direction off,
switch input status, the second represents
the deadman switch input status, and the
third represents the directional input
status. If "XXX" is displayed while the test is
For the first two characters, a "1" indicates running, then communication shutdown
that the input is being read as "on" and a has occurred.
"0" indicates that the input is being read as If "OFF" is displayed when this test is run,
"off." then the key switch input is detected as
For the directional, or third, character, a OFF.
"B" indicates that both directional inputs If "---" is displayed when this test is run,
are being read as "on," an "F" indicates that then the voltage output of the TPC
only the forward directional is "on," an "R" Contactor has dropped below 16V. The
indicates that only the reverse directional is amplifiers require at least 16V to turn on.
"on," and an "N" indicates that neither
directional is "on." Diagnosis and Repair
NOTE: The signals that are sent to the
amplifiers are not physically connected It may be helpful to compare the results of this
to the key, deadman, and EPO switches. test with the Translator Card LEDs while the
test is running. Troubleshoot deviations
accordingly.
6-122
Output Tests
Output Tests
6-123
Output Tests
Test O01 - Toggle the Load Hold 5. If the solenoid is off when it should be on:
(SOL1) Solenoid a. Turn the truck OFF.
b. Disconnect both wires from the solenoid
This test is used to turn the load hold solenoid coil.
(SOL1) ON and OFF.
c. Connect the leads of an ohmmeter to the
terminals on the solenoid coil.
d. Set the ohmmeter scale to R x 1.
None.
e. The resistance should be approx.
33.7 ±5 ohms. If not, replace the
solenoid coil. If OK, proceed to next step.
! WARNING
f. Reconnect wire SOl1-1 to Solenoid 1.
Be sure the forks are fully lowered
g. Turn the truck back on. Re-enter this
before performing this test. test in the truck’s maintenance mode.
h. Connect the (+) lead of a voltmeter to
! CAUTION wire SOL1-1. Connect the (-) lead to wire
SOL1-2.
The lowering function normally uses the
proportional lower solenoid in i. Toggle the test ON. The voltmeter should
read positive battery voltage. If it does
conjunction with the load hold solenoid.
not, go to the next step.
j. Connect the (-) lead of the voltmeter to
Press Enter to run test: JPC9-6. Connect the (+) lead to JPC9-3.
ON/OFF will be displayed on the operator k. If the voltmeter reads positive battery
display. The test can be toggled ON and OFF voltage when the test is toggled ON,
with the UP/DOWN keys. replace the wires. If it does not, replace
the Interface Card.
Diagnosis and Repair 6. If the solenoid is on all the time:
a. Disconnect wire to SOL1-2. If the
! CAUTION solenoid drops out (you will hear a
click), check the wiring to JPC9-6.
Repair the wire as necessary. If the wire
Static Precautions on page 2-12. is OK, replace the Interface Card.
b. If the solenoid did not drop out, check it
1. Enter this test in the truck’s maintenance for mechanical binding and repair or
mode. replace it.
2. Disconnect wire SOL1-1 from solenoid 1.
3. Connect an ammeter between this wire and
terminal SOL1-1 on the solenoid.
4. Toggle this test ON. When the operator
display shows ON, the ammeter should
read 900 to 1100mA (0.9 to 1.1A). If this
reading is OK, the test is a success.
6-124
Output Tests
Test O02 - Toggle the Sideshift e. The resistance should be approx. 33.7
±5 ohms. If not, replace the solenoid
(SOL2) Solenoid (optional) coil. If OK, proceed to next step.
This test is used to turn the sideshift solenoid f. Reconnect wire SOL2-1 to Solenoid 2.
(SOL2) ON and OFF. g. Turn the truck back on. Re-enter this
test in Maintenance Mode.
Related messages, codes, and tests h. Connect the (+) lead of a voltmeter to
None. wire SOL2-1. Connect the (-) lead to wire
SOL2-2.
Press Enter to run test: i. Toggle the test ON. The voltmeter should
ON/OFF will be displayed on the operator not, proceed to next step.
display. The test can be toggled ON and OFF
with the UP/DOWN keys.
JPC9-12. Connect the (+) lead to
JPC9-3.
k. If the voltmeter reads positive battery
voltage when the test is toggled ON,
! CAUTION replace the wires. If it does not, replace
the Interface Card.
Static Precautions on page 2-12. 6. If the solenoid is on all the time:
NOTE: The sideshift option must be installed solenoid drops out (you will hear a
before this test is available. click), check the wiring to JPC9-12.
1. Enter this test while in the truck’s is OK, replace the Interface Card.
Maintenance Mode.
2. Disconnect wire SOL2-1 from Solenoid 2. for mechanical binding and repair or
3. Connect an ammeter between this wire and replace it as necessary.
5. If the solenoid is off when it should be on:
a. Turn the truck OFF.
coil.
6-125
Output Tests
Test O04 - Toggle the Tilt (SOL4) g. Turn the truck back on. Re-enter this
Solenoid
This test is used to turn the tilt solenoid (SOL4) wire SOL4-1. Connect the (-) lead to wire
ON and OFF. SOL4-2.
i. Toggle the test ON. The voltmeter should
Related messages, codes, and tests read positive battery voltage. If it does
not, proceed to next step.
None.
JPC9-1. Connect the (+) lead to JPC9-3.
NOTE: ON/OFF will be displayed on the voltage when the test is toggled ON,
operator display. The test can be toggled replace the wires. If it does not, replace
ON and OFF with the UP/DOWN keys. the Interface Card.
6. If the solenoid is on all the time:
solenoid drops out (you will hear a
! CAUTION click), check the wiring to JPC9-1.
is OK, replace the Interface Card.
for mechanical binding. Repair or
1. Enter this test in Maintenance Mode. replace it as necessary.
2. Disconnect wire SOL4-1 from Solenoid 4.
coil.
solenoid coil. If it is, proceed to next
step.
f. Reconnect wire SOL4-1 to Solenoid 4.
6-126
Output Tests
Test O05 - Toggle the Aux PSI j. Connect the (-) lead of the voltmeter to
Select (SOL5) Solenoid
This test is used to turn the Aux PSI Select voltage when the test is toggled ON,
Solenoid (SOL5) ON and OFF. replace the wires. If it does not, replace
the Interface Card.
Related messages, codes, and tests 6. If the solenoid is on all the time:
None. a. Disconnect wire to SOL5-2. If the

