Logic Card2ec15 MONTACARGAS CATERPILLAR

EV100ZX DIAGNOSTIC STATUS CODES
Basic Checks ........................................................................................................ 7-1
On Board Diagnostics ...................................................................................... 7-2
Status Codes......................................................................................................... 7-4

Basic Checks
The biggest mistake technicians can make is to and hour meter reading. This will keep us from getting
assume they know the problem before starting to work confused trying to count to the proper fault code storage
on a truck. Unfortunately while making our life easier location and the information may later prove helpful. I
self-diagnostics also make us more susceptible to this would suggest that these codes only be zeroed out
type of mistake. Never start to fix a truck based solely after the truck is repaired and running properly.
on the number on the dash or handset display. Always
follow the basic troubleshooting steps. Now we can utilize the Status Codes in the following
pages to find the component or area to check for our
fault. A bad card can cause virtually any problem
Talk to the operator imaginable, yet it is the one part we cannot test.
Therefore any Status Code could be the result of a
• Confirm their description of the problem with card failure. If all the pertinent areas to check are in
an operational check. proper operating condition then check all the card
inputs and if they are good then we have no choice
but to replace the card. Some discretion here is
• Visually inspect cables, connectors, contactor
advisable as approximately 70% of the control cards
tips, etc.
replaced have nothing wrong with them. Ironically
enough this is about the same ratio as is found in the
• Perform basic battery cables to frame resistance automotive industry for computers on cars.
tests. You should have at least 20,000 ohms.
Notes
• Check the battery condition.
Now we are ready to allow the self-diagnostics to give

us a starting point to repair the truck. Turn the key
switch on and check when the 8 88 8 is displayed to be
sure all of the LED’s are functional. At this time note
the status (fault) code (if any) and then turn the key
switch off so you can note the hours on the meter.
Disconnect the battery and discharge the capacitor.
Remove the Y plug which connects the dash gauge to
the card and insert the handset plug connector. Plug
in the battery. While holding the CONT button down
on the handset turn on the key switch to enter the
programming mode. When you get the 8 8 88 push
down on the Function I button to double check the
Status Code stored in the memory which should be
the same as the dash gauge (if it showed one).
Before proceeding we need to check the card’s
programming.
Always check each function and always write

down the reading.
Nobody has a perfect memory and you may not get a

second chance to know how the card was programmed.
If the programming fails to match the specifications,
reprogram the card and check the truck operationally
before going any further. If repairs are required, turn
the key switch off, then push the CONT and ESC
keys at the same time to enter the scrolling mode
7-1
On-Board Diagnostics
7-2
On-Board Diagnostics
7-3
TABLE OF CONTENTS
STATUS DESCRIPTION PAGE
CODE
Blank No input voltage to control card or display ................................................................ 7-5
-00 Battery is extremely discharged ................................................................................. 7-6
-01 No input signal from seat switch ................................................................................ 7-6
-02 Forward switch closed on initial start ......................................................................... 7-7
-03 Reverse switch closed on initial start ......................................................................... 7-7
-04 Start switch - low voltage after start........................................................................... 7-8
-05 Start or Brake switch did not close ............................................................................ 7-8
-06 Accelerator depressed, no direction selected ............................................................ 7-9
-07 Accelerator input voltage too high.............................................................................. 7-9
-08 Accelerator input voltage too low or power to control card after key in ON position 7-10
-09 Both Forward and Reverse switches closed at same time...................................... 7-10
-11 Start switch is closed when the key switch is closed and voltage is applied to the control card .7-11
-15 Battery volts too low ................................................................................................. 7-11
-16 Battery volts too high ............................................................................................... 7-12
-17 Wrong control card installed..................................................................................... 7-12
-21 Accelerator input is less than 0.25 volts .................................................................. 7-13
-23 Coil current low, Forward or Reverse contactor ..................................................... 7-13
-24 Voltage at T2 too low ............................................................................................... 7-14
-25 1A contactor does not open or opens too slowly ..................................................... 7-14
-26 Shorted coil driver for 1A, RB, or PS contactor ....................................................... 7-15
-41 Open thermal protector or motor control temperature too high .............................. 7-15
NOTE: Motor speed is decreased when code -41 is indicated
-42 Motor sensor input missing (green wire).................................................................. 7-16
-43 Motor sensor input missing (yellow wire) ................................................................. 7-16
-44 1 REC did not turn OFF correctly ............................................................................ 7-17
-45 1 REC did not turn ON correctly .............................................................................. 7-17
-46 T2 voltage too high .................................................................................................. 7-18
-47 2 REC does not turn ON correctly ........................................................................... 7-18
-48 T2 voltage too low .................................................................................................... 7-19
-49 5 REC does not turn ON correctly ........................................................................... 7-19
-50 C1 voltage too low ................................................................................................... 7-20
-51 C1 voltage too high with high motor current ............................................................ 7-20
-52 C1 voltage too high with low motor current ............................................................. 7-21
-53 1 REC does not go OFF during plugging ................................................................ 7-21
-54 Short-circuit, Forward, Reverse or 1A contactor coil driver ..................................... 7-22
-57 Polarity check, current sensor input voltage ............................................................ 7-22
-70 Current sensor input missing (wire #22) .................................................................. 7-23
-71 Current sensor input missing (wire #21) .................................................................. 7-23
-72 Regenerative braking contactor does not energize ................................................. 7-24
-73 Regenerative braking contactor does not de-energize or de-energizes slowly ....... 7-24
-74 Regenerative braking contactor energizes too slowly ............................................. 7-25
-75 1 REC does not go OFF during regenerative braking ............................................. 7-25
-76 C1 voltage too high during regenerative braking ..................................................... 7-26
-90 Voltage at terminal 1 of the TMM at zero volts ........................................................ 7-26
-92 Voltage at terminal 4 of the TMM at zero volts ........................................................ 7-27
-94 Voltage at terminal 8 and 10 of the TMM at zero volts ............................................ 7-27
(*) Not used on all models of lift trucks. Status Codes in this group will flash on the display.
7-4
TABLE OF CONTENTS
STATUS DESCRIPTION PAGE
CODE
-95 Voltage at terminal 11 and 12 of the TMM at zero volts ......................................... 7-28
-99 Maintenance Alert Code........................................................................................... 7-28
-117 Wrong control card installed (*)................................................................................ 7-29
-123 Pump PMT contactor coil current is too low (*) ....................................................... 7-29
-124 Voltage at T2 too high (*) ......................................................................................... 7-30
-125 1A contactor does not de-energize or opens too slowly (*) ..................................... 7-30
-141 Open thermal protector or motor control temperature too high (*) .......................... 7-31
-142 Motor sensor input missing (green wire) (*)............................................................. 7-31
-143 Motor sensor input missing (yellow wire) (*) ............................................................ 7-32
-144 1 REC did not go OFF correctly (*).......................................................................... 7-32
-145 1 REC did not go ON correctly (*) ........................................................................... 7-33
-146 T2 voltage too low (*) ............................................................................................... 7-33
-147 2 REC did not go ON correctly (*) ........................................................................... 7-34
-148 Voltage at T2 too low (*)........................................................................................... 7-34
-149 5 REC does not go ON correctly (*) ........................................................................ 7-35
-150 C1 volts low (*) ......................................................................................................... 7-35
-151 C1 volts high with high motor current (*) ................................................................. 7-36
-152 C1 volts high with low motor current (*) ................................................................... 7-36
-154 Short-circuit in electronic driver for the hydraulic pump contactor or 1A contactor (*) ....... 7-37
-157 Polarity check, current sensor input voltage (*) ....................................................... 7-37
(*) Not used on all models of lift trucks. Status Codes in this group will flash on the display.
TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Segments do not illuminate on the No input voltage to the Logic Card or the display
NONE Dash Display and/or the Handset. unit.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Display screen on Dash Display and/or
Handset is blank.
POSSIBLE CAUSE
Positive or negative control voltage is not present. CONTROL
• Insure that the key switch is closed and voltage FUSE KEY
Circuits valid is present between PZ7 & PZ3 control SWITCH
negative. Also check for voltage between TB4 ➤
➤
for and PZ3 control negative.
Traction
Open circuit between logic card Plug Y & the POWER
Controller Dash Display or Handset. TB4
FUSE
& • Check for an open circuit or loose connection ➤
going from the “Y” plug and the Dash Display
Pump or Handset. P
Controller
➤
Defective Dash Display or Handset. PZ7 CAP