solenoid drops out (you will hear a
click), check the wire to JPC9-7. Repair
Press Enter to run test: the wire as necessary. If the wire is OK,
NOTE: ON/OFF will be displayed on the replace the Interface Card.
operator display. The test can be toggled b. If the solenoid did not drop out, check it
ON and OFF with the UP/DOWN keys. for mechanical binding and repair or
replace it.
1. Enter this test while in Maintenance Mode.
coil.
solenoid coil. If it is, go to the next step.
wire SOL5-1. Connect the (-) lead to wire
SOL5-2.
i. Toggle the test ON. The voltmeter should
6-127
Output Tests
Test O06 - Toggle the Auxiliary e. The resistance should be approx.

Direction A Solenoid (SOL6) solenoid coil. If it is, go to the next step.
This test is used to turn the auxiliary direction f. Reconnect wire SOL6-1 to solenoid 6.
A solenoid (SOL6) ON and OFF. g. Turn the truck back on. Re-enter this
test in the truck’s maintenance mode.
Related messages, codes, and tests h. Connect the (+) lead of a voltmeter to
None. wire SOL6-1. Connect the (-) lead wire
SOL6-2.
Press Enter to run test: i. Toggle the test ON. The voltmeter should
NOTE: ON/OFF will be displayed on the not, proceed to next step.
operator display. Test can be toggled ON
and OFF with the UP/DOWN keys.
Diagnosis and Repair k. If the voltmeter reads positive battery

1. Enter this test in the truck’s maintenance replace the wires. If it does not, replace
mode. the Interface Card.
2. Disconnect wire SOL6-1 from solenoid 6. 6. If the solenoid is on all the time:
3. Connect an ammeter between this wire and a. Disconnect wire to SOL6-2. If the
terminal SOL6-1 on the solenoid. solenoid drops out (you will hear a
click), check the wiring to JPC9-8.
reading is OK, the test is a success. b. If the solenoid did not drop out, check it
for mechanical binding and repair or
replace it.
coil.
6-128
Output Tests
Test O07 - Toggle the i. Toggle the test ON. The voltmeter should
Equalization (SOL7) Solenoid not, proceed to next step.
This test is used to turn the equalization j. Connect the (-) lead of the voltmeter to
solenoid (SOL7) ON and OFF. JPC9-9. Connect the (+) lead to JPC9-3.
Related messages, codes, and tests voltage when the test is toggled ON,
replace the wires. If it does not, replace
None. the Interface Card.
6. If the solenoid is on all the time:
NOTE: ON/OFF will be displayed on the solenoid drops out (you will hear a
operator display. This test can be click), check the wiring to JPC9-9.
toggled ON and OFF with the UP/DOWN Repair the wire as necessary. If the wire
keys. is OK, replace the Interface Card.
Diagnosis and Repair for mechanical binding and repair or
replace it.
1. Enter this test in Maintenance Mode.
coil.
step.
f. Reconnect wire SOL7-1 to solenoid 7.
SOL7-2.
6-129
Output Tests
Test O08 - Toggle the Auxiliary i. Toggle the test ON. The voltmeter should
Direction B (SOL8) Solenoid not, proceed to next step.
This test is used to turn the auxiliary direction j. Connect the (-) lead of the voltmeter to
B solenoid (SOL8) ON and OFF, if installed. JPC9-10. Connect the (+) lead to
JPC9-3.
Related messages, codes, and tests k. If the voltmeter reads positive battery
None. replace the wires. If it does not, replace
the Interface Card.
Press Enter to run test: 6. If the solenoid is on all the time:
NOTE: ON/OFF will be displayed on the a. Disconnect wire to SOL8-2. If the
operator display. This test can be solenoid drops out (you will hear a
toggled ON and OFF with the UP/DOWN click), check the wiring to JPC9-10.
keys. Repair the wire as necessary. If the wire
Diagnosis and Repair b. If the solenoid did not drop out, check it
for mechanical binding and repair or
1. Enter this test in Maintenance Mode.
replace it.
coil.
solenoid and coil. If it is, proceed to next
step.
f. Reconnect wire SOL8-1.
test in the truck’s maintenance mode.
SOL8-2.
6-130
Output Tests
Test O09 - Toggle the High Flow g. Turn the truck back on. Re-enter this
Auxiliary (SOL9) Solenoid
(Optional) wire SOL9-1. Connect the (-) lead to wire
SOL9-2.
This test is used to turn the high flow auxiliary
solenoid (SOL9) ON and OFF. i. Toggle the test ON. The voltmeter should
j. Connect the voltmeter to the SOL9-1
None. wire (+) and to JPA2-5 (-). The meter
should show battery positive voltage. If
Press Enter to run test: it does not, move the positive lead of the
meter to JPA2-4. The meter should show
NOTE: ON/OFF will be displayed on the battery positive, with the key ON. If it
operator display. This test can be does, replace the cable at JPA2-4.
toggled ON and OFF with the UP/DOWN
keys. k. If it does not, move the positive meter
lead to JPA2-3 (+). With the key ON, the
meter should show battery (+). If it does
Diagnosis and Repair not, repair or replace the wiring back to
the key switch.
! CAUTION l. If there is B+ at the meter, replace the
Observe proper ESD precautions. See Attachment Card.
Static Precautions on page 2-12. m. Toggle the test ON.
n. Remove the wires from JPA2-3 and
1. Enter this test in Maintenance Mode. JPA2-8. Connect the voltmeter to those
terminals on the Attachment Card.
o. If the meter shows (+) voltage with the
test ON, repair or replace the wire from
JPA2-8 to SOL9-2. If there was no
4. Toggle this test ON. When the operator voltage, remove cable JPA1 from the
display shows ON, the ammeter should Attachment Card and JPC7 from the
read 900 to 1100mA (0.9 to 1.1A). If this Interface Card. Check it for continuity
reading is OK, the test is a success. and repair or replace it as necessary.
5. If the solenoid is off when it should be on: p. Connect the voltmeter to JPA1-7 (+) and
a. Turn the truck OFF. JPA1-9 (-). With the test toggled ON, the
meter should read approx. 4.5V. If it
b. Disconnect both wires from the solenoid does, replace the Attachment Card. If it
coil. does not, replace the Interface Card.
6-131
Output Tests
Test O10 - Toggle the High Flow g. Turn the truck back on. Re-enter this
Attachment 1 (SOL10) Solenoid
(Optional) wire SOL10-1. Connect the (-) lead to
wire SOL10-2.
This test is used to turn the high flow
attachment 1 solenoid (SOL10) ON and OFF. i. Toggle the test ON. The voltmeter should
lead to JPA2-3 (+). With the key switch
ON, the meter should show battery (+). If
Diagnosis and Repair it does not, repair or replace the wiring
back to the key switch.
b. Disconnect both wires from the solenoid does, replace the Interface Card. If it
6-132
Output Tests
Test O11 - Toggle the High Flow g. Turn the truck back ON. Re-enter this
Attachment 2 (SOL11) Solenoid
(Optional) wire SOL11-1. Connect the (-) lead to
wire SOL11-2.
This test is used to turn the high flow
attachment 2 solenoid (SOL11) ON and OFF. i. Toggle the test ON. The voltmeter should
lead to JPA2-3 (+). With the key ON, the
meter should show battery (+). If it does
Diagnosis and Repair not, repair or replace the wiring back to
the key switch.
b. Disconnect both wires from the solenoid does, replace the Attachment Card. If it
step.
6-133
Output Tests
Test O12 - Toggle the TPC Diagnosis and Repair