• Replace Dash Display or Handset.
➤
7-5

STATUS CODE Truck does not operate. Key on Battery extremely discharged.
-00 in direction.

NO Battery connected. Key on in direction. Truck
will not move.
POSSIBLE CAUSE
Battery extremely over discharged.
Circuits valid Charge Battery overnight.

for
Traction
Controller
&
Pump
Controller

STATUS CODE No seat switch or deadman switch This status code will be displayed when TB3 is
-01 input. less than 50% battery volts.

NO Forward or Reverse contractor will not close.
POSSIBLE CAUSE
Mis-adjusted or defective seat or deadman
KEY SEAT
switch.
SWITCH SWITCH
➤
• Check to see that the seat switch closes

Circuits valid properly. ➤
➤
for
Open circuit between battery positive and TB3.
Traction • Check for loose connections or broken wires:
Controller -Between the seat switch and TB3.
-Between the key switch and the battery
TB4 TB3
positive side of the seat switch.
-Between the seat switch and TB4.
7-6

STATUS CODE Forward directional switch is closed This status code will be displayed when TB5 is
-02 on initial power up. greater than 60% of battery voltage at initial key
switch on.

NO Forward contactor will not close because of
Static Return to Off (SRO) lock out.
POSSIBLE CAUSE
Forward directional switch is closed on initial SEAT BRAKE
start up (i.e. closure of battery, key switch or SWITCH SWITCH
Circuits valid seat/deadman switch). ➤
• Return directional switch lever to neutral and
for then return lever to forward position.
Traction ACCEL
Forward directional switch is welded closed or START
Controller mis-adjusted to be held closed. SWITCH
• Replace or adjust directional switch to insure TB4 TB3
that it opens when the directional switch is
returned to neutral.
Short circuit between TB3 and TB5. TB2

• Disconnect the wire from the TB5 and check FWD
for a short circuit between TB3 and the wire
that was connected to TB5. TB5
Defective logic card.
• Disconnect wire at TB5 and measure voltage.
It should be less than 60% of battery volts.

STATUS CODE Reverse directional switch is closed This status code will be displayed when TB6 is
-03 on initial power up. greater than 60% of battery voltage at initial key
switch on.

NO Reverse contactor will not close because of
Static Return to Off (SRO) lock out.
POSSIBLE CAUSE
SEAT BRAKE
Reverse directional switch is closed on initial
SWITCH SWITCH
start up (i.e. closure of battery, key switch or
Circuits valid seat/deadman switch). ➤
• Return directional switch lever to neutral and
for then return lever to reverse position.
Traction ACCEL
Reverse directional switch is welded closed or START
Controller mis-adjusted to be held closed. SWITCH
TB4 TB3
• Replace or adjust directional switch to insure
that it opens when the directional switch is
returned to neutral.
TB2
Short circuit between TB3 and TB6. REV
• Disconnect the wire from TB6 and check for
a short circuit between TB3 and the wire.
TB6
• Disconnect wire at TB6 and measure voltage.
It should be less than 60% of battery volts.
7-7

STATUS CODE Start switch input low after initial start This status code is displayed when TB2 voltage is
-04 up. less than 60% of battery volts at initial start-up (seat
switch closure).

NO Forward or reverse contactor will not pick-up.
POSSIBLE CAUSE BRAKE

Forward or reverse directional switch closed on SWITCH
initial start up. ➤
• Depress accelerator to close start switch.
Circuits valid Status code will change to 03 if reverse
directional switch or to 02 if forward directional ACCEL
➤
for switch is closed. If either of these codes START
Traction appear, return directional switch to neutral and SWITCH
then select the desired direction.
Controller
Excessive leakage from TB2 to battery negative.
• Check voltage at TB2 with key and seat ➤
switches closed and directional switch in
neutral. Voltage should be greater than 60% of
➤
battery voltage.
• If less than 60% battery voltage. Remove wire TB2
and measure ohmic value from wire to SCR
negative. Value should be less than 22k ohms.

STATUS CODE Start switch or brake switch fails to This status code will be displayed when TB1 is
-05 close. less than 2.5 volts and TB2 is less than 60% of
battery volts.

NO Forward or reverse contactor will not pick up.
POSSIBLE CAUSE SEAT BRAKE

Defective brake switch circuit. SWITCH SWITCH
➤
• Check brake switch to insure closure with
brake pedal released. ACCEL
Circuits valid • Check for open circuit or loose connection in
➤
ACCEL
wiring from brake switch to seat switch and
for TB3, and from brake switch to start switch.
START
SWITCH
Traction
Controller Defective start switch circuit.
• Check start switch to insure closure when
accelerator is depressed.
• Check for open circuit or loose connections
in wiring from brake switch to start switch
and from TB2 to start switch.
TB4
TB3
TB2
TB1
7-8

STATUS CODE Accelerator depressed with no This status code will be displayed when TB5 &
-06 direction selected. TB6 are less than 60% of battery volts, and TB1 is
less than 2.5 volts.

POSSIBLE CAUSE
Accelerator pedal is depressed before closing ACCEL
CONTROL
forward or reverse directional switch.
➤
• Status code will disappear when directional
Circuits valid switch is closed or when accelerator pedal is FWD
REV
DIR SWITCH
released.
for FWD
REV
FOOT DIR SWITCH
Traction Defective directional switch.

• Check forward or reverse switch to insure
Controller closure when direction is selected.
Open circuit between directional switch(es) and

battery positive or between directional
switch(es) and TB5 or TB6.
• Check all control wires and connections
TB5
TB6
TB1
shown in Trouble Shooting Diagram.

STATUS CODE Accelerator input voltage too high. This status code will be displayed when the
-07 accelerator input voltage at TB1 is higher than 3.7
volts, and a directional contactor is picked up.