Contactor
This test turns the TPC contactor ON and OFF.
! CAUTION
• Code 44 - TPC Contactor Detected Closed 1. Check for binding in the contactor. Repair
When Commanded Open or replace as necessary.
• Code 45 - TPC Contactor Detected Open 2. Using an ohmmeter, check the resistance of
When Commanded Closed the coil. With the wires removed from the X
and Y terminals, the resistance should be
10-50 ohms. Replace as necessary.
! CAUTION
Jack the drive wheels off the floor for 3. The cable JPC8 from the Interface Card to
this test. See Jacking Safety on the contactor coil may be bad. Check it for
continuity. Repair or replace cable as
page 2-14.
necessary.
4. Using a voltmeter, check for B+KC (36V) at
JPC8-14 (+) with reference to TP4 (B-). If
! WARNING B+KC exists at JPC8-13 but not at
The traction system may not act as JPC8-14, replace the Interface Card.
expected during this test. If the traction 5. Measure the voltage at TP1 (contactor fuse
power amplifier is shorted, the truck panel) with reference to TP4 (B-). It should
may start to travel when the contactor is read B+ (36V). If it does not, then check the
toggled ON/OFF. K3 relay. Replace as necessary.
6. If B+KC is present at JPC8-14 (+) with
reference to JPC8-12 (B-F) and the
contactor still will not operate, replace the
NOTE: This test can be toggled by using the Interface Card.
UP/DOWN keys on the operator display.
If the contactor does not cycle in/out when the
test is toggled, the test has failed.
6-134
Output Tests
Test O13 - Toggle the LPC Diagnosis and Repair

Contactor
This test is used to turn the LPC contactor ON
! CAUTION
and OFF. Observe proper ESD precautions. See
1. Check for binding in the contactor. Repair
• Code 42 - LPC Contactor Detected Closed or replace as necessary.
When Commanded Open
2. Using an ohmmeter, check the resistance of
• Code 43 - LPC Contactor Detected Open the coil. With the wires removed from the X
When Commanded Closed and Y terminals, the resistance should be
10-50 ohms. Replace as necessary.
! CAUTION 3. The cable JPC8 from the Interface Card to
The ceiling height should be higher than the contactor coil may be bad. Check it for
maximum elevated height of the vehicle continuity. Repair or replace cable as
necessary.
under test.
B+KC exists at JPC8-13 but not at
! WARNING JPC8-14, replace the Interface Card.
The lift system may not act as expected 5. Measure the voltage at TP1 (contactor fuse
during this test. If the lift power panel) with reference to TP4 (B-). It should
amplifier is shorted, the mast may lift read B+ (36V). If it does not, then check the
when the contactor is toggled ON/OFF. K3 relay. Replace as necessary.
Press Enter to run test: reference to JPC8-12 (B-F) and the
NOTE: This test can be toggled by using the Interface Card.
6-135
Output Tests
Test O14 - Toggle the STR Diagnosis and Repair

Contactor 1. Check for binding in the contactor. Repair
or replace as necessary.
This test is used to turn the STR contactor ON
and OFF. 2. Using an ohmmeter, check the resistance of
the coil. With the wires removed from the X
Related messages, codes, and tests 10-50 ohms. Replace as necessary.
• Code 4B - STR Contactor Detected Closed 3. The cable JPC8 from the Interface Card to
When Commanded Open the contactor coil may be bad. Check it for
• Code 4C - STR Contactor Detected Open continuity. Repair or replace cable as
When Commanded Closed necessary.
! WARNING B+KC exists at JPC8-13 but not at
JPC8-14, replace the Interface Card.
DO NOT attempt to drive the truck while
conducting this test. 5. Measure the voltage at TP1 (contactor fuse
panel) with reference to TP4 (B-). It should
read B+ (36V). If it does not, then check the
K3 relay. Replace as necessary.
! CAUTION
The steer system may not act as
expected during this test. The steer
motor will run when the contactor is Interface Card.
toggled ON and OFF.

NOTE: This test can be toggled by using the
6-136
Output Tests
Test O15 - Toggle the AUX Diagnosis and Repair

Contactor 1. Check for binding in the contactor. Repair
or replace as necessary.
This test is used to turn the AUX contactor ON
and OFF. 2. Using an ohmmeter, check the resistance of
the coil. With the wires removed from the X
Related messages, codes, and tests 10-50 ohms. Replace as necessary.
None. 3. The cable JPC8 from the Interface Card to
the contactor coil may be bad. Check it for
continuity. Repair or replace cable as
! WARNING necessary.
DO NOT attempt to drive the truck while 4. Using a voltmeter, check for B+KC (36V) at
conducting this test.
B+KC exists at JPC8-13 but not at
JPC8-14, replace the Interface Card.
! CAUTION 5. Measure the voltage at TP1 (contactor fuse

panel) with reference to TP4 (B-). It should
The steer system may not act as
read B+ (36V). If it does not, then check the
expected during this test. The steer K3 relay. Replace as necessary.
motor will run when the contactor is
toggled ON and OFF. 6. If B+KC is present at JPC8-14 (+) with
Press Enter to run test: Interface Card.
NOTE: This test can be toggled by using the

6-137
Output Tests
Test O16 - Ramp the #1 (left) Press Enter to run test:

Traction Power Amplifier NOTE: The deadman pedal must be depressed
for the brake to release.
This test turns on the left traction power
amplifier (#1) by gradually increasing the 1. This test will ramp from 0 to 100% in 10%
command to it through the CAN bus. increments when the UP/DOWN buttons
are pushed. To change directions, press the
enter button. The voltage readings should
Related messages, codes, and tests change according to the table below. The
• Code 29 - No Movement Detected When voltages may vary slightly from those in the
Travel is Requested table depending on the battery voltage.
Operator Approximate
Display Message Voltage
! WARNING
0% 36.0V
The left traction motor may rotate during 10% 34.0V
this test. Jack the drive wheels up or
20% 30.0V
allow sufficient room for maneuvering.
30% 26.0V
40% 22.0V
! CAUTION 50% 19.0V
Current level of 100A for 5 seconds or 60% 15.0V
50A for 10 seconds should not be
70% 12.0V
exceeded without wheel movement.
Prolonged application of the current to 80% 8.0V
the motor without movement will cause 90% 5.0V
damage to the motor. 100% 0.0V
NOTE: The (+) meter lead connects
to the A2 (+) hookup and the
(-) lead connects to the F1 or
F2 (B-) hookup on the motor.
2. During this test, the field terminal F1 and

F2 will drop approx. 6V (while the test is
running).
Meter Lead Meter Lead

Connection Connection
(Forward) (Reverse)
(+) (-) (+) (-)
A2 F1 A2 F2
The meter will start at battery voltage and

drop approx. 6V when the test is operating.
6-138
Output Tests
! CAUTION
1. If the percentage on the operator display

changes and the voltage on the meter
changes according to the table above but
the motor does not turn, check the motor
and repair or replace as necessary.
changes but the voltage on the power
amplifier does not change, then replace the
power amplifier.
3. If the percentage on the display does not
change, replace the Interface Card.
6-139
Output Tests
Test O17 - Ramp the #2 (right) Press Enter to run test:

Traction Power Amplifier NOTE: The deadman pedal must be depressed
for the brake to release.
This test turns on the right traction power
amplifier (#2) by gradually increasing the 1. This test will ramp from 0 to 100% in 10%
command to it through the CAN bus. increments when the UP/DOWN buttons
are pushed. To change directions, press the
enter button. The voltage readings should
Related messages, codes, and tests change according to the table below. The
• Code 29 - No Movement Detected When voltages may vary slightly from those in the
Travel is Requested table depending on the battery voltage.
Operator Approximate
Display Message Voltage
! WARNING
0% 36.0V
The right traction motor may rotate 10% 34.0V
during this test. Jack the drive wheels up
20% 30.0V
or allow sufficient room for
maneuvering. 30% 26.0V
40% 22.0V
50% 19.0V
! CAUTION 60% 15.0V
Current level of 100A for 5 seconds or
70% 12.0V
50A for 10 seconds should not be
exceeded without wheel movement. 80% 8.0V
Prolonged application of the current to 90% 5.0V
the motor without movement will cause 100% 0.0V
damage to the motor.
NOTE: The (+) meter lead connects
to the A2 (+) hookup and the
(-) lead connects to the F1 or
F2 (B-) hookup on the motor.
2. During this test, the field terminal F1 and

F2 will drop approx. 6V (while the test is
running).
Meter Lead Meter Lead

Connection Connection
(Forward) (Reverse)
(+) (-) (+) (-)
A2 F2 A2 F1
The meter will start at battery voltage and

drop approx. 6V when the test is operating.
6-140
Output Tests
! CAUTION

changes and the voltage on the meter
changes according to the preceding table
but the motor does not turn, check the
motor and repair or replace as necessary.
changes but the voltage on the power
amplifier does not change, then replace the
power amplifier.
3. If the percentage on the display does not
change, replace the Interface Card.
6-141
Output Tests
Test O18 - Toggle Traction 4. If the meter shows battery voltage, repair or
replace the cable and go to step 5. If it does
Motor Brake #1 (left) not, replace the Interface Card.
This test turns the brake on traction motor #1 5. Connect a voltmeter to JB1-2(-) and
(left) ON or OFF. JPB1-1(+). With the test toggled ON, the
meter should show B+. If it does not,
replace the Interface Card.
• Code 29 - No Movement Detected When
Travel is Requested
! WARNING
Do not drive the truck while conducting
this test.
! CAUTION
The left brake may not operate as
expected during this test.

NOTE: ON/OFF will appear on the operator
display. This test can be toggled ON and
OFF with the UP/DOWN keys.
! CAUTION
NOTE: In order to make the brakes operate, the

deadman pedal must be depressed.
1. Disconnect connection JPB1.
2. Using an ohmmeter, measure the
resistance of the brake coil. The resistance
should be 21 to 25 ohms. If it is not correct,
replace the brake coil.
3. With the key switch ON, connect a
voltmeter at JPB1-1(+) and TP4(B-). The
meter should show battery voltage. If it
does not, move the meter lead to JPC10-20
at the Interface Card.
6-142
Output Tests
Test O19 - Toggle Traction 4. If the meter shows battery voltage, repair or
replace the cable and go to step 5. If it does
Motor Brake #2 (right) not, replace the Interface Card.
This test turns the brake on traction motor #2 5. With connector JPB2 disconnected, connect
(right) ON or OFF. a voltmeter to JB2-2(-) and JPB2-1(+). With
the test toggled ON, the meter should show
B+. If it does not, replace the Interface
Card.
• Code 29 - No movement detected when
travel is requested
! WARNING
Do not drive the truck while conducting
this test.
! CAUTION
The right brake may not operate as
expected during this test.

! CAUTION
NOTE: In order to make the brakes operate, the

deadman pedal must be depressed.
1. Disconnect connection JPB2.
2. Using an ohmmeter, measure the
resistance of the brake coil. The resistance
should be 21 to 25 ohms. If it is not correct,
replace the brake coil.
3. With the key switch ON, connect a
voltmeter at JPB2-1(+) and TP4(B-). The
meter should show battery voltage. If it
does not, move the meter lead to JPC10-21
at the Interface Card.
6-143
Output Tests
Test O20 - Ramp the Frequency

to the Operator Display Alarm
This test turns on the operator display alarm by
gradually increasing the signal sent.