NO Forward or reverse contactor picks up but
control will not operate when accelerator
pedal is depressed or status code -07 is dis- ACCEL
played then disappears when the vehicle CONTROL
starts to accelerate.
POSSIBLE CAUSE
Circuits valid Accelerator input mis-adjusted or defective.
for • Input voltage at TB1 should be less than 3.7 volts.
Adjust or replace accelerator unit to insure that
Traction the voltage at TB1 will vary from 3.5 volts to less
Controller than .5 volts when the pedal is depressed.
Open circuit between battery negative and TB1
in accelerator input circuit.
• Check for broken wires or loose connections
or open potentiometer / voltage supply in the
circuit shown in trouble-shooting diagram.
TB1
Short circuit from battery positive to wiring in

accelerator input circuit.
• Disconnect wire from TB1 and measure voltage
at wire to negative. Should ne zero volts for
potentiometer type and less than 3.7 volts for
solid state type accelerator input.
7-9

STATUS CODE Accelerator input voltage too low on This status code will be displayed when the
-08 power up after initial key switch accelerator input voltage at TB1 is less than 3.0 volts,
closure. and any of the following connections are opened &
closed: battery plug, seat switch or key switch.
NO Forward or reverse contactor does not pick up.
POSSIBLE CAUSE ACCEL

Accelerator input mis-adjusted or defective. CONTROL
• Input voltage at TB1 should be more than 3.0
volts. Adjust or replace accelerator unit to
Circuits valid insure that the voltage at TB1 is more than 3.0
volts before depressing pedal.
for
Traction Short circuit between battery negative and TB1
in accelerator input circuit.
Controller • Disconnect wire from TB1. Check for short
circuit from wire to battery negative.
Resistance should be greater than 4.7 ohms.
Defective Card.
• Disconnect wire from TB1. Measure voltage
TB1
from TB1 to negative. Voltage should be
greater than 4.5 volts, if not, replace card.

STATUS CODE Both the forward and reverse This status code will be displayed when TB5 & TB6
-09 directional switches are closed at the are greater than 60% of battery volts at the same
same time. time.

POSSIBLE CAUSE
➤
Forward or reverse directional switch welded

closed or mis-adjusted to be held closed.
• Replace or adjust directional switches to insure ➤
Circuits valid that they open when directional switch is
returned to neutral. TB2 Directional
for FORWARD REVERSE Switches
Traction Short circuit between battery positive and TB5
and / or TB6.
Controller • Disconnect wires from TB5 and TB6 and TB5
check wire for short circuit to positive side of
directional switch. TB6
Defective card.
• Disconnect wires and measure voltage at TB5
and TB6. Voltage should be less than 60% of
battery volts.
7-10

STATUS CODE Start switch closed on power up after This status code will be displayed when TB2 is
-11 initial key switch closure. greater than 60% of battery voltage when the key
switch is closed.

POSSIBLE CAUSE BRAKE

Start switch input mis-adjusted or defective. SWITCH
• Input voltage at TB2 should be less than 60% ➤
battery volts at key switch closing. Adjust or
Circuits valid replace accelerator unit to insure that the
ACCEL
➤
voltage at TB2 is less than 60% battery volts
for before closing the start switch pedal. START
Traction SWITCH
Short circuit between battery positive and TB2 in
Controller start switch input circuit.
• Disconnect wire from TB2. Check for short
circuit from wire to battery positive. Resistance
should be greater than 4.7K ohms.
Defective card.
• Disconnect wire from TB3. Measure voltage TB2
from TB3 to negative. Voltage should be zero,
if not, replace card.
• Check for JP1 Jumper in card on wrong pins.

STATUS CODE Battery voltage is too low or control This status code will be displayed when the battery
-15 card is mis-adjusted. volts are less than 1.95 volts per cell at initial key
switch on. See table below.

POSSIBLE CAUSE
Discharged battery. BATTERY
CONNECTION MINIMUM
• Check battery for proper open circuit voltage NOMINAL
LIMIT VOLTS
➤
as outlined in the Figure and charge battery, if BATTERY

AT 1.95 VDC
Circuits valid required. VOLTS
PER CELL
for Defective battery.
BATTERY 24 23.4
Traction • Check each battery cell for proper voltage
(greater than 1.95 volts at cell). Replace or 36 35.1
Controller repair battery. 48 46.8
72 70.2
➤
Incorrect control card adjustment.

BATTERY 84 81.9
• Check function 15 for proper adjustment for
battery being used. See Handset instruction CONNECTION
sheet for details. Adjust to proper settings.
7-11

STATUS CODE Battery voltage is too high or control This status code will be displayed when the bat-
-16 card is mis-adjusted. tery volts are greater than 2.40 volts per cell at ini-
tial key switch on. See table below.

NO Forward and reverse contactor will not pick up. SENSOR #2
➤
POSSIBLE CAUSE P
Incorrect control card adjustment.
• Check function 15 for proper adjustment for YEL
➤
7 REC
battery being used. See Handset instructions
Circuits valid for details. Adjust to proper setting. BATTERY
CONNECTION
➤
PA4
for
➤
Battery over-charged or incorrect battery used.
Traction • Check battery for proper open circuit voltage
per table in trouble-shooting diagram. If voltage
Controller excessive-check battery for proper output BATTERY MAXIMUM
voltage. NOMINAL
LIMIT VOLTS
BATTERY
AT 2.40 VDC
• Defective accelerator. VOLTS
PER CELL
➤
BATTERY
CONNECTION 24 28.8
36 43.2
48 57.6
72 86.4
84 100.5

STATUS CODE “Card Type” selection is invalid. This status code will be displayed when the card
-17 type selection value is set to an invalid number.

NO Forward or reverse contactors will not close.
POSSIBLE CAUSE
Invalid card type selection.
• Review function 17 in the “Handset” section.
Adjust and set card type value as instructed
Circuits valid by the Service Manual.
for
Traction
Verify that the correct logic card catalog
Controller number is installed in the controller.
7-12

STATUS CODE Accelerator input is less than .25 volts. This status code will be displayed when the voltage
-21 at TB1 is less than .25 volts.

NO Controller will not operate.
POSSIBLE CAUSE ACCEL

Accelerator input needs adjustment or is damaged. CONTROL
• Input voltage at TB1 must be greater than .25
volts when the accelerator pedal is fully
Circuits valid released. Adjust or replace accelerator unit.
for
Short-circuit between battery negative and TB1
Traction in accelerator input circuit.
Controller • Disconnect wire from TB1 and check for
short-circuit from end of wire to battery negative.
Resistance must be greater than 4.7K ohms.
Defective Card.
• Disconnect wire from TB1. Measure voltage
TB1
from TB1 to negative. Voltage should be
greater than 4.5 volts, if not, replace card.

STATUS CODE Forward and reverse contactor coil This status code will be displayed when the cur-
-23 current is low. rent draw in the forward or reverse contactor coil
circuit is less than 100 milliamps.

Status code may alternate between code 23
and code 24. Complete check for code 23, if
➤
➤
➤
➤
➤
the problem is not found, perform check for

code 24.
+
Circuits valid POSSIBLE CAUSE
Defective F and R contactor coil circuit. F +
for • Check for open circuit or loose connection R +
Traction between PB4 and positive side of F contactor
PB4
coil and between PB5 and positive side of R 1A +
Controller contactor coil. PB5 RB +
PB6
• Remove plug B. Check ohmic value from PB4 PS +
to positive side of F coil. Value should be 10 to PB2
FW
14 ohms. Make same check for R coil.
PB3
Defective 1A, FW, RB, or PS contactor coil. PB1
• Remove plug B. Check ohmic value from
positive side of each coil to its respective plug
connection. Value should be 10 to 14 ohms.
7-13

STATUS CODE T2 voltage is too high. (Greater than 12% This status code will be displayed when T2 volts is
-24 battery volts). greater than 12% of battery volts and the “F” & “R”
driver is energized.

Control does not operate. Status code may alter-
➤
NO nate between code 23 and code 24. Complete T2
checks for 24, if the problem is not found, perform ➤
code 23 check.
POSSIBLE CAUSE R
F
Defective F or R contactor.
Circuits valid • F or R power tips fail to close because: S1 S2
for 1) Welded normally closed power tips. FIELD
2) Binding contactor tip assembly.
Traction 3) Defective F or R contactor coil. F R
Controller (See status code 23)
Defective RB contactor.
A1
A1
• Check RB contactor power tips for closure and
➤
proper pick up. ARMATURE
• Check for open circuit or loose connections between A2
positive side of RB contactor coil and PB2.
Open Motor Circuit. RB
• Check for open circuit or loose connection in
motor circuit from the A1 connection to the A2 A2
connection on the SCR control panel.
Defective 1A, RB, PS or FW contactor.
➤
• Perform checks as outlined in status 23.
• Loose Terminal on 3 REC.

STATUS CODE 1A contactor does not drop out or drops This status code will be displayed when 1A
-25 out slowly. contactor drop out time exceeds .060 seconds.

YES Short tip life on F and R or 1A contactor. Status ➤ P
code 46 displayed and no fault found. ➤
POSSIBLE CAUSE
➤
Note: This status code can only be found by

using the handset and looking at function 1. This
Circuits valid status code is furnished as a
for troubleshooting aid for status code 46.
Traction Defective 1A contactor.
Controller • Check 1A contactor for binding or slow
1A
operation when dropping out.
➤
T2
➤
➤
➤
7-14

STATUS CODE Shorted coil driver for PS or FW This status code will be displayed when there is a
-26 contactor. shorted PS, RB, or FW coil driver.

NO PS or FW contactor picks up immediately
when key switch is closed.
➤
➤
POSSIBLE CAUSE
Defective coil driver internal to logic card.
• Replace logic card.
Circuits valid
for
+
Traction RB +
Controller
PS +
PB6
FW
PB2
PB3

STATUS CODE Open thermal protector (TP) or This status code will be displayed when the voltage
-41 control over temperature. between PZ1 and PZ5 is greater than 1.8 volts.

NO Reduced or no power to traction motor in
SCR range.
POSSIBLE CAUSE
Open thermal protector circuit.
• Check for loose connection or broken wire
Circuits valid between:
Black
-Black wire - Thermal protector and PZ1 PZ1
for -Gray wire - Thermal protector and PZ5
Traction THERMAL
Defective thermal protector. PROTECTOR
Controller • Disconnect wires from PZ1 and PZ5. At room
PZ5
temperature (25° C or 75° F) measure Gray
resistance between Black and Gray wire.
Replace TP if ohmic value is greater than 300
ohms.
SCR is in thermal cut-back.

• Allow control to cool, status code should
disappear.
7-15

STATUS CODE Controller “motor current sensor” This status code will be displayed when the voltage
-42 input is missing. between PY7 and Negative is greater than 1.6
volts with no current flowing in the motor circuit.

NO No power to traction motor in SCR range.
POSSIBLE CAUSE
➤
Open sensor wire circuit to PZ4.
(green wire) from current sensor to PZ4 on
Circuits valid the logic card. A2
for
Traction Green
SCR PZ4
Controller CURRENT
➤
SENSOR
➤
➤
NEG

STATUS CODE Controller “motor current sensor” input This status code will be displayed when the voltage
-43 is missing. between PY7 and Negative is less than .84 volts
with no current flowing in the motor circuit.

NO No power to traction motor in control range.
POSSIBLE CAUSE
➤

• Check for loose connections to broken wire
(yellow wire) from current sensor to PZ3 on
Circuits valid the logic card. A2
for
Traction SCR ➤
CURRENT
Controller SENSOR PZ3
Yellow
➤
➤
NEG
7-16

STATUS CODE 1 REC did not turn off properly. This status code will be displayed when, during
-44 SCR operation, 1 REC fails to turn off.

YES Forward or reverse contactors open and
close, then can only be closed by opening
➤
P
and closing the key switch.
POSSIBLE CAUSE REC

Defective 5 REC circuit.
➤
➤
➤
➤
Circuits valid • Check for shorted 5 REC.
2 REC CHOKE
• Check for shorted 5 REC snubber (25 REC). T5
for • Power cables switched. 1X
Traction
Controller Defective 2 REC circuit.
• Check for shorted 2 REC.
• Check for shorted 2 REC snubber (22 REC).
22 REC
➤
➤
Open choke (1X). 5 REC
• Check for open circuit between T5 and T3.
Ohm meter should read zero ohms. T4 T3
Defective 1 REC. ➤
• Turn off time for 1 REC out of specification.
No field test is possible. Replace 1 REC after 25 REC
above checks, show no problem found.

STATUS CODE 1 REC did not turn on properly. This status code will be displayed when 1 REC fails
-45 to gate “on”.

YES Forward or reverse contactor will open and
close, then open and then can only be
closed by opening and closing the key ➤ P
switch. ➤
POSSIBLE CAUSE
Circuits valid Defective 2 REC circuit.
1 REC Wht/Blu
• Check for shorted 2 REC. PZ8
for PZ9
• Check for shorted 2 REC snubber (22 REC). Blu
Traction
➤

• Check for open circuit or loose connections 2 REC
between 1 REC and PZ8. (white/blue wire). ➤
• Check for open circuit or loose connection
between 1 REC (3 REC snubber) and PZ9.
(blue wire).
Defective 1 REC. 22 REC

• Intermittent or open 1 REC gate. Field test
may or may not show defect. Replace 1 REC
after above checks show no problem found.
7-17

STATUS CODE “Look Ahead” test for T2 volts. (greater This status code will be displayed when the voltage
-46 than 85% of battery volts). at T2 is greater than 85% of battery volts.

POSSIBLE CAUSE
➤
➤
Defective 1 REC. P
Circuits valid • Check for defective 1 REC insulator (co-therm) 1 REC ➤

that may short 1 REC heat sink to base plate.
for ➤
Traction
Defective 1A contactor.
Controller • Check for welded 1A contactor power tips.
1A
➤
➤
T2
➤
STATUS CODE 2 REC does not turn properly. This status code will be displayed when the 2 REC
-47 fails to turn on.