None.

If the sonalert does not sound when the ENTER
key is pushed, the test has failed.
! CAUTION
1. If you are able to access Maintenance Mode,

then the keypad and associated wiring are
working properly.
2. If the sonalert does not work, the operator
display cable may be bad. Use an
ohmmeter to check its continuity. Repair or
3. The operator display may be bad. Replace
as necessary.
necessary.
6-144
Output Tests
Test O21 - Toggle the Horn

This test turns the truck’s horn ON and OFF.

• Test I10 - Horn switch

When the ENTER key is pressed the horn
should sound. If it does not sound, the test has
failed.
NOTE: Check all hydraulic functions of the
truck for operation. They receive battery
voltage from the same source as the
horn. If they work, B+KA to the Interface
Card is present.
! CAUTION
1. Disconnect the terminals from the horn.

Using an ohmmeter, the resistance of the
horn should be 10 to 50 ohms. If it is not in
this range, replace the horn.
2. The cable from the Interface Card (JPC8) to
the horn may be bad. Check its continuity
using an ohmmeter.
3. If test I10 (horn switch) passes and all of
the above steps pass, then replace the
Interface Card.
6-145
Output Tests
Test O22 - Toggle the Travel

Alarm (optional)
This test turns the truck’s horn ON and OFF.
None.

When the ENTER key is pressed the travel
alarm should sound. If it does not sound, the
test has failed.
6-146

Mitsubishi FBC15/18/20/25KS Service Manual Messages, Codes, and Tests

Uploaded by

Document Information

Original Title

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

Mitsubishi FBC15/18/20/25KS Service Manual Messages, Codes, and Tests

Uploaded by

Copyright:

Available Formats

Mitsubishi FBC15/18/20/25KS Service Manual Messages, Codes, and Tests

Messages, Codes, and Tests 6:

List of Codes and Tests

Code L3 - Throttle Command With Deadman Input Not Selected . . . . . . . . . . . . . . . . . . . . . . . 6-61

Test I17 - Lift Motor Brush Wear Indicator (lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109

Message and Code Summary Tables

Message and Code Summary Tables

Informational/Performance Limiting Fault Codes

Message and Code Summary Tables

Contactor Fault Codes

Message and Code Summary Tables

Communications Fault Codes

Lift System Fault Codes

Operator’s Controls Fault Codes

Message and Code Summary Tables

System Fault Codes

MTX Fault Codes

Function Controller Fault Codes

Steering Fault Codes

Message and Code Summary Tables

Left Power Amp Fault Codes

Message and Code Summary Tables

Right Side Power Amp Fault Codes

Messages and Codes

Messages and Codes

Messages and Codes

Code 10 - Power ON; SelfTest

Code Title Power ON; SelfTest

During power-up, the truck will run through SelfTest to

Operator Display SelfTest

Travel PC Contactor Energized

Lift PC Contactor Energized

Travel System Operational

Lift/Lower System Operational

How To Clear This is a status indication only; there is no need to clear.

Tests to Run None

Messages and Codes

Code 1H - Traction Power Amp #1 Overheated

Code Title Traction Power Amplifier #1 Overheated

Reason The traction power amplifier #1 has overheated.

Alarm Sounds Yes

Operator Display Code 1H. Overheated, Allow Time to Cool.

Travel PC Contactor Energized

Lift PC Contactor Energized

Travel System 2.5 mph speed limit

Lift/Lower System Operational

How To Clear Allow time for power amplifier to cool. Self-resetting.

Tests to Run O14 - Ramp Command to Traction Power Amp #1

NOTE: Code 1H corresponds to GE Amplifier

Messages and Codes

Code 1L - Interface Card Detected EPO Switch Down

The Interface Card Detected The Emergency Power

Reason The emergency power off switch has been depressed.

Alarm Sounds Yes

Operator Display Code 1L. Lift Emergency Stop Button.

Travel PC Contactor De-energized

Lift PC Contactor De-energized

Travel System Shutdown

Lift/Lower System Shutdown

Turn key switch OFF, lift emergency off button, then

Tests to Run I01 - Emergency Power Off Switch

Messages and Codes

Code 1T - Battery Low