YES Forward or reverse contactor will open and ➤
close, then open and then can only be closed P
by opening and closing the key switch.
POSSIBLE CAUSE REC ➤

➤
Defective 2 REC circuit. ➤

➤
Circuits valid • Check that 2 REC will gate on. 2 REC

T5
CHOKE
• Check for open circuit or loose connection
for between 2 REC gate and PZ10 (white/red wire). 1X
Traction • Check for open circuit or loose connection
1 REC and 1 C through the 2 REC circuit.
Controller
• Check for shorted 5 REC. 22 REC
➤
➤
• Check for shorted 5 REC snubber (25 REC) 5 REC

Open Choke (1X). T4 T3
• Check for open circuit between T5 and T3.
Ohm meter should read zero ohms.
➤
F or R contactor or power tips bouncing open.

• Check that power tips on F and R contactor
25 REC
power tips do not bounce open during operation
(ie: travel over speed bumps or dock plates).
7-18

STATUS CODE “Look Ahead” test for T2 volts (less This status code will be displayed when the voltage
-48 than 12% of battery volts. at T2 is less than 12% of battery volts.

➤
T2
POSSIBLE CAUSE
Defective forward or reverse contactor.
• Check for welded forward or reverse contactor F R
power tips. S1 S2
Circuits valid FIELD
• Check for sluggish operation of forward or
for reverse contactor.
F R
Traction ➤
Defective 3 REC circuit. A1
Controller • Check for shorted 3 REC. 23FL
➤
ARMATURE
3 REC
A2
A2
SCR
➤
CURRENT ➤
SENSOR
➤
NEG

STATUS CODE 5 REC does not turn on properly. This status code will be displayed when the 5 REC
-49 circuit fails to turn on.

Forward or reverse contactor will open and
YES close, then open and then can only be closed
by opening and closing the key switch.
POSSIBLE CAUSE
➤
Defective 5 REC circuit. PZ12 PZ14

White/Violet
➤
• Check for shorted 5 REC snubber (25 REC). White/Violet Orange

➤
for • Check that 5 REC will gate on. 1X
Traction • Check for open circuit or loose connection T5 CHOKE

2 REC Orange
between 5 REC gate and PZ12
➤
Wire 2 REC
Controller (white/violet wire).
5 REC REACTOR
➤
T4 T3 T5 T4
Shorted 2 REC circuit.
➤
T3
• Check 2 REC and 2 REC snubber (22 REC)
REACTOR
for short circuit.
25 REC
Defective capacitor circuit.

• Check for open capacitor.
• Check for loose connection at capacitor
terminals.
Defective reactor circuit.

• Check for open reactor circuit.
• Check for high resistance in reactor circuit.
7-19

STATUS CODE Capacitor volts low. This status code will be displayed when 2 REC circuit
-50 fails to turn on at initial key switch on.

NO Forward or reverse contactor picks up. BUS A
Control does not operate.
SPIDER
➤
POSSIBLE CAUSE
5 REC
• Open circuit or loose connection between
➤
Circuits valid spider assembly and 5 REC (BUS A). BUS B ➤
Red Wire
➤
for • Open circuit or loose connection between White/Red 2 REC
Traction 5 REC and 2 REC. Wire
Controller • Open circuit or loose connection between PZ10

2 REC and PZ11 (red wire) and between
➤
➤
2 REC gate and PZ10 (white/red wire). White/Red
• Check 2 REC to insure that it will gate on. 1 REC

1C
T5 1X
2 REC
➤
STATUS CODE Excessive capacitor voltage when This status code will be displayed when capacitor
-51 motor current is high. volts exceed 225 volts and motor current is greater
than 300 amps.

➤
YES Forward or Reverse contactors open and T2

POSSIBLE CAUSE F R
Excessive source inductance. S1 S2
Circuits valid • Tag lines without filters are being used. FIELD
for • Battery cables are too long.
F R
Traction A1
Controller High peak current in motor.
A1
ARMATURE
• Check for shorted field winding.
A2
• Check for shorted armature winding.
A2
SCR
➤
CURRENT ➤
SENSOR
➤
NEG
7-20

-52 motor current is low. volts exceed 225 volts and motor current is less
than 200 amps.

➤
YES Forward or reverse contactors open and T2
F R
POSSIBLE CAUSE
Excessive source inductance. S1 S2
Circuits valid • Tag lines without filters are being used. FIELD
• Battery cables are too long. F
for R
Traction Defective 4 REC circuit.
• Check for shorted 4 REC. A1
Controller • Check for open circuit, or loose connection in ARMATURE
4 REC circuit. 3 REC
A2
• Check for open circuit or loose connection in A2 4 REC
3 REC circuit.
SCR
➤
CURRENT ➤
SENSOR
➤
NEG

STATUS CODE 1 REC fails to turn off during plugging This status code will be displayed when any failure
-53 operation. of 1 REC to turn off during plug cycle occurs.

SYMPTOM
MEMORY RECALL Forward or reverse contactor opens and
➤
closes, then opens and can only be closed

YES by opening and closing the key switch.
T2
Severe plugging.
POSSIBLE CAUSE F R
1 REC turn off failure not related to plugging.
S1 S2
• Stall vehicle in both directions and note any status
Circuits valid codes displayed that may more closely define the
for failure mode. Troubleshoot per new status code. F R
Traction 1 REC turn off related to plugging.
• Check 4 REC circuit for open 4 REC, loose or A1
Controller A1
open cable/bus connections.
• Check current sensor for loose or open connec- ARMATURE
tion in power circuit. Check yellow and green wire A2
from sensor to logic card for open and loose 4 REC
connection. Check yellow and green wires for A2
correct pin location on control.
Defective motor circuit. SCR Green
PZ4
• Check motor circuit for open or loose connections. CURRENT
SENSOR Yellow PZ3
• Check motor brushes for proper seating.
F or R contactor power bouncing open. ➤
➤
• Insure that F and R contactor does not bounce
NEG
open during vehicle operation (ie: traveling over
speed bumps and dock plates).
7-21

STATUS CODE Shorted Forward, Reverse, or 1A This status code will be displayed when any of the
-54 contactor coil driver. Forward, Reverse or 1A contactor coil driver is
shorted internal to the logic card.

NO Control will not operate.
POSSIBLE CAUSE
Circuits valid
for
Traction
Controller

STATUS CODE Controller “motor current sensor” input This status code will be displayed when the voltage
-57 voltage polarity check. input to PZ4 and PZ3 is the wrong polarity.

NO Forward or reverse contactors open and
➤

POSSIBLE CAUSE A1
Reversed yellow and green current sensor wires.
Circuits valid • Insure that the green wire connects to PZ4
with no open circuits and that the yellow wire A2
for connects to PZ3 with no open circuits or
Traction loose connections. A2
Controller Reversed power cable connection.
• Insure that the battery positive cable connects SCR Green
PZ4
to SCR negative and the motor A2 cable con- CURRENT
SENSOR Yellow PZ3
nects to SCR A2.
➤
NEG
7-22

STATUS CODE Regenerative current sensor input This status code will be displayed when the input
-70 missing (wire #22). signal at PA4 is missing.

YES Control does not operate.
POSSIBLE CAUSE
Defective regenerative sensor input circuit.
• Check sensor wire #22 for open circuit or POS SENSOR 2
loose connection between sensor (welded ➤
Circuits valid connection) and PA4.
for
➤
Traction
Controller Wire Wire
7 REC
#22 #21
PA4 PA5
➤
STATUS CODE Regenerative current sensor input This status code will be displayed when the input
-71 missing (wire #21). signal at PA5 is missing.

YES Control does not operate.
POSSIBLE CAUSE
Defective regenerative sensor input circuit.
• Check sensor wire #21 for open circuit or POS SENSOR 2
loose connection between sensor (welded ➤
Circuits valid connection) and PA5.
for
➤
Traction
Controller 7 REC
Wire Wire
#22 #21
PA4 PA5
➤
7-23

STATUS CODE Regenerative contactor (RB) does not This status code will be displayed when the logic
-72 pick up. card is in the run mode and 2.5 volts or greater is
present at PA6.

YES Regenerative control does not operate.
POSSIBLE CAUSE
Open connection in the PA6 circuit.
➤
• Check for open circuit of loose connection
➤
between PA6 and the A2 connection of the
Circuits valid RB contactor. RB COIL
7 REC
➤
for • Check for open circuit or loose connection
Traction between 7 REC and the A2 connection of the DRIVE
RB contactor. MOTOR PB2 PA6
Controller A2
17
RB CONTACTOR
TIPS
A2

STATUS CODE Regenerative contactor (RB) does not This status code will be displayed when the RB
-73 drop out or drops out slowly. contactor power tips fail to open after 100 milliseconds
after power is removed from the RB contactor coil.

YES Forward or reverse contactor opens and
closes, then opens and can only close by
opening and closing the key switch.
➤
POSSIBLE CAUSE
Defective RB contactor.
7 REC
➤
Circuits valid • Check RB contactor for smoothness of

operation and excessive wear on moving DRIVE
for parts. MOTOR PA6
Traction A2
Intermittent PA6 input.
Controller • Check for loose connections in PA6 circuit 17
from PA6 to RB contactor A2 connection.
RB CONTACTOR
TIPS
A2
➤
7-24

STATUS CODE Regenerative contactor (RB) picks up This status code will be displayed when the RB
too slowly. contactor power tips do not close within 100 milliseconds
-74 after power is applied to the RB contactor coil.

➤
POSSIBLE CAUSE
Defective RB contactor. RB COIL
Circuits valid • Check RB contactor for smoothness of 7 REC
➤
operation and excessive wear on moving
for parts. DRIVE
Traction MOTOR PB2 PA6
Intermittent PA6 input. A2
Controller • Check for loose connections in PA6 circuit
from PA6 to RB contactor A2 connection. 17
Defective RB contactor coil circuit.

• Check RB contactor coil for proper ohmic
RB CONTACTOR
value. It should be 10-14 ohms.
TIPS
A2
• Check coil connection from PB2 to RB coil (-)
➤
for loose connection.
• Check coil connection from battery positive to
RB coil (+) for loose connection.

STATUS CODE 1 REC fails to turn off during regen. This status code will be displayed when any failure of
1 REC to turn off during regen cycle.
-75

Forward or reverse contactor opens and closes,
YES then opens and can only close by opening and
closing the key switch. POS SENSOR 2
➤
POSSIBLE CAUSE
1 REC turn off failure not related to regen.
• Stall vehicle in both directions and note any status
➤
Circuits valid codes displayed that may more closely define the
failure mode. Trouble shoot per new status code.
for 1 REC turn off related to regen.
Wire Wire
Traction • Check for loose connections on all regen power 7 REC
➤
#22 #21
circuits from battery positive to RB contactor
Controller A2 connection. DRIVE
MOTOR PA4 PA5
• Check for loose connection on regen input circuits. PA6
• Wire #22 from sensor 2 to PA4.
• Wire #21 from sensor 2 to PA5.
• Wire #17 from RB contactor to PA6. 17
Defective motor circuit.
• Check motor circuit for open or loose connections. RB CONTACTOR
• Check motor brushes for proper seating. TIPS
F or R contactor power bouncing open. A2
➤
• Insure that F and R contactor does not bounce

open during vehicle operation (ie: traveling over
speed bumps and dock plates).
• Power cables switched.
7-25

STATUS CODE Capacitor voltage too high during This status code will be displayed when capacitor
-76 regen. voltage is greater than 225 volts during the regen
cycle.

POSSIBLE CAUSE
Intermittent connection in battery power circuit.
LINE
Circuits valid • Check battery power circuit, both positive and BATTERY FUSE
CTR
negative for loose connections. CONNECTION
for CAPACITOR
Traction • Check power fuse, battery connectors, line
➤
➤
BATTERY
contactors and etc., for possible opening
Controller during regen cycle.
BATTERY
Excessive source inductance. CONNECTION
• Check for unfiltered tag lines.
➤ NEGATIVE
• Check for long battery cables.

STATUS CODE Drive Motor Thermostat. This status code will be displayed when the voltage
-90 at terminal 1 of the TMM is at zero volts.

NO Status Code flashes “on and off”.
POSSIBLE CAUSE
Indicates Drive Motor has overheated and
thermostat switch is closed. TRUCK MANAGEMENT
Circuits valid MODULE (TMM1)
Other causes for status code: 1
for
• Terminal 1 is shorted to Negative.
Truck
• Defective input switch (shorted).
Management • Defective TMM card.
Module SW1
NOTE: When SCR Pump Control is used with
internal TMM function, input terminal is PA3 on
Pump Logic Card.
BATTERY ➤
NEGATIVE
7-26

STATUS CODE Pump Motor Thermostat. This status code will be displayed when the voltage
-92 at terminal 4 of the TMM is at zero volts.

POSSIBLE CAUSE
Indicates Pump Motor has overheated and
thermostat switch is closed.
Circuits valid Other causes for status code:

TRUCK MANAGEMENT
for MODULE (TMM1)
• Terminal 4 is shorted to Negative. 41
Truck • Defective input switch (shorted).
• Defective TMM card.
Management
Module
NOTE: When SCR pump control is used with SW4
SW1
internal TMM function, input terminal is PB6 on
pump logic card.
BATTERY ➤
NEGATIVE

STATUS CODE Drive Motor Brush Wear Indicators. This status code will be displayed when the voltage
-94 at terminal 8 and 10 of the TMM is at zero volts.

POSSIBLE CAUSE
Indicates Drive Motor Brushes have worn
through the sensing wires.
TRUCK MANAGEMENT
Circuits valid Other causes for status code: MODULE (TMM1)
85 6
10
for • Terminal 8 and 10 is shorted to Negative.
Management
Module SW8
SW5 SW10
SW6
NOTE: When SCR pump control is used with
internal TMM function, input terminal is PA4 and
PA5 on pump logic card.
BATTERY ➤
NEGATIVE
7-27

STATUS CODE Pump Motor Brush Wear Indicators. This status code will be displayed when the voltage
-95 at terminal 11 and 12 of the TMM is at zero volts.

NO Status Code flashes “on and off.”
POSSIBLE CAUSE
Indicates Pump Motor Brushes have worn
through the sensing wires.
TRUCK MANAGEMENT
Circuits valid Other causes for status code: MODULE (TMM1)
11
5 6
12
for • Terminal 11 and 12 is shorted to Negative.
Management
Module SW11
SW5 SW12
SW6
NOTE: When SCR pump control is used with
internal TMM function, input terminal is PB1 and
PB2 on pump logic card.
BATTERY ➤
NEGATIVE

STATUS CODE USER DEFINED STATUS CODE This status code will be displayed when the “normal”
-99 Maintenance Alert Code. hourmeter reading exceeds the “maintenance alert
hours” setting for the truck.
CORRECTIVE ACTIONS NO DIAGRAM

NO Status Code flashes on and off.
“Maintenance alert hours” have been reached.

User should perform required maintenance and
reset maintenance alert hours. See Functions 19
and 20 in the Handset Section.
USER SHOULD PERFORM
Circuits valid
for
THE DESIRED MAINTENANCE
Traction FUNCTION.
Controller
7-28

STATUS CODE “Card Type” selection is invalid. This status code will be displayed when the card
-117 type selection value is set to an invalid number.

NO Pump contactor will not close.
POSSIBLE CAUSE
Invalid card type selection.
• Review function 17 in the Handset Instruction
sheets. Adjust and set card type value as
Circuits valid instructed by Service Manual.
for
Pump Verify that the correct logic card catalog
number is installed in the controller.
Controller
HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Pump contactor coil current is low. This status code will be displayed when the current
-123 draw in the pump contactor coil circuit is less than
100 milliamps.

NO Pump contactor will not pick up. Status code
may alternate between code 123 and code
➤
124. Complete check for code 123, if the

problem is not found, perform check for
code 124.
Circuits valid POSSIBLE CAUSE

Defective Pump contactor coil circuit.
for • Check for open circuit or loose connection
+
Pump between PB4 and positive side of Pump P
contactor coil.
Controller
• Remove plug A. Check ohmic value from PB4 PB4
to positive side of F coil. Value should be
between 10 and 14 ohms.
Defective P1A contactor coil.

• Remove plug A. Check ohmic value from
positive side of coil to its plug connection.
Value should be between 10 and 14 ohms.
7-29

STATUS CODE T2 voltage is too high (greater than This status code is displayed when T2 voltage is
-124 12% battery volts). greater than 12% of battery volts and the Pump
driver is energized.

NO Control does not operate. Status code may
➤
alternate between code 123 and code 124. T2
Complete checks for 124; if the problem is
not found, perform code 123 check.
➤
P
POSSIBLE CAUSE
Circuits valid Defective Pump contactor.
• Pump power tips fail to close because:
for 1) Welded normally closed power tips +
Pump 2) Binding contactor tip assembly
P
3) Defective Pump contactor coil
Controller 4) Incorrect pump contactor coil resistance.
5) Defective pump contactor coil snubber. A1 PB4
ARMATURE
(See status code 123)
A2
Open motor circuit.
pump motor circuit from the A1 connection to
the A2 connection on the control panel. A2
Defective 1A contactor.
➤
• Perform checks as outlined in status 123. NEG

STATUS CODE Pump contactor does not drop out or This status code is displayed when Pump contactor
-125 drops out slowly. drop out time exceeds .060 seconds.

NO Short tip life on Pump contactor. Status code
46 displayed and no fault found.
➤ P
➤
POSSIBLE CAUSE
1 REC
➤
Note: This status code can only be found by

Circuits valid using the handset and looking at function 1.
This status code is furnished as a
for troubleshooting aid for status code 146.
Pump
Defective Pump contactor.
Controller • Check Pump contactor for binding or slow
T2
operation when dropping out.
PUMP
CONTACTOR
➤
➤
7-30

STATUS CODE Open thermal protector (TP) or control This status code is displayed when the voltage
-141 is over temperature (greater than between PZ1 and PZ5 is greater than 1.8 volts.
194ºF).

NO Reduced or no power to pump motor in SCR
range.
POSSIBLE CAUSE
Open thermal protector circuit.
Circuits valid between:
Black
Black wire-Thermal protector and PZ1. PZ1
for Gray wire-Thermal protector and PZ5.
Pump THERMAL
Defective thermal protector. PROTECTOR
Controller • Disconnected wires from PZ1 and PZ5. At
PZ5
room temperature (25° C or 75° F) measure Gray
resistance between Black and Gray wire.
Replace TP if ohmic value is greater than
300 ohms.
SCR is in thermal cut-back.

• Allow control to cool, status code should
disappear.

STATUS CODE Control “motor current sensor” input is This status code is displayed when the voltage
-142 missing. between PY7 and Negative is greater than 1.6 volts

NO No power to pump motor in SCR range.
➤
POSSIBLE CAUSE
(green wire) from current sensor to PZ4 on A2
Circuits valid the logic card.
for Green
SCR PZ4
Pump CURRENT
➤
Controller SENSOR
➤
➤
NEG
7-31

STATUS CODE Control “motor current sensor” input is This status code is displayed when the voltage
-143 missing. between PY7 and Negative is less than .84 volts

NO Stall currents in SCR range higher than
normal and uncontrollable with C/L
➤
adjustment.
POSSIBLE CAUSE
Open sensor wire circuit to PZ3. A2
Circuits valid • Check for loose connection or broken wire
(yellow wire) from current sensor to PZ3 on
for the logic card. SCR ➤
Traction CURRENT
SENSOR PZ3
Controller Yellow
➤
➤
NEG

STATUS CODE 1 REC did not turn off properly. This status code is displayed when, during SCR
-144 operation, 1 REC fails to turn off.

YES Pump contactor opens and closes, then can ➤
only be closed by opening and closing the P
key switch.

5 REC circuit defective.
➤
➤
➤

2 REC CHOKE
• Check for shorted 5 REC snubber (25 REC). T5
for 1X
Pump 2 REC circuit defective.
Controller
22 REC
➤
➤
Open Choke (1X).

• Check for open circuit between T5 and T3. 5 REC
T4 T3
1 REC defective.
➤
• Turn off time for 1 REC is out of specification.

No field test is possible. Replace 1 REC after
above checks show no problem.
25 REC
7-32

STATUS CODE 1 REC did not turn on properly. This status code is displayed when 1 REC fails to
-145 turn on.

YES Pump contactor will open and close, then
open and then can only be closed by opening
➤ P
POSSIBLE CAUSE ➤
• Check for shorted 2 REC snubber (22 REC). 1 REC Wht/Blu
for PZ8
Pump PZ9
Defective 1 REC circuit. Blu
• Check for open circuit or loose connections
Controller
➤
between 1 REC and PZ8 (white/blue wire).
• Check for open circuit or loose connection 2 REC
➤
between 1 REC (3 REC snubber) and PZ9
(blue wire).
Defective 1 REC.
• Intermittent or open 1 REC gate. Field test
22 REC
may or may not show defect. Replace 1 REC
after above checks show no problem found.

STATUS CODE “Look Ahead” test for T2 volts (greater This status code will be displayed when the voltage
-146 than 85% of battery volts). at T2 is greater than 85% of battery volts.

NO Pump contactor will not pick up.
POSSIBLE CAUSE
➤
P
Defective 1 REC.
• Check for shorted 1 REC. ➤
1 REC
• Check for defective 1 REC insulator (co-therm)
Circuits valid that may short 1 REC heat sink to base plate. ➤
for Defective 1A contactor.
Pump • Check for welded 1A contactor power tips.
Controller ➤
➤
T2
P CONTACTOR
➤
PS2
7-33

STATUS CODE 2 REC does not turn properly. This status code will be displayed when the 2 REC
-147 fails to turn on.

YES Pump contactor will open and close, then ➤
open and then can only be closed by opening P
➤
Defective 2 REC circuit. ➤
➤
Circuits valid • Check that 2 REC will gate on. 2 REC CHOKE
• Check for open circuit or loose connection T5
for between 2 REC gate and PZ10 (white/red wire). 1X
Pump • Check for open circuit or loose connection
1 REC and 1 C through the 2 REC circuit.
• Check for shorted 5 REC. 22 REC
➤
➤
• Check for shorted 5 REC snubber (25 REC)
5 REC
Open Choke (1X).
• Check for open circuit between T5 and T3. T4 T3
➤
Pump contactor or power tips bouncing open.
• Check that Pump contactor power tips do not T2
bounce open during operation (ie: travel over 25 REC
speed bumps or dock plates).
• Replace 2 REC

STATUS CODE “Look Ahead” test for T2 volts (less This status code will be displayed when the voltage
-148 than 12% of battery volts. at T2 is less than 12% of battery volts.

➤
NO Pump contactor will not pick up.

T2
POSSIBLE CAUSE
Defective Pump contactor. P
• Check for welded Pump contactor power tips.
• Check for sluggish operation of Pump contactor.
Circuits valid A1
for Defective 3 REC circuit.
Pump • Check for shorted 3 REC snubber (23 REC).
A1
Controller ARMATURE 23FL
3 REC
A2
A2
SCR
➤
CURRENT ➤
SENSOR
➤
NEG
7-34

STATUS CODE 5 REC does not turn on properly. This status code will be displayed when the 5 REC
-149 circuit fails to turn on.

YES Pump contactor will open and close, then
open and then can only be closed by opening
➤
POSSIBLE CAUSE
PZ12 PZ14
Defective 5 REC circuit. White/Violet
➤
White/Violet Orange
➤
for • Check that 5 REC will gate on.
1X
CHOKE
Pump • Check for open circuit or loose connection 2 REC T5 Orange
➤
Wire 2 REC
between 5 REC gate and PZ12 5 REC REACTOR
Controller (white/violet wire). ➤
T4 T3 T5 T4
Shorted 2 REC circuit.
➤
T3
• Check 2 REC and 2 REC snubber (22 REC) REACTOR
for short circuit. 25 REC
Defective capacitator circuit.

• Check for open capacitor.
• Check for loose connections at capacitor
terminals.
• Replace 5 REC

STATUS CODE Capacitor volts low. This status code will be displayed when 2 REC circuit
-150 fails to turn on at initial key switch on.

NO Pump contactor picks up. Control does not
operate.
BUS A
POSSIBLE CAUSE
SPIDER
➤

• Open circuit or loose connection between 5 REC
Circuits valid spider assembly and 5 REC (BUS A).
➤
• Open circuit or loose connection between BUS B
for
➤
Red Wire
➤
5 REC and 2 REC. White/Red 2 REC

Pump • Open circuit or loose connection between 2 REC Wire
Controller and PZ11 (red wire) and between 2 REC gate PZ10
and PZ10 (white/red wire).
➤
➤
➤
• Check 2 REC to insure that it will gate on. White/Red
1 REC
1C
T5 1X
2 REC
➤
7-35

STATUS CODE Excessive Capacitor voltage when This status code will be displayed when capacitor
-151 motor current is high. volts exceed 225 volts and motor current is greater
than 300 amps.

➤
YES Pump contactors open and close, then can T2
only be closed by opening and closing the
key switch.
P
POSSIBLE CAUSE
Excessive source inductance.
Circuits valid • Tag lines without filters are being used.
A1
• Battery cables are too long.
for
Pump High peak current in motor.
• Check for shorted field winding. A1
Controller • Check for shorted armature winding. ARMATURE
A2
A2
SCR
➤
CURRENT ➤
SENSOR
NEG

-152 motor current is low. volts exceed 225 volts and motor current is less
than 200 amps.

➤
YES Pump contactors open and close, then can

T2
key switch.
P
POSSIBLE CAUSE
Excessive source inductance.
Circuits valid • Tag lines without filters are being used. A1
• Battery cables are too long.
for
Pump Defective 3 REC circuit.
A1
Controller 3 REC circuit. ARMATURE 23FL
3 REC
A2
A2
SCR
➤
CURRENT ➤
SENSOR
➤
NEG
7-36

STATUS CODE Shorted Pump or 1A contactor coil This status code will be displayed when either the
-154 driver. Pump or 1A contactor coil driver is shorted internal
to the logic card.

NO Control will not operate.
POSSIBLE CAUSE
Circuits valid
for P COIL
Pump
51 7
Controller
PB4 TB4

STATUS CODE Current sensor input voltage polarity This status code will be displayed when the voltage
-157 check. input to PZ4 and PZ3 is of the wrong polarity.

NO Pump contactors open and close, then can
➤

key switch.
POSSIBLE CAUSE A1
Reversed yellow and green current sensor wires.
Circuits valid • Insure that the green wire connects to PZ4
A2
with no open circuits and that the yellow wire
for connects to PZ3 with no open circuits or
A2
Pump loose connections.
Controller Reversed power cable connection. SCR Green
• Insure that the battery negative cable connects
PZ4
CURRENT
to SCR Negative and the motor A2 cable SENSOR Yellow PZ3
connects to SCR A2.
➤
NEG
7-37

Logic Card2ec15 MONTACARGAS CATERPILLAR

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EV100ZX DIAGNOSTIC STATUS CODES

Basic Checks ........................................................................................................ 7-1

On Board Diagnostics ...................................................................................... 7-2

Status Codes......................................................................................................... 7-4

Now we are ready to allow the self-diagnostics to give

Always check each function and always write

Nobody has a perfect memory and you may not get a

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Defective Dash Display or Handset. PZ7 CAP

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Circuits valid Charge Battery overnight.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

• Check to see that the seat switch closes

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Short circuit between TB3 and TB5. TB2

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

POSSIBLE CAUSE BRAKE

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

POSSIBLE CAUSE SEAT BRAKE

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Traction Defective directional switch.

Open circuit between directional switch(es) and

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Short circuit from battery positive to wiring in

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

POSSIBLE CAUSE ACCEL

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Forward or reverse directional switch welded

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

POSSIBLE CAUSE BRAKE

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

as outlined in the Figure and charge battery, if BATTERY

Incorrect control card adjustment.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

POSSIBLE CAUSE ACCEL

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

the problem is not found, perform check for

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Note: This status code can only be found by

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